Kawasaki Kcm 80ZV-2 WHEEL LOADER SHOP MANUAL 93209-00442 (1)

Page 1

80ZV-2

93209-00442

SHOP MANUAL General Information Function & Structure

Printed in Japan (K) （ヨーロッパ • オセアニア用）

93209-00442

©2015 KCM Corporation. All rights reserved.

April 2015

SHOP MANUAL WHEEL LOADER

80ZV-2 General Information Standard Measurement Values for Performance Check Function & Structure Check & Adjustment Powered by CUMMINS QSC8.3 Engine Serial No. 80C5-9001 and up

93209-00442 April 2015

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.

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

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

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

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

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

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

CONTENTS 00 General Information ......................................................................................................................................... 00-1 How to Use Manual ........................................................................................................................................... 00-2 Safety precautions ...................................................................................................................................... 00-2 Symbols ...................................................................................................................................................... 00-3 Outline ............................................................................................................................................................... 00-4 Layout of main components ........................................................................................................................ 00-4 Inspection and maintenance table .............................................................................................................. 00-5 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 9001~9128) ......................................................................................................................... 12-5 Fuel tank (S/N 9129~) ................................................................................................................................. 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 ......................................................................................................................................................... 13-4 Adjusting shim ............................................................................................................................................. 13-4 Installing bearing cover ............................................................................................................................... 13-4 Installing bearing outer ring ......................................................................................................................... 13-5 22 Function & Structure Power Group .................................................................................................................. 22-1 Power Line ........................................................................................................................................................ 22-2 Engine / Transmission ....................................................................................................................................... 22-3 Engine / transmission mount ....................................................................................................................... 22-3 Radiator (S/N 9001~9100) ................................................................................................................................ 22-4 Radiator mount ............................................................................................................................................ 22-5 Radiator (S/N 9101~) ........................................................................................................................................ 22-6 Radiator mount ............................................................................................................................................ 22-7 Propeller Shaft .................................................................................................................................................. 22-8 Second propeller shaft assembly ................................................................................................................ 22-9 Third propeller shaft assembly .................................................................................................................. 22-10 Axle Assembly ................................................................................................................................................. 22-11 Axle Support .................................................................................................................................................... 22-12 Differential Gear .............................................................................................................................................. 22-14 Torque proportioning type ......................................................................................................................... 22-14 Operation of T.P.D ..................................................................................................................................... 22-17 Limited Slip Differential (option) ...................................................................................................................... 22-18 LSD structure ............................................................................................................................................ 22-18 LSD function .............................................................................................................................................. 22-21 LSD operation ........................................................................................................................................... 22-21 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 Tightening torque ........................................................................................................................................ 23-4 Axle ................................................................................................................................................................... 23-5 Axle nut tightening procedure ..................................................................................................................... 23-5 Differential gear adjustment procedure ....................................................................................................... 23-6

32 Function & Structure Torque Converter and Transmission Group ................................................................... 32-1 Torque Converter .............................................................................................................................................. 32-2 Torque converter structure .......................................................................................................................... 32-2 Power flow path .......................................................................................................................................... 32-2 Torque multiplication ................................................................................................................................... 32-2 Torque Converter Gear Pump ........................................................................................................................... 32-3 Gear pump specifications ........................................................................................................................... 32-3 Transmission ..................................................................................................................................................... 32-4 Clutch combination ..................................................................................................................................... 32-4 Shift lever position ....................................................................................................................................... 32-4 Downshift button operation ......................................................................................................................... 32-4 Gear train and number of teeth ................................................................................................................... 32-5 Clutch specifications ................................................................................................................................... 32-6 Clutch Pack ....................................................................................................................................................... 32-7 Forward and 3rd speed clutches ................................................................................................................. 32-7 Reverse and 2nd speed clutches ................................................................................................................ 32-8 1st speed clutch .......................................................................................................................................... 32-9 4th speed clutch ........................................................................................................................................ 32-10 Power Flow Path in the Transmission ..............................................................................................................32-11 Hydraulic System Diagram ............................................................................................................................. 32-14 Hydraulic Circuit Diagram ............................................................................................................................... 32-15 Oil Flow ........................................................................................................................................................... 32-16 Oil flow in the torque converter line ........................................................................................................... 32-16 Oil flow to the clutch .................................................................................................................................. 32-16 T/C and T/M Oil Circulation ............................................................................................................................. 32-17 Control Valve ................................................................................................................................................... 32-19 System diagram ........................................................................................................................................ 32-20 Modulation Mechanism ................................................................................................................................... 32-21 Clutch control oil pressure curve ............................................................................................................... 32-22 Traveling at forward 1st speed .................................................................................................................. 32-23 Changing from forward 1st speed to reverse 1st speed ........................................................................... 32-24 Trimmer engagement ................................................................................................................................ 32-25 Clutch engagement starting ...................................................................................................................... 32-26

Clutch Solenoid Valve ..................................................................................................................................... 32-27 For forward/reverse and speed clutches ................................................................................................... 32-27 For trimmer ................................................................................................................................................ 32-29 33 Check & Adjustment Torque Converter and Transmission Group ................................................................... 33-1 Clutch Oil Pressure ........................................................................................................................................... 33-2 Measuring clutch oil pressure ..................................................................................................................... 33-2 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 9001~9250) .............................................................................................................. 42-12 Hydraulic Tank (S/N 9251~) ...................................................................................................................... 42-14 Hydraulic Pump ............................................................................................................................................... 42-16 Hydraulic pump specifications ................................................................................................................... 42-16 Hydraulic pump principle ........................................................................................................................... 42-17 Hydraulic pump wear plate ........................................................................................................................ 42-18 Hydraulic pump bushing lubrication .......................................................................................................... 42-18

Hydraulic Cylinder ........................................................................................................................................... 42-19 Boom cylinder ........................................................................................................................................... 42-19 Bucket cylinder .......................................................................................................................................... 42-19 Steering cylinder ....................................................................................................................................... 42-20 Hydraulic cylinder specifications ............................................................................................................... 42-21 Loading System .............................................................................................................................................. 42-22 Reducing Valve (for Pilot Pressure) ................................................................................................................ 42-23 Pilot Valve (S/N 9001~9205) ........................................................................................................................... 42-24 Pilot valve function .................................................................................................................................... 42-27 Pilot valve operation (modulated position) ................................................................................................ 42-27 Pre-detent and detent magnet solenoid .................................................................................................... 42-29 Pilot Valve (S/N 9206~) ................................................................................................................................... 42-30 Multiple Control Valve (KML28/2T102) ........................................................................................................... 42-35 Multiple control valve specifications .......................................................................................................... 42-36 Multiple control valve main relief valve ..................................................................................................... 42-37 Multiple control valve overload relief valve (with make-up function) ......................................................... 42-38 Multiple control valve make-up valve ........................................................................................................ 42-40 Multiple control valve bucket spool ........................................................................................................... 42-41 Multiple control valve boom spool ............................................................................................................. 42-43 Adapter (Orifice) .............................................................................................................................................. 42-46 Ride Control (OPT) ......................................................................................................................................... 42-47 Ride control hydraulic circuit ..................................................................................................................... 42-47 Ride control function ................................................................................................................................. 42-47 Ride control operation ............................................................................................................................... 42-48 Ride control valve assembly ..................................................................................................................... 42-50 Solenoid valve ........................................................................................................................................... 42-53 Accumulator (for ride control) .................................................................................................................... 42-55 Steering System .............................................................................................................................................. 42-56

Orbitrol® ........................................................................................................................................................... 42-57 Orbitrol® structure ..................................................................................................................................... 42-57 Orbitrol® specification ................................................................................................................................ 42-58 Orbitrol® operation .................................................................................................................................... 42-59 Orbitrol® feed-back mechanism operation ................................................................................................ 42-61 Steering speed and flow rate control ......................................................................................................... 42-62 Hydraulic pump oil amount and steering force .......................................................................................... 42-62 Orbit rotor operation principle .................................................................................................................... 42-63 Steering Valve (KVS25-A3.0/20) ..................................................................................................................... 42-64 Steering valve operation ........................................................................................................................... 42-66 Steering plunger variable throttle .............................................................................................................. 42-68 Steering valve flow control plunger ........................................................................................................... 42-69 Steering valve main relief valve ................................................................................................................ 42-70 Steering valve overload relief valve .......................................................................................................... 42-72 Steering pilot circuit and its operation ....................................................................................................... 42-74 Stop Valve ....................................................................................................................................................... 42-76 Stop valve function .................................................................................................................................... 42-77 Stop valve operation ................................................................................................................................. 42-77 Reducing Valve (for Orbitrol®) ......................................................................................................................... 42-78 Steering Line Filter .......................................................................................................................................... 42-79 K-Lever (OPT) ................................................................................................................................................. 42-80 Hydraulic circuit ......................................................................................................................................... 42-80 Hydraulic line diagram ............................................................................................................................... 42-81 Hydraulic line ............................................................................................................................................. 42-82 Solenoid valve assembly (1/2) .................................................................................................................. 42-83 Solenoid valve assembly (2/2) .................................................................................................................. 42-84 Efficient Loading System ................................................................................................................................. 42-85 Efficient loading system outline ................................................................................................................. 42-85 Mounting of the ELS valve ........................................................................................................................ 42-86 Mounting of the variable kickout sensor .................................................................................................... 42-87 Efficient loading system operation ............................................................................................................ 42-88 Fan Motor System ........................................................................................................................................... 42-89 Mounting of fan motor ............................................................................................................................... 42-89 Fan Motor Line ................................................................................................................................................ 42-90 Hydraulic circuit (fan motor normal rotation) ............................................................................................. 42-92

Reversing Fan Motor Line (OPT) .................................................................................................................... 42-98 Reversing fan motor function .................................................................................................................... 42-98 Hydraulic circuit (Reverse rotation) ......................................................................................................... 42-102 Secondary Steering ....................................................................................................................................... 42-103 Secondary steering operation ................................................................................................................. 42-104 Secondary steering motor and pump ...................................................................................................... 42-105 43 Check & Adjustment Hydraulic Group .............................................................................................................. 43-1 Loading/Steering Circuit Relief Valve/Ride Control Circuit Reducing Valve (OPT) ........................................... 43-2 Loading circuit relief valve setting pressures .............................................................................................. 43-2 Ride control circuit reducing valve setting pressures (OPT) ....................................................................... 43-7 Steering circuit relief valve setting pressures .............................................................................................. 43-9 Hydraulic Cylinder ........................................................................................................................................... 43-14 Cylinder natural drift .................................................................................................................................. 43-14 Stop Valve ....................................................................................................................................................... 43-16 Stop valve adjustment procedure ............................................................................................................. 43-16 52 Function & Structure Brake Group ................................................................................................................... 52-1 Brake System Outline ....................................................................................................................................... 52-2 Service brake .............................................................................................................................................. 52-2 Parking brake .............................................................................................................................................. 52-2 Adjustment of axle internal pressure ........................................................................................................... 52-2 Brake Units Layout ............................................................................................................................................ 52-3 Unloader Valve .................................................................................................................................................. 52-4 Unloader valve operation ............................................................................................................................ 52-6 Valve Unit .......................................................................................................................................................... 52-7 Accumulator ...................................................................................................................................................... 52-9 In-Line Filter .................................................................................................................................................... 52-10 Brake Valve ......................................................................................................................................................52-11 Brake valve performance chart ................................................................................................................. 52-12 Brake valve outline .................................................................................................................................... 52-13 Service Brake .................................................................................................................................................. 52-15 Service brake operation ............................................................................................................................ 52-15 Service brake friction plate ........................................................................................................................ 52-16 Service brake steel plate ........................................................................................................................... 52-16 Brake circuit air bleeding procedure ......................................................................................................... 52-17

Parking Brake .................................................................................................................................................. 52-18 Parking brake operation ............................................................................................................................ 52-19 Parking brake solenoid valve .................................................................................................................... 52-20 Parking Brake Manual Release ....................................................................................................................... 52-21 Parking Brake Spring Chamber ....................................................................................................................... 52-23 Brake Circuit Check Valve ............................................................................................................................... 52-24 Pressure Sensor (for stop lamp and declutch) ................................................................................................ 52-25 Pressure sensor (for declutch) .................................................................................................................. 52-25 Pressure sensor (for stop lamp) ................................................................................................................ 52-25 53 Check & Adjustment Brake Group ................................................................................................................... 53-1 Brake Circuit Oil Pressure ................................................................................................................................. 53-2 Unloader valve setting pressure .................................................................................................................. 53-2 Brake valve oil pressure .............................................................................................................................. 53-4 Service Brake .................................................................................................................................................... 53-6 Service brake performance check ............................................................................................................... 53-6 Service brake friction plate wear measurement .......................................................................................... 53-7 Cautions on installing brake discs ............................................................................................................... 53-8 Parking Brake .................................................................................................................................................... 53-9 Parking brake performance check .............................................................................................................. 53-9 Parking brake clearance adjustment ......................................................................................................... 53-10 62 Function & Structure Electrical Group .............................................................................................................. 62-1 How to Use Electrical Wiring Diagram .............................................................................................................. 62-2 Utilisation des schémas des câblages électriques (FRANÇAIS) ...................................................................... 62-3 Verwendung des elektrischen Schaltplans (DEUTSCH) ................................................................................... 62-4 Modalità di utilizzo dello schema dei collegamenti elettrici (ITALIANO) ............................................................ 62-5 Cómo utilizar un Diagrama de Alambrado Eléctrico (ESPAÑOL) ..................................................................... 62-6 Como Utilizar o Diagrama de Ligações Eléctricas (PORTUGUÊS) .................................................................. 62-7 Electrical Cable Color Codes ............................................................................................................................ 62-8 Electrical Circuit Symbols .................................................................................................................................. 62-9 Sensor Mount .................................................................................................................................................. 62-10 Fuse ................................................................................................................................................................ 62-11 Fuse box ................................................................................................................................................... 62-11 Fusible link ................................................................................................................................................ 62-13

Engine Start Circuit ......................................................................................................................................... 62-14 Engine start circuit diagram ...................................................................................................................... 62-14 Neutral starter ........................................................................................................................................... 62-14 Starter switch ............................................................................................................................................ 62-16 Battery relay .............................................................................................................................................. 62-17 Alternator R terminal wire ......................................................................................................................... 62-18 Diode unit .................................................................................................................................................. 62-18 Neutral relay .............................................................................................................................................. 62-19 Magnetic switch ........................................................................................................................................ 62-20 Voltage relay ............................................................................................................................................. 62-21 Power Generating/Charging Circuit ................................................................................................................ 62-22 Alternator .................................................................................................................................................. 62-22 ECM (Engine Controller) ................................................................................................................................. 62-23 Function of ECM ....................................................................................................................................... 62-23 Connection diagram .................................................................................................................................. 62-23 Monitor lamp test ...................................................................................................................................... 62-24 Failure diagnosis ....................................................................................................................................... 62-25 Quantum fault code information ................................................................................................................ 62-28 Accelerator pedal ...................................................................................................................................... 62-34 Transmission Control Circuit and Monitor Circuit ............................................................................................ 62-37 Machine control unit (MCU) ...................................................................................................................... 62-37 Machine control unit (MCU) connection diagram (S/N 9001~9350) ......................................................... 62-39 Machine control unit (MCU) connection diagram (S/N 9351~) ................................................................. 62-41 Machine control unit (MCU) function ......................................................................................................... 62-43 Adjustable declutch preset switch ............................................................................................................. 62-48 Monitoring system ..................................................................................................................................... 62-55 Instrument Panel and Switch .......................................................................................................................... 62-57 Instrument panel ....................................................................................................................................... 62-57 Instrument panel rear surface ................................................................................................................... 62-59 Gauge circuit ............................................................................................................................................. 62-61 Fuel level sensor ....................................................................................................................................... 62-63

MODM ............................................................................................................................................................. 62-65 MODM function ......................................................................................................................................... 62-65 Monitor Changeover .................................................................................................................................. 62-65 Information Monitor ................................................................................................................................... 62-68 Replacement Monitor ................................................................................................................................ 62-72 Fault Log Monitor ...................................................................................................................................... 62-78 Input/Output Monitor ................................................................................................................................. 62-85 Parameter Setting Monitor ........................................................................................................................ 62-89 Specification Setting Monitor ..................................................................................................................... 62-98 Electrical Detent Circuit ................................................................................................................................. 62-104 Bucket leveler .......................................................................................................................................... 62-104 Detent solenoid ....................................................................................................................................... 62-105 Lift kickout & lower kickout ...................................................................................................................... 62-106 Sensor assy ............................................................................................................................................ 62-108 Detent solenoid ....................................................................................................................................... 62-110 Preset height adjustment ........................................................................................................................ 62-110 Diode ..............................................................................................................................................................62-111 Diode check method ............................................................................................................................... 62-112 Caution for diode check method ............................................................................................................. 62-112 Surge voltage and surge suppression diodes ......................................................................................... 62-114 72 Function & Structure Operator Station Group .................................................................................................. 72-1 Cabin ................................................................................................................................................................. 72-2 Glass ........................................................................................................................................................... 72-3 Wiper mount ................................................................................................................................................ 72-6 Wiper motor ................................................................................................................................................. 72-7 Operator Seat .................................................................................................................................................... 72-9 Steering and Transmission Shift Lever ............................................................................................................ 72-10 Tilt case ..................................................................................................................................................... 72-11 Column shaft ............................................................................................................................................. 72-12 Shift lever .................................................................................................................................................. 72-12

Air Conditioner ................................................................................................................................................ 72-13 Denso air conditioner components ........................................................................................................... 72-13 Denso air conditioner structure ................................................................................................................. 72-14 Function of cooling mechanism ................................................................................................................ 72-19 Cooling circuit ........................................................................................................................................... 72-22 Electrical circuit ......................................................................................................................................... 72-23 Air conditioner functions of components ................................................................................................... 72-24 Charge of refrigerant ................................................................................................................................. 72-52 Air conditioner troubleshooting ................................................................................................................. 72-69 73 Check & Adjustment Operator Station Group .................................................................................................. 73-1 Air Conditioner .................................................................................................................................................. 73-2 Adjustment of lubricating oil quantity when components of air conditioner are replaced ............................ 73-2 Adjustment of air gap (between hub and rotor) in compressor magnetic clutch ......................................... 73-5 Compressor V-belt adjustment .................................................................................................................... 73-6 Parts to be replaced periodically ................................................................................................................. 73-8 92 Drawing & Diagrams ........................................................................................................................................ 92-1 Axle Assembly .................................................................................................................................................. 92-2 Torque Converter and Transmission ................................................................................................................. 92-3 Hydraulic & Brake Circuit .................................................................................................................................. 92-4 Brake Circuit ..................................................................................................................................................... 92-5 Electrical Wiring Diagram (1/3) (S/N 9001~9038) ............................................................................................. 92-6 Electrical Wiring Diagram (2/3) (S/N 9001~9038) ............................................................................................. 92-7 Electrical Wiring Diagram (3/3) (S/N 9001~9038) ............................................................................................. 92-8 Electrical Wiring Diagram (1/3) (S/N 9039~9100) ............................................................................................. 92-9 Electrical Wiring Diagram (2/3) (S/N 9039~9100) ........................................................................................... 92-10 Electrical Wiring Diagram (3/3) (S/N 9039~9100) ............................................................................................92-11 Electrical Wiring Diagram (1/3) (S/N 9101~9200) ........................................................................................... 92-12 Electrical Wiring Diagram (2/3) (S/N 9101~9200) ........................................................................................... 92-13 Electrical Wiring Diagram (3/3) (S/N 9101~9200) ........................................................................................... 92-14 Electrical Wiring Diagram (1/3) (S/N 9201~9350) ........................................................................................... 92-15 Electrical Wiring Diagram (2/3) (S/N 9201~9350) ........................................................................................... 92-16 Electrical Wiring Diagram (3/3) (S/N 9201~9350) ........................................................................................... 92-17 Electrical Wiring Diagram (1/3) (S/N 9351~) ................................................................................................... 92-18 Electrical Wiring Diagram (2/3) (S/N 9351~) ................................................................................................... 92-19 Electrical Wiring Diagram (3/3) (S/N 9351~) ................................................................................................... 92-20

Electrical Wiring Diagram ................................................................................................................................ 92-21 Way of looking at connectors .................................................................................................................... 92-21 Electrical wiring diagram abbreviation chart .............................................................................................. 92-23 Electrical Wiring Diagram (CAB) ..................................................................................................................... 92-25 Electrical Connection Diagram (1/2) (S/N 9001~9100) ................................................................................... 92-28 Electrical Connection Diagram (2/2) (S/N 9001~9100) ................................................................................... 92-29 Electrical Connection Diagram (1/2) (S/N 9101~9200) ................................................................................... 92-30 Electrical Connection Diagram (2/2) (S/N 9101~9200) ................................................................................... 92-31 Electrical Connection Diagram (1/2) (S/N 9201~9350) ................................................................................... 92-32 Electrical Connection Diagram (2/2) (S/N 9201~9350) ................................................................................... 92-33 Electrical Connection Diagram (1/2) (S/N 9351~) ........................................................................................... 92-34 Electrical Connection Diagram (2/2) (S/N 9351~) ........................................................................................... 92-35 Electrical Wiring Diagram (Cabin Air Conditioner) .......................................................................................... 92-36 Electrical Circuit Diagram (Cabin Air Conditioner) .......................................................................................... 92-37 Equipment Operation Table (Cabin Air Conditioner) ....................................................................................... 92-38 Electrical Equipment Layout ............................................................................................................................ 92-39 Electrical Equipment Layout (K-Lever) ............................................................................................................ 92-52 Outline of MODM (Machine Operation Diagnostic Module) Operation ........................................................... 92-53 MODM: Input/Output Monitor - Input/Output Signal Correspondence Table ................................................... 92-62

80ZV-2 EU 00-1 00 General Information

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

80ZV-2 EU 00-2 00 General Information How to Use Manual

How to Use Manual Safety precautions

- Do not start to work in an enclosed area if adequate ventilation is not provided.

The most important point in providing repair service is safety. To ensure safety, observe the general cautions described below.

- To remove a heavy unit (20 kg (40 lbs) or more), be sure to use a crane or other lifting device.

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

- Just after stopping operation, be careful not to directly touch a hot component. You may get burned. - Contact tire manufacturer's local dealer for tire servicing and changing. - Always store the tools in good condition, and use them properly. - Keep the work area clean. Clean up spills immediately. - Avoid the use of flammable solvents and cleaners.

- Place the machine on level and solid ground, and place chocks against the wheels to prevent movement.

- When working outdoors keep work areas, ladders, steps, decks and work platforms clear of snow, ice, and mud.

- Remove the cable from the battery before starting the service work, and attach a "DO NOT OPERATE!" tag to the steering wheel.

- Use safe work platforms to reach higher areas of the machine.

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

- Any technician that operates a refrigerant recovery and recycling machine must first be certified through an EPA approved testing program. More information is available at http://www.epa.gov/ ozone/title6/608/technicians/608certs.html.

80ZV-2 EU 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 92-23. E/G ........... Engine T/C ........... Torque converter T/M ........... Transmission SOL ........... Solenoid valve SW ........... Switch F ........... Front or Forward A/M ........... Auto/Manual B ........... Battery R ........... Rear or Reverse

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

3rd ............3rd speed 4th ............4th speed M/C ............Machine min-1 ............RPM ELS ............Efficient loading system MODM ........Machine operation diagnostic module MCU ...........Machine control unit

80ZV-2 EU 00-4 00 General Information Outline

Outline Layout of main components

16 (S/N 9101~)

7

20

5

6

3

21

22

23

8

9

19

17 10 15

11

13

4

18

2

14

12

1

24

16 (S/N 9001~9100)

K80V2U00001

1. Engine assembly (Cummins QSC8.3) 2. Transmission/Torque converter assy 3. Hydraulic pump 4. Multiple (loader) control valve 5. Steering valve 6. Pilot valve (for loading) 7. Transmission control valve 8. Air cleaner

9. Muffler 10. Radiator 11. Front axle assembly 12. Rear axle assembly 13. 2nd propeller shaft 14. 3rd propeller shaft 15. Hydraulic oil cooler (air-to-oil type) 16. T/C oil cooler

17. Air charge cooler 18. Parking brake 19. Fan motor 20. Brake valve 21. Accumulator 22. Combination valve 23. Unloader valve 24. Fan

80ZV-2 EU 00-5 00 General Information Outline

Inspection and maintenance table IMPORTANT Refer to Operation & Maintenance Manual for maintenance procedures.

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

Section

Item for check 10

50

250

500

1000

2000

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

1 

Replace Engine Oil and Oil Filter Cartridge Replace Fuel Filter Cartridges Inspect Automatic Belt Tensioner Pulley Clean Fuel Tank Check and Adjust Valve Lash Clearance Check Vibration Damper Clean or Replace Air Cleaner Element Clean Radiator / Air cooler / Hydraulic oil cooler Fins Clean or Replace Air Cleaner Element Replace Coolant

Note 1 applies to machines from S/N 9201 and up. Refer to Operation & Maintenance Manual for details. Check Transmission Oil Level Transmission & Torque Converter

Replace Transmission Oil Filter Cartridge Replace Transmission Oil Clean or Replace Transmission Breather

After six cleanings or once a year Every 2 years or 3000 hours

When Required

80ZV-2 EU 00-6 00 General Information Outline : First time replacement or cleaning only Operating hours Section

Item for check 10

50

250

500

1000

Check Tire for Damage, Air and Tread Depth Greasing (Axle support) Check Tire Air Pressure Check Differential Gear Oil Check Planetary Gear Oil Greasing (Pillow block bearing unit) Axle system

Check Tightness of Wheel Bolts Check Tightness of Axle Mount Bolts Greasing (2nd Propeller Shaft Spline) Replace Differential Gear Oil Replace Planetary Gear Oil Greasing (2nd Propeller Shaft)

Every 12000 hours

Greasing (3rd Propeller Shaft)

Every 12000 hours

Check Steering Wheel Operation Steering system Greasing (Steering Cylinder) Clean Filter for Orbitrol® Check Service Brake Operation Check Parking Brake Operation Adjust Parking Brake Lining Brake system Check Service Brake Disk Wear Check Brake Accumulator Clean Filter for Brake Line Check Hydraulic Oil Level Greasing Replace Hydraulic Oil Return Filter Replace Hydraulic Oil, Clean Filter Loading system Replace Filter in the Hydraulic Tank Cap (S/N 9001~9250) Replace Filter in the Hydraulic Tank Breather Valve (S/N 9251~) Replace Bucket Teeth (option) Replace Cutting Edge Adjust and Check Rear View Mirrors ROPS (Roll Over Protective Structure) Cab Greasing (Center Pin) Chassis Check Ride Control Accumulator (option) Check and/or Replace Seat Belt Check Windshield Washer Fluid

2000

When Required

80ZV-2 EU 00-7 00 General Information Outline : First time replacement or cleaning only Operating hours Section

Item for check 10

50

250

500

1000

2000

Check Monitor Panel Operation Check Horn Operation Electrical system

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

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

Walk-Around Inspection

Every 3 years or 6000 hours

When Required

80ZV-2 EU 00-8 00 General Information Outline

Recommended lubricants Refill capacity (Approximate)

Kind of Oil

Engine

33 liter

Engine oil (CH4 or CI4)

Transmission

35 liter

Engine oil (CD) or ATF

Hydraulic tank

1 85 liter

3 Hydraulic oil

Differential & Planetary

Front: 54 liter Rear: 59 liter

Engine oil (CD)

Fuel tank

290 liter

Diesel fuel

Ambient Temperature (ºC) -30

-20

-10

0

10

20

30

40

Change Interval (Hours)

SAE10W-30 SAE15W-40

2 500

SAE10W

1,000

ATF ISO VG32 ISO VG46 Engine oil SAE40 or SAE50

ASTM D975 No.1 ASTM D975 No.2

2,000 2,000 daily

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

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

Transmission

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

Hydraulic System

Use industrial-type hydraulic oils which are certified by suppliers having anti-wear, antifoam, anti-rust and anti-oxidation additive properties for heavy duty use. Use of the wrong viscosity of oil can cause improper operation of hydraulic functions or premature pump failure. 3. In a case that fire-resistant fluid is used in the hydraulic circuit, some hydraulic equipment, such as pumps and/or fan motor, must be replaced periodically. Warning: When operating in cold ambient temperatures (15 ºC or colder) ISO VG32 or equivalent hydraulic oil use is recommended. When changing over to cold climate hydraulic oil (i.e. from thicker ISO VG46 to thinner ISO VG32), brake system bleeding at each wheel hub will be required to remove thicker oil and prevent delayed reaction of brake application and release.

Differential & 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.

80ZV-2 EU 00-9 00 General Information Outline

Diesel Fuel

Requirements for diesel fuel Specifications Grade No.1-D Flash Point

ºC.

min.

Water and Sediment % vol.

max

Distillation Temperature

90% vol.

ºC

recovered

2

Kinematic Viscosity mm /s at 40ºC

38

52

0.05

0.05

max.

288

338

min.

1.3

1.9

max. Ash % mass

Grade No.2-D

max.

2.4

4.1

0.01

0.01

Sulfur % mass

max.

0.50

0.50

Cetane Number

min.

40

40

0.15

0.35

Carbon residue on 10% distillation residue % mass

max.

80ZV-2 EU 00-10 00 General Information Outline

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

Recommended mixture of antifreeze Expected minimum ambient temperature

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

-20ºC (-4ºF)

-15ºC (5ºF)

Pure Water

(liter) (gal)

14.6 (3.9)

16.1 (6.7)

17.7 (4.7)

19.2 (5.1)

20.8 (5.5)

Antifreeze

(liter) (gal)

16.4 (4.3)

14.9 (39)

13.3 (3.5)

11.8 (3.1)

10.2 (2.7)

53

48

43

38

33

Mixture Ratio (%)

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

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

80ZV-2 EU 00-11 00 General Information Outline

Lubrication chart HYDRAULIC TANK

DIFF & GEAR BOX

2ND PROPELLER SHAFT

GO TRANSMISSION

G

DIFF & GEAR BOX

EVERY 12000Hr

GO

EVERY 2000Hr

HO

EVERY 1000Hr

TO

ENGINE OIL PAN

LINK SYSTEM

G

EVERY 500Hr

EO

PILLOW UNIT GO

G

EVERY 250Hr

GO

CENTER PIN

EVERY 50Hr

G TO

HO

EVERY DAY

EO

G AXLE SUPPORT

G

G

BUCKET

G

STEERING CYL.

2ND PROPELLER SHAFT

G 3RD PROPELLER SHAFT 65-85ZV2-44794-23321 EU

Grease point

G Multipurpose grease

HO Hydraulic oil

Check and add if necessary

GO Gear oil

TO Engine oil

Oil replacement

EO Engine oil

80ZV-2 EU 00-12 00 General Information Outline

Weight of main components

Part name

Approx. weight (kg)

Approx. weight (lb)

Bucket

1,430

3,150

Item Unit name

Boom

1,130

2,490

"Z" -Lever

310/pc

685/pc

Link (Bucket to Lever)

65/pc

145/pc

280

620

Hydraulic tank

125

275

Excluding oil

Fuel tank

150

330

Excluding fuel

Floor board

160

355

Cab (ROPS)

500

1,100

65

145

With handrail With handrail

Left side

Deck

65

145

Front chassis

Right side

1,445

3,180

Rear chassis

1,355

2,980

Counter weight

1,670

3,680

Engine

695

1,530

Excluding oil

Radiator assembly

380

840

Excluding water and oil

Transmission

600

1,320

Excluding oil

Second propeller shaft

50

110

Third propeller shaft

15

35

Front axle assembly

960

2,110

Excluding tires and oil

Rear axle assembly

1,120

2,460

Excluding tires and oil (Including axle support)

Differential

170

375

Multiple control valve

55

120

Pilot valve

10

25

Steering valve

25

55

Orbitrol Hydraulic system

Other

GSC bucket

Engine room assembly

Chassis

Power line

Remarks

®

Gear pump

6

15

35

80

Triple pump

Fan motor

15

35

Boom cylinder

140/pc

310/pc

Excluding oil

Bucket cylinder

200/pc

440/pc

Excluding oil

Steering cylinder

25/pc

55/pc

Excluding oil

Tire

520/pc

1,150/pc

With rim (23.5R25

Battery

30/pc

65/pc

)

80ZV-2 EU 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 diameter

Pitch

8.8 (8T)

10.9 (11T)

M8

8

(C) 1.25

26

38

(C) 1.5

53

76

(F) 1.25

55

80

(C) 1.75

90

132

(F) 1.25

96

142

(C) 2.0

142

206

(F) 1.5

152

221

(C) 2.0

216

314

(F) 1.5

226

330

(C) 2.5

299

436

(F) 1.5

324

476

(C) 2.5

417

608

(F) 1.5

451

662

(C) 2.5

559

814

(F) 1.5

598

878

(C) 3.0

721

1,030

(F) 2.0

770

1,128

(C) 3.0

1,030

1,520

(F) 2.0

1,128

1,618

(C) 3.5

1,422

2,109

M10

10

M12

12

M14

14

M16

16

M18

18

M20

20

M22

22

M24

24

M27

M30

Unified thread

Bolt strength

Nominal dimension

27

30

M33

33

5/16

05

(F) 2.0

1,569

2,256

(C) 3.5

1,912

2,844

(F) 2.0

2,059

3,040

18 UNC

25

35

3/8

06

16 UNC

44

65

7/16

07

14 UNC

71

103

1/2

08

13 UNC

103

147

9/16

09

12 UNC

147

216

5/8

10

11 UNC

201

294

3/4

12

10 UNC

358

525

7/8

14

9 UNC

554

809

1

16

8 UNC

868

1,275

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

80ZV-2 EU 00-14 00 General Information Outline

(kgf-m) Bolt size Type

Metric thread

Nominal diameter

Pitch

8.8 (8T)

10.9 (11T)

M8

8

(C) 1.25

2.7

3.9

(C) 1.5

5.4

7.8

(F) 1.25

5.6

8.2

(C) 1.75

9.2

13.5

(F) 1.25

9.8

14.5

(C) 2.0

14.5

21.0

(F) 1.5

15.5

22.5

(C) 2.0

22.0

32.0

(F) 1.5

23.0

33.7

(C) 2.5

30.5

44.5

(F) 1.5

33.0

48.5

(C) 2.5

42.5

62.0

(F) 1.5

46.0

67.5

(C) 2.5

57.0

83.0

(F) 1.5

61.0

89.5

(C) 3.0

73.5

105.0

M10

10

M12

12

M14

14

M16

16

M18

18

M20

20

M22

22

M24

24

M27

M30

Unified thread

Bolt strength

Nominal dimension

27

30

M33

33

5/16

05

(F) 2.0

78.5

115.0

(C) 3.0

105.0

155.0

(F) 2.0

115.0

165.0

(C) 3.5

145.0

215.0

(F) 2.0

160.0

230.0

(C) 3.5

195.0

290.0

(F) 2.0

210.0

310.0

18 UNC

2.5

3.6

3/8

06

16 UNC

4.5

6.6

7/16

07

14 UNC

7.2

10.5

1/2

08

13 UNC

10.5

15.0

9/16

09

12 UNC

15.0

22.0

5/8

10

11 UNC

20.5

30.0

3/4

12

10 UNC

36.5

53.5

7/8

14

9 UNC

56.5

82.5

1

16

8 UNC

88.5

130.0

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

80ZV-2 EU 00-15 00 General Information Outline

(lb-ft) Bolt size Type

Metric thread

Nominal diameter

Pitch

8.8 (8T)

10.9 (11T)

M8

8

(C) 1.25

19.5

28

(C) 1.5

39

56

(F) 1.25

40

59

(C) 1.75

66

97

(F) 1.25

70

105

(C) 2.0

105

150

(F) 1.5

110

160

(C) 2.0

160

230

(F) 1.5

165

245

(C) 2.5

220

320

(F) 1.5

235

350

(C) 2.5

305

450

(F) 1.5

330

490

(C) 2.5

410

600

(F) 1.5

440

650

(C) 3.0

530

760

M10

10

M12

12

M14

14

M16

16

M18

18

M20

20

M22

22

M24

24

M27

M30

Unified thread

Bolt strength

Nominal dimension

27

30

M33

33

5/16

05

(F) 2.0

565

830

(C) 3.0

760

1,120

(F) 2.0

830

1,190

(C) 3.5

1,050

1,550

(F) 2.0

1,160

1,660

(C) 3.5

1,410

2,100

(F) 2.0

1,520

2,240

18 UNC

18.0

26

3/8

06

16 UNC

32

47

7/16

07

14 UNC

52

76

1/2

08

13 UNC

76

105

9/16

09

12 UNC

110

160

5/8

10

11 UNC

150

215

3/4

12

10 UNC

265

385

7/8

14

9 UNC

410

595

1

16

8 UNC

640

940

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

80ZV-2 EU 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

M5

0.8

7

M6

1

12

M8

1.25

28

M10

1.5

53

M12

1.75

94

8.8 (8T)

M16

2

231

M20

2.5

441

M24

3

765 (kgf-m)

Bolt size Type

Metric thread

Bolt strength

Nominal dimension

Pitch

M5

0.8

0.7

M6

1

1.2

8.8 (8T)

M8

1.25

2.9

M10

1.5

5.4

M12

1.75

9.6

M16

2

23.5

M20

2.5

45.0

M24

3

78.0 (lb-ft)

Bolt size Type

Metric thread

Bolt strength

Nominal dimension

Pitch

8.8 (8T)

M5

0.8

5.0

M6

1

8.6

M8

1.25

20.9

M10

1.5

38.9

M12

1.75

69.1

M16

2

169.2

M20

2.5

324.0

M24

3

561.6

80ZV-2 EU 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

16

1.2

4

40

2.9

Hose band

Tightening torque (N-m)

Tightening torque (kgf-cm)

Tightening torque (lb-ft)

69002-02200

1.6

16

1.2

4

40

2.9

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

16.5

7.9

18.5

9.5

20.5

12.7

24.5

15.9

29.9

19.0

30.0

25.4

38.0

69002-04400

31.8

45.8

69002-05200

38.1

52.1

69002-05700

50.8

67.8

69002-07100

60.5

76.0

69002-08200

75.5

93.0

69002-09500

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

16.5

8

18.5

9

20.5

9

22.0

12

24.5

12

26.0

15

29.0

15

30.5

19

32.0

19

34.0

25

39.5

25

41.5

32

46.0

32

48.0

38

54.0

50

70.5

50

73.0

69002-02700 69002-03100

69002-02300 69002-02700

69002-03100

69002-03800

69002-04400

69002-05200 69002-05700 69002-07600

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

Fix the band avoiding the beading.

2~3 mm (1/8 in) Pipe

Hose Hose band

K50V200002

80ZV-2 EU 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 (200~250°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 prepares metal surface of the threads and speeds curing time. Antiseize Agent Code

Manufacturer

AC01

Loctite®

Product name Loctite® 767 (Paste or spray)

80ZV-2 EU 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

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.

80ZV-2 EU 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.

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

2. Remove the battery terminals both positive and negative sides from the battery.

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

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

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

Example 1

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

35C00002

Example 2

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

Section to be welded

Ground this section. (correct grounding)

35C00006

80ZV-2 EU 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

Heat-resistant cloth Section to be welded

Hydraulic hose Nylon tube Harness

Remove and if necessary wrap Chassis

35A00005

Plated section (Mask this section.)

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

Pin section with pin temporarily inserted Pin

Plated section (Mask this section.) 35C00003

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

1m or more

Scrap material, etc.

Section to be welded

1m or more 35C00004

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

80ZV-2 EU 00-22 00 General Information

MEMO

80ZV-2 EU 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

80ZV-2 EU 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 tank before removing the plug from the pressure measurement port so that the internal pressure of the hydraulic tank is released and burst of the high pressure oil can be prevented.

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

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

80ZV-2 EU 03-3 03 Measurement for Performance Check Standard Measurement Values for Performance Check

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

Item Measurement item

System

Engine speed (min-1) (rpm)

Engine

(S/N 9001~9200)

(S/N 9201~)

Transmission

Minimum no-load speed, Low Idle (LI)

800±50

Maximum no-load speed, High Idle (HI)

2,300±50

Maximum speed in torque converter stall mode

2,270±100

2,095±100

Maximum speed in multiple control valve relief mode

2,275±100

2,025±100

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

1,830 +150 - 100

1,695 +150 - 100

Minimum no-load speed, Low Idle (LI) Engine speed (min-1) (rpm)

Fuel efficient mode

Normal

800±50

Maximum no-load speed, High Idle (HI)

2,300±50

2,100±50

Maximum speed in torque converter stall mode

2,270±100

2,095±100

Maximum speed in multiple control valve relief mode

2,275±100

2,285±100

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

1,830 +150 - 100

1,695 +150 - 100

Remarks

725 in hibernate mode

725 in hibernate mode

Idling (LI)

1.3±0.2 (13±2) (185±28)

Maximum (HI)

1.5±0.2 (15±2) (213±28)

Clutch pressure MPa (kgf/cm2) (psi)

Engine speed

Clutch time lag (sec)

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

0.3±0.1

Before wheels move

80ZV-2 EU 03-4 03 Measurement for Performance Check Standard Measurement Values for Performance Check

Standard measurement values for performance check

Item Measurement item

System

Normal

Hydraulic pressure

Cylinder drift Boom cylinder (when boom and bucket are horizontal and with no load) Bucket cylinder (mm/min) (in/min)

Engine speed

Full steering time (sec)

Engine speed

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

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

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

Remarks

3 (1/8) or less

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

Boom rising time (no load) (sec)

Fuel efficient mode

21±3.0 -1

1,500 min (rpm)

10±1.0

Maximum (HI)

6.0±0.5

Idling (LI)

5.0±0.5

1,500 min-1 (rpm)

2.1±0.3

Maximum (HI)

2.0±0.3

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)

Steering line overload relief pressure (LI)

+10 24.5 +1.0 0 (250 0 ) (3,555 +1420 )

Run engine at lowest possible speed while setting

Pilot line reducing pressure (LI)

3.5 (36) (512)

Run engine at lowest possible speed while setting

Engine water temp. <80ºC (180ºF) T/C oil temp. <110ºC (230ºF) Hydraulic oil temp. <90ºC (195ºF)

1,050 +75 - 200

Engine water temp. >95ºC (205ºF) T/C oil temp. >115ºC (240ºF) Hydraulic oil temp. >95ºC (205ºF)

1,500 +100 - 50

Engine water temp. <60ºC (140ºF) Engine idle revolution

500 +50 - 200

Run engine at lowest possible speed while setting

80ZV-2 EU 03-5 03 Measurement for Performance Check Standard Measurement Values for Performance Check

Standard measurement values for performance check

Item Measurement item

System

Shift lever position

2nd speed reverse

Engine speed

Maximum (HI)

Shift lever position

3rd speed reverse

Performance of service brake

Performance of parking brake

Brake

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)

Unloader valve setting pressure

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

Remarks

Slowly increase the engine Brake pedal fully speed, and check that the depressed and held machine does not move at the down during test. maximum engine speed.

Ditto Engine speed

Brake line setting pressure MPa (kgf/cm2) (psi)

Fuel efficient mode

Normal

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

3.9±0.5 (40±5) (569±71)

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 tuned on.

at least 8 times

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

Declutch engagement (cm) (in)

Engine: Maximum speed/ declutch pedal: Quick release (Distance the loader rolls back before moving forward.)

15 (6) or less

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

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

10

80ZV-2 EU 03-6 03 Measurement for Performance Check

MEMO

80ZV-2 EU 12-1 12 Function & Structure Chassis Group

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

80ZV-2 EU 12-2 12 Function & Structure Chassis Group Front Chassis

Front Chassis Loading linkage

5 4

3 9

10 2 8

1

7

6

80ZVE12001

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)

80ZV-2 EU 12-3 12 Function & Structure Chassis Group Front Chassis

(Hinge pin height at bucket on ground) Typical bucket roll-back stopper adjustment (Contact attachment supplier for details on non-standard attachments)

(13.22 ft)

4,030

Even contact both sides

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. (FM) 80V2U12001b

80ZV-2 EU 12-4 12 Function & Structure Chassis Group Front Chassis

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

2. Boom - Lever

3. Boom - Boom cylinder

4. Front chassis - Boom

5. Attachment - Link

6. Lever - Link

7. Lever - Bucket cylinder

8. Bucket cylinder Front chassis

9. Boom cylinder Front chassis

10. Front chassis Steering cylinder

11. Steering cylinder Rear chassis

8

4

7 9 2

5 10

11

3

6 1

80ZV12002

80ZV-2 EU 12-5 12 Function & Structure Chassis Group Rear Chassis

Rear Chassis Fuel tank (S/N 9001~9128) 2

7

6

A-A

3

4 9 2

10

1

A

5

6. Inspection hole cover 7. Gasket (Rubber seal type) 8. Suction pipe 9. Fuel return pipe 10. Fuel level sensor cover

290 L (76.6 gal)

1. Fuel tank 2. Fuel level sensor 3. Fuel tank filler assembly 4. Filter 5. Drain cock

6

324 L (85.6 gal)

8

A

80V2E12001

80ZV-2 EU 12-6 12 Function & Structure Chassis Group Rear Chassis

Fuel tank (S/N 9129~)

(S/N 9273~)

6. Inspection hole cover 7. Gasket (Rubber seal type) 8. Suction pipe 9. Fuel return pipe 10. Fuel level sensor cover 11. Fuel level sensor (S/N 9273~)

1. Fuel tank 2. Fuel level sensor 3. Fuel tank filler assembly 4. Filter 5. Drain plug (S/N 9351~ Square socket head)

80ZV-2 EU 12-7 12 Function & Structure Chassis Group Rear Chassis

Floor board mount

Viscous mount

Floor board

1

1

2

2

3 4 80ZVE12007

5

1. Floor board 2. Viscous mount 6

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.

7

8

9

70ZV12007

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. 1. Stud 2. Cushion rubber 3. Case 4. Cap 5. Damping plate 6. Plain washer 7. Head bolt 8. Silicon oil 9. Plug

80ZV-2 EU 12-8 12 Function & Structure Chassis Group Center Pin

Center Pin Upper center pin

Lower center pin

8 4

6

8

7

10

7

5 3

11

4

2

5 6

1 3

Front chassis Rear chassis

12 9 Upper

2

5 Rear chassis Front chassis

1 Lower

80ZVE12008

Upper

Lower

1. Center pin 2. Cover 3. Bearing cover 4. Sleeve 5. Shim 6. Bearing assembly 7. Dust seal 8. Bushing 9. Bolt 10. Bolt 11. Grease nipple 12. Washer

1. Center pin 2. Bearing retainer 3. Bearing assembly 4. Dust seal 5. Bushing 6. Bolt 7. Plane washer 8. Grease nipple

80ZVE12011

80ZV-2 EU 12-9 12 Function & Structure Chassis Group Center Pin

Dust seal

Center pin

Dust seal position 80ZVE12014

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.

80ZV-2 EU 12-10 12 Function & Structure Chassis Group

MEMO

80ZV-2 EU 13-1 13 Check & Adjustment Chassis Group

13 Check & Adjustment Chassis Group Linkage Pin ............................................................. 13-2 Center Pin ............................................................... 13-4

80ZV-2 EU 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

4 5

3

7

6 2 1

80ZVE12005

Adjustment portion

1

2

3

4

5

6

7

Liner hole dia. mm (in)

71 (2.80)

81 (3.19)

121 (4.76)

101 (3.98)

91 (3.58)

Adjustment unnecessary

46 (1.81)

80ZV-2 EU 13-3 13 Check & Adjustment Chassis Group Linkage Pin

Adjustment

*

*

95ZV12005

Adjust the clearance (*) to 1.2 mm (0.05 in) or less between the bosses using liner of 1 mm (0.04 in) thickness. For the steering cylinder, be sure to adjust the clearance on the rear chassis side first and then on the front chassis side while checking that the cylinder is not inclined.

80ZV-2 EU 13-4 13 Check & Adjustment Chassis Group Center Pin

Center Pin Adjusting shim

Installing bearing cover B

8 4

7

Grease nipple direction

3

10 3

11

Front

B 5 6

Grease nipple direction

3 Front chassis Rear chassis

12 9 Upper

2

1 80ZVE12008

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).

B-B

80ZVE12010

Install the bearing cover (3) so that the grease nipple mounting hole is positioned at the specified angle as shown in the figure.

80ZV-2 EU 13-5 13 Check & Adjustment Chassis Group Center Pin

Installing bearing outer ring 6

8

7

5

4

2

1 3

5 Rear chassis Front chassis Lower

80ZVE12011

3 Front Split of outer bearing

Grease nipple direction

40

80ZVE12012

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

80ZV-2 EU 13-6 13 Check & Adjustment Chassis Group

MEMO

80ZV-2 EU 22-1 22 Function & Structure Power Group

22 Function & Structure Power Group Power Line .............................................................. 22-2 Engine / Transmission............................................. 22-3 Radiator (S/N 9001~9100) ...................................... 22-4 Radiator (S/N 9101~) .............................................. 22-6 Propeller Shaft......................................................... 22-8 Axle Assembly......................................................... 22-11 Axle Support............................................................ 22-12 Differential Gear ...................................................... 22-14 Limited Slip Differential (option) .............................. 22-18

80ZV-2 EU 22-2 22 Function & Structure Power Group Power Line

Power Line

"

'

!

!

(S/N 9101~)

$

"

&

#

%

(~S/N 9100) & 8 -

1. Engine 2. Torque converter and transmission 3. Radiator 4. 2nd propeller shaft 5. 3rd propeller shaft 6. Front axle differential gear 7. Rear axle differential gear 8. Parking brake 9. Air cleaner 10. Muffler 11. Hydraulic oil cooler 12. Torque converter oil cooler 13. Air charge cooler 14. Fan motor

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 and an external air type hydraulic oil cooler. On the second propeller shaft side of the transmission, a parking brake is installed.

80ZV-2 EU 22-3 22 Function & Structure Power Group Engine / Transmission

Engine / Transmission Engine / transmission mount

B A B

C A

3

Transmission side

Engine crankshaft center

Engine side

Transmission Flywheel

1

1

Ring gear Ring

2

3 A-A

2 B-B

Detail of C

80V2E22002

1. Bushing-Rubber 2. Washer 3. Bracket

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

80ZV-2 EU 22-4 22 Function & Structure Power Group Radiator (S/N 9001~9100)

Radiator (S/N 9001~9100)

Air charge cooler OUT

Air charge cooler IN

Coolant IN

1 3 C

C

2 A

A

D

B

D

B

4

Hydraulic oil cooler OUT

Hydraulic oil cooler IN

5 T/C oil cooler IN T/C oil cooler OUT

Drain

Coolant OUT

80V2U22003

1. Radiator assembly 2. Stay (Bracket) 3. Air charge cooler 4. Hydraulic oil cooler 5. T/C oil cooler

The radiator incorporates the engine coolant, cooling fin, air charge cooler, and an external air type hydraulic oil cooler. For the engine coolant, air charge cooler and hydraulic oil, the air-cooling system is used. For the torque converter oil, the water-cooling system is used. The air charge cooler is required to meet engine emission regulations.

80ZV-2 EU 22-5 22 Function & Structure Power Group Radiator (S/N 9001~9100)

Radiator mount 1

3 3 2

2

4

4

3

Rear chassis

1 Rear chassis

A-A

B-B

3 Rear chassis

C-C

D-D 80V2E22004

1. Stay (Bracket) 2. Bushing-Rubber 3. Washer 4. Plate Capacity in radiator: 42 L (11 gal) Cooling water 3.6 L (1.0 gal) Hydraulic oil Torque converter oil 2.4 L (0.6 gal) Dry weight

380 kg (840 lbs)

80ZV-2 EU 22-6 22 Function & Structure Power Group Radiator (S/N 9101~)

Radiator (S/N 9101~)

T/C oil cooler IN

Coolant IN Air charge cooler IN

Air charge cooler OUT

B 3

B 5

1

2

A

C D

A

D C

4

Drain

T/C oil cooler OUT Coolant OUT

Hydraulic oil cooler OUT

Hydraulic oil cooler IN

K85V2J22002

1. Radiator assembly 2. Stay (Bracket) 3. Air charge cooler 4. Hydraulic oil cooler 5. T/C oil cooler

The radiator incorporates the engine coolant, cooling fin, air charge cooler, torque converter oil cooler and an external air type hydraulic oil cooler. For the engine coolant, air charge cooler, hydraulic oil and torque converter oil, the air-cooling system is used. The air charge cooler is required to meet engine emission regulations.

80ZV-2 EU 22-7 22 Function & Structure Power Group Radiator (S/N 9101~)

Radiator mount Radiator

1 3

Radiator

3

Rear chassis

4

2

Rear chassis

3

1 A-A

Radiator

B-B

C-C

4

2 Rear chassis

3

D-D

K85V2J22003

1. Stay (Bracket) 2. Bushing-Rubber 3. Washer 4. Plate Capacity in radiator: 16.4 L (4.4 gal) Cooling water 3.6 L (1.0 gal) Hydraulic oil Torque converter oil 9.2 L (2.5 gal) Dry weight

380 kg (840 lbs)

80ZV-2 EU 22-8 22 Function & Structure Power Group Propeller Shaft

Propeller Shaft 1

3

4

2

80V2E22005

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.

80ZV-2 EU 22-9 22 Function & Structure Power Group Propeller Shaft

Second propeller shaft assembly Front differential – Transmission 1

3

1

d

2 c

1

Grease nipple installation angle (a,b,c,d)

a

b

45 Z

View Z

4

4

Every 2000 hours greasing

3

1

Transmission

1 Every 12000 hours greasing Front differential

2 Every 12000 hours greasing

1

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

80V2U22001

80ZV-2 EU 22-10 22 Function & Structure Power Group Propeller Shaft

Third propeller shaft assembly Transmission – Rear differential 1

2

1 Grease nipple installation angle

45

B

45

A View B

View A

1

2

1

Every 12000 hours greasing 80ZV22003

1. Journal spider assembly 2. Coupling yoke

80ZV-2 EU 22-11 22 Function & Structure Power Group Axle Assembly

Axle Assembly 1

44

3 38 12 15

25 15

41 41 35

33

41

7(RH) 6(LH)

32

2

40

31

39 23

45 18 13

16 26

30

24

11

27

10

19

28 16 17 9 14 43

36 21

22

37 29

41

20

5

4 35

8 42 34

80ZVE22011

1. Differential assembly 2. Axle housing assembly 3. Wheel hub 4. Spider (planetary carrier) 5. Cover 6. Axle shaft 7. Axle shaft 8. Sun gear 9. Disc gear 10. Planetary gear 11. Internal gear 12. Internal gear hub 13. Snap ring 14. Planetary pin 15. Plug

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. Needle cage 29. Snap ring 30. Floating seal

31. O-ring 32. O-ring 33. O-ring 34. O-ring 35. Magnet plug 36. Spring pin 37. Bolt 38. Bleed screw 39. Ring 40. O-ring 41. Seal washer 42. Bolt 43. O-ring 44. O-ring 45. Bolt

80ZV-2 EU 22-12 22 Function & Structure Power Group Axle Support

Axle Support A Rear side of axle support

9 8

7 13

Grease pipe connection port (PT1/8)

Grease pipe connection port Axle housing

(PT1/8)

Front

8

8

3

4

Front side of axle support

A 1

View A-A

2

10

5 12

11

9

6

#9 Details (Front side)

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

10 Groove #10 Details (Rear side)

8. Breather 9. Bushing 10. Bushing 11. Ring 12. Bolt 13. Bolt

80V2U22004

80ZV-2 EU 22-13 22 Function & Structure Power Group Axle Support

Rear axle assy

8 (S/N ~9023) 8 (S/N 9024~)

5

9 (S/N ~9023) 8

5 11 4 12 7

1

(S/N 9024~) 8

3 7

14

13

10

13

2 6

K80V2U22001

1. Rear axle support (front) 2. Rear axle support (rear) 3. Plate 4. Plate 5. Lip seal 6. Lip seal 7. Wear ring 8. Breather (S/N ~9023) Elbow fitting (S/N 9024~) 9. Bushing 10. Bushing 11. Ring 12. Bolt 13. Bolt 14. Dowel pin

80ZV-2 EU 22-14 22 Function & Structure Power Group Differential Gear

Differential Gear Torque proportioning type Front differential gear

1

2

21 3 4 6 5 20 7 8 9

19 10

11 12

18 13 15

18 16 17

14 80V2E22008

1. Nut 2. Flange yoke 3. Oil seal 4. Flange 5. Shim 6. Taper roller bearing 7. Spacer

8. Spiral gear set 9. Carrier assembly 10. Taper roller bearing 11. Adjusting nut 12. Plate 13. Wear ring 14. Side gear

15. Differential pinion 16. Wear ring 17. Spider 18. Housing 19. Roller bearing 20. O-ring 21. O-ring

80ZV-2 EU 22-15 22 Function & Structure Power Group Differential Gear Rear differential gear

1 2 22 3 5 4

7 6

21

8 9

10

20 11

12 13

19

19

14 16

15 17

18

80V2E22009

1. Nut 2. Flange yoke 3. Oil seal 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. Wear ring 18. Spider 19. Housing 20. Roller bearing 21. O-ring 22. O-ring

80ZV-2 EU 22-16 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

R2

Difference in gear shapes

R1

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 35~50 % longer than the conventional differential.

80ZV-2 EU 22-17 22 Function & Structure Power Group Differential Gear

Operation of T.P.D Rotational direction

Pinion

Pinion Side gear

L

R2

R

L

R2

R1

R

R

R2

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

R1

L

[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 1.6. In other words, until the difference in the surface resistance between the right and left tires is increased to 60 %, 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.

80ZV-2 EU 22-18 22 Function & Structure Power Group Limited Slip Differential (option)

Limited Slip Differential (option) LSD structure Differential assembly

Note 1. Clutch assembly (2) is built with three plates as a unit. Do not change this combination. 2. When installing clutch assembly (2), make sure of the direction of plates (surfaces with lining and surface without lining). With lining Without lining

2 Side gear

Differential cage

1 4

5

3 2 1 5

2 3

4

3 2

Limited Slip Differential 1 K80V22001

1. Differential cage 2. Clutch assembly 3. Side gear 4. Pin 5. Bolt

80ZV-2 EU 22-19 22 Function & Structure Power Group Limited Slip Differential (option) Front differential gear

1

2

21 3 4 6 5 20 7 8 9

19 10 22 11 12

20 13 15

18

16 17

14 80V2E22010

1. Nut 2. Flange yoke 3. Oil seal 4. Flange 5. Shim 6. Taper roller bearing 7. Spacer 8. Spiral gear set

9. Carrier assembly 10. Taper roller bearing 11. Adjusting nut 12. Plate 13. Clutch assembly 14. Side gear 15. Differential pinion 16. Wear ring

17. Spider 18. Housing 19. Roller bearing 20. O-ring 21. O-ring 22. Pin

80ZV-2 EU 22-20 22 Function & Structure Power Group Limited Slip Differential (option) Rear differential gear

1 2 23 3 5 7 4

6

22 8 9 10

21 11 17 12 13

20 14 16

20

18 19

15 80V2E22011

1. Nut 2. Flange yoke 3. Oil seal 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. Clutch assembly 15. Side gear 16. Differential pinion 17. Pin 18. Wear ring 19. Spider 20. Housing 21. Roller bearing 22. O-ring 23. O-ring

80ZV-2 EU 22-21 22 Function & Structure Power Group Limited Slip Differential (option)

LSD function

LSD operation Performance comparison between LSD and TPD LSD TPD

Differential pinion

LSD Differential point 0.57 (bias ratio 1.75) LS D O

Torque

LSD clutch assembly Differential cage

re e ti On

0

Axle shaft

Side gear

Side gear moves to the left and pushes LSD clutch.

0.1

spi

i ns

e ra n th

nge

A

in th pins s e r ti One

nge e ra

peratin

g range

ati Oper TPD

1

nge

TPD Differential point 0.63 (bias ratio 1.6)

0.2 0.3 0.4 0.5 0.6 0.7 0.8 Friction ratio between right and left tires

0.57

n g ra

0.9

1

Torque is transferred to the right and left tires evenly until the friction ratio between the right and left tires comes to 0.57:1. The result is that the LSD adds tractive effort.

A - Detail 85V2E22006

LSD (Limited-Slip Differential) is installed between the side gear and the differential cage in TPD (Torque Proportioning Differential), and increases tractive effort. If the surface traction of the right and left tires differ from each other during operation, LSD clutch engages and prevents traction loss. The performance of LSD is shown by using the bias ratio. The bias ratio is the ratio between the driving force of the right and left tires while the differential pinion is turned. When the bias ratio is larger, it is easier to gain traction on the ground surface with less resistance.

85V2E22007

The following shows operation for the left tire. A rotating driving force is transmitted from the differential cage via spider (cross shaft) to the differential pinion and the side gear. When the ground surface resistance for the left tire lessens, the tapered interface between the differential pinion and the left side gear induces a side force. It pushes the left side gear to the left resulting in frictional engagement with the differential cage, thus impeding free left side gear rotation and gaining traction.

80ZV-2 EU 22-22 22 Function & Structure Power Group

MEMO

80ZV-2 EU 23-1 23 Check & Adjustment Power Group

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

80ZV-2 EU 23-2 23 Check & Adjustment Power Group Engine

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

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

Measurement instrument - Pressure gauge

Install position 1. Location (A) 2. Measuring port: NPTF 1/8 3. Oil pressure gauge: 1.0 MPa (10 kgf/cm2) (142 psi)

Standard measurement value Engine speed -1

2,300 min

Service standard (Regulator set pressure) 0.2 MPa (2.1 kgf/cm2) (30 psi)

[Engine coolant temperature 50ºC (120ºF)]

Measuring engine speed Measurement instrument

A

- Tachometer

Standard measurement value Low idle (min-1): 800±50 High idle (min-1): 2,300±50

QSC8.3 Engine

80V2E23001

80ZV-2 EU 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 will extremely vibrate, 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.

80ZV-2 EU 23-4 23 Check & Adjustment Power Group Propeller Shaft

Tightening torque 2nd propeller shaft

Front diff.

Pillow block (center bearing)

1

4 7

2

3rd propeller shaft

3

Rear diff.

6

Front diff. side

5 80V2E23002

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) (325 lb-ft) 5. 155 N-m (15.8 kgf-m) (114 lb-ft) 6. 69 N-m (7.0 kgf-m) (51 lb-ft) 7. 18 N-m (1.8 kgf-m) (13 lb-ft)

1, 2, 3: Screw lock agent (Three Bond 1327) 4: Screw lock agent (Loctite® 262)

80ZV-2 EU 23-5 23 Check & Adjustment Power Group Axle

Axle Axle nut tightening procedure 5

8

7

6 PT1/4 Brake oil inlet

2

4 9 1

3 80V2U23001

2. Loosen the axle nut.

: 1. 89.7 N-m (9.15 kgf-m) (66 lb-ft) 2. 216 N-m (22.0 kgf-m) (159 lb-ft) 3. 86.3 N-m (8.8 kgf-m) (64 lb-ft) 4. 53.0 N-m (5.40 kgf-m) (39 lb-ft)

3. Tighten the axle nut again with 1,177 N-m (120 kgfm) (868 lb-ft) tightening torque.

#1, 2, 4, 9: Screw lock agent (Three Bond 1327)

1. Tighten axle nut (5) with 1,177 N-m (120 kgf-m) (868 lb-ft) tightening torque to install taper roller bearing (6)(7).

4. Turn wheel hub (8) 2~3 turns back and forth, and measure the preload applied to section ( part). Preload of section ( part) 206~245 N (21~25 kgf) (46~55 lbf)  This is "breakaway" force. The force required to start the wheel turning. Note Use jig to install the floating seal to the axle assembly.

80ZV-2 EU 23-6 23 Check & Adjustment Power Group Axle

Differential gear adjustment procedure 1

9 7 2

6

8 5

4

3 80V2E23004

: 1. 883 N-m (90.0 kgf-m) (651 lb-ft) 2. 314 N-m (32.0 kgf-m) (232 lb-ft) 3. 330 N-m (33.7 kgf-m) (244 lb-ft) 4. 52.5 N-m (5.35 kgf-m) (39 lb-ft) 5. 235 N-m (24.0 kgf-m) (174 lb-ft)

#2, 3, 4, 5: Screw lock agent (Three Bond 1327) #1, 9: Liquid gasket (Three Bond 1215 or a locally procured Room Temperature Vulcanizer (RTV) that does not contain Acetic Acid)

80ZV-2 EU 23-7 23 Check & Adjustment Power Group Axle

Preload adjustment

Bearing installation

Measure the preload at the bolt hole of cage (7).

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

Standard preload 57~66 N (5.8~6.7 kgf) (13~14 lbf)

Pinion gear Snap ring

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.

Bearing (8)

Note There are 14 types of spacers from 16.70 mm (0.657 in) to 16.98 mm (0.668 in) in increments of 0.02 mm (0.0007 in). Thicker spacers reduce preload; thinner spacers increase preload.

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 oil seal (9), be sure to apply grease to the lip.

Apply grease when assembling.

K85ZV23004

80ZV-2 EU 23-8 23 Check & Adjustment Power Group Axle

Adjusting tooth contact Tooth contact

Possible cause

Adjusting method

A

Correct

B

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.

C

Ring gear is too far from the drive pinion

Do the reverse adjusting as B.

Drive pinion is too close to the ring gear.

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

2

2

D

2

1

E

Drive pinion is too far from the ring gear.

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

2

1

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

80ZV-2 EU 23-9 23 Check & Adjustment Power Group Axle Three types of tooth contact shown below are acceptable as the best tooth contact. Tooth contact position and length (rate) 10 1

Pattern A

5 TOP

4

HEEL 4~5

Pitch line TOE

10

BOTTOM 10 2

Pattern B

4 TOP

4

HEEL

Pitch line

4~5

10

TOE BOTTOM 10 3

Pattern C

4

TOP TOE

3

HEEL 4~5

10

Pitch line BOTTOM

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

80ZV-2 EU 23-10 23 Check & Adjustment Power Group

MEMO

80ZV-2 EU 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 Transmission ........................................................... 32-4 Clutch Pack ............................................................. 32-7 Power Flow Path in the Transmission ..................... 32-11 Hydraulic System Diagram...................................... 32-14 Hydraulic Circuit Diagram........................................ 32-15 Oil Flow ................................................................... 32-16 T/C and T/M Oil Circulation ..................................... 32-17 Control Valve ........................................................... 32-19 Modulation Mechanism ........................................... 32-21 Clutch Solenoid Valve ............................................. 32-27

80ZV-2 EU 32-2 32 Function & Structure Torque Converter and Transmission Group Torque Converter

Torque Converter Torque multiplication

Output

Torque ratio (t)

4

Input

3

2

S P

1

T

95ZV32002

0.5 Speed ratio (e)

1.0

95ZV32003

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.

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.

80ZV-2 EU 32-3 32 Function & Structure Torque Converter and Transmission Group Torque Converter Gear Pump

Torque Converter Gear Pump Gear pump specifications

1 2 7

Theoretical

64.5 cc/rev (3.9 in3/rev)

Maximum operation pressure

2 MPa (20 kgf/cm2) (284 psi)

Maximum operation speed

2,400 min-1 (rpm)

3 Actual discharge

4

6

8

5

9

80ZVE32002

1. Driven gear 2. Needle bearing 3. Driven gear shaft 4. Oil seal 5. Drive gear 6. Housing 7. Pump cover 8. Dowel pin 9. Gasket

Approx. 120 L/min (31.7 gpm) Conditions: Pump speed 2,200 min-1 Oil temp. 80~100°C (176~212°F) Oil viscosity 40CST (SAE10W) Discharge pressure 1.4~1.6 MPa (14~16 kgf/cm2) (199~228 psi)

80ZV-2 EU 32-4 32 Function & Structure Torque Converter and Transmission Group Transmission

Transmission Clutch combination Clutch Speed range

F

R

1

2

Downshift button operation 3

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

4

F1

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

F2 F3 F4 N

*

*

*

(Either 1st or 2nd or 3rd)

R1 R2 R3 R4

The transmission is equipped with six clutches: Forward range, reverse, and 1st, 2nd, 3rd and 4th speeds. Combining the clutches as shown in the table here provides four forward speeds, and four reverse speeds for a total of eight speeds. Two clutches must be engaged at the same time to move the machine.

Shift lever position Position of shift lever

Function

1

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

2

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

3

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

A

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

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

80ZV-2 EU 32-5 32 Function & Structure Torque Converter and Transmission Group Transmission

Gear train and number of teeth 9

8 4

14 16 12 12

9

18

61 70

29

20 23

8

27

4

20 65

32

33

26

24

31 12

34 20

14

18

16

41

68

82

52 38

23 Gear arrangement

4

3

F

4

3

F

1

2

R

2

R

24 34

23

26

29

27 34

23

34

37 53 32

67

31

55

80V2E32001

Note Numbers below correspond to page 92-3. No.

Gear name

Number of teeth

No.

Gear name

Number of teeth

4

Turbine shaft gear

33

23

4th speed clutch gear

82

8

PTO drive gear A

65

24

1st speed clutch gear

67

9

PTO drive gear B

61

26

Counter gear C

23

12

Idle gear

41

27

Counter shaft C gear

23

14

Forward clutch gear

34

29

Reverse clutch gear

34

16

3rd speed clutch gear

68

31

Counter gear D

53

18

Counter gear A

52

32

2nd speed clutch gear

37

20

Counter gear B

38

34

Output shaft gear

55

80ZV-2 EU 32-6 32 Function & Structure Torque Converter and Transmission Group Transmission

Clutch specifications

Name of clutch

Piston stroke (mm)

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

Forward clutch

3.8±0.3

8

7

20

Reverse clutch

4.3±0.3

8

7

20

1st speed clutch

3.8 +0.5 -1.0

10

2nd speed clutch

3.0±1.0

5

3rd speed clutch

3.0±1.0

5

4

16

4th speed clutch

2.95±1.0

5

4

16

ø167 ø104.8 (6.57 in) (4.12 in)

2.0±0.1 / 1.8

9 4

ø182 ø116 (7.16 in) (4.57 in)

1.8±0.1 / 1.6

16 16

Note: All friction plates, steel plates and return springs are the same for each clutch.

Friction plate: mm (in)

Detailed drawing of groove 80ZV32001

1. Plate 2. Facing

80ZV-2 EU 32-7 32 Function & Structure Torque Converter and Transmission Group Clutch Pack

Clutch Pack Forward and 3rd speed clutches

3

11 5

7

6

12

4

8 9 2

3

1 F

13

14

14

10 K80V2U32001

1. Counter shaft 2. Forward clutch gear (T/M S/N ~0140: Helical, T/M S/N 0141~: Spur) 3. 3rd speed clutch gear (Helical) 4. Forward clutch 5. 3rd speed clutch 6. Forward clutch piston 7. 3rd speed clutch piston 8. Steel plate 9. Friction plate 10. Return spring 11. Clutch drum (with counter gear) (Helical) 12. Residual pressure prevention orifice 13. Seal rings 14. Needle bearings

80ZV-2 EU 32-8 32 Function & Structure Torque Converter and Transmission Group Clutch Pack

Reverse and 2nd speed clutches

11 5

7

6

4

8 9

12

2

3

15

2

1 R

13

14

10 K80V2U32002

1. Counter shaft 2. Reverse clutch gear (T/M S/N ~0140: Helical, T/M S/N 0141~: Spur) 3. 2nd speed clutch gear (Helical) 4. Reverse clutch 5. 2nd clutch 6. Reverse clutch piston 7. 2nd speed clutch piston 8. Steel plate 9. Friction plate 10. Return spring 11. Clutch drum (also used as counter gear) (Helical) 12. Residual pressure preventive orifice 13. Seal rings 14. Needle bearings 15. Thrust bearing

80ZV-2 EU 32-9 32 Function & Structure Torque Converter and Transmission Group Clutch Pack

1st speed clutch 8

4

1

2

10

5

7

6

3

1

9 80ZV32007J

1. Counter shaft 2. Counter gear A (Helical) 3. Counter gear B (Helical) 4. Clutch drum 5. Clutch piston 6. Steel plate 7. Friction plate 8. 1st speed clutch gear (Helical) 9. Return spring 10. Residual pressure preventive orifice

80ZV-2 EU 32-10 32 Function & Structure Torque Converter and Transmission Group Clutch Pack

4th speed clutch

7

6

5

4

9

3 2

4 1

8

80ZV32008J

1. Counter shaft 2. Counter gear (Helical) 3. Clutch drum 4. Clutch piston 5. Steel plate 6. Friction plate 7. 4th speed clutch gear (Helical) 8. Return spring 9. Residual pressure preventive orifice

80ZV-2 EU 32-11 32 Function & Structure Torque Converter and Transmission Group Power Flow Path in the Transmission

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

Forward 2nd speed power flow path

The idle gear shown here is also connected to the reverse clutch gear.

12 20

24 25 26

19

18

15

15

26

14

34 35

34 35 27

32

33 31

80ZV32002

80ZV32003

1. The power from the torque converter is transmitted to idle gear (12) and to forward clutch gear (14) where forward clutch (15) is connected. The forward clutch then transmits the power to counter shaft A (19).

1. The power from the torque converter is transmitted to forward clutch (15). The forward clutch transmits the power to counter gear A (18), and then, to counter gear D (31).

2. Counter shaft A (19) is spline-connected to counter gear B (20), therefore the power is then transmitted to 1st speed clutch gear (24). 3. The 1st speed clutch gear is connected to 1st speed clutch (25) that transmits the power to counter gear C (26), and then, to output shaft gear (34). After that, the power is finally transmitted to output shaft (35).

2. When 2nd speed clutch (33) is engaged, the power will be transmitted to 2nd speed clutch gear (32). 3. Since 2nd speed clutch gear (32) is spline-connected to counter shaft C (27), the power is transmitted to counter gear C (26), and then, to output shaft gear (34). After that, the power is finally transmitted to output shaft (35).

80ZV-2 EU 32-12 32 Function & Structure Torque Converter and Transmission Group Power Flow Path in the Transmission

Forward 3rd speed power flow path

16

Forward 4th speed power flow path

23

21 20 19

18

15

17 15

32 27 26

26 27

34 35

34 35

80ZV32004

80ZV32005

1. The power from the torque converter is transmitted to forward clutch (15), and then, to 3rd speed clutch (17) that is connected to 3rd speed clutch gear (16). The power is then transmitted to 2nd speed clutch gear (32).

1. The power from the torque converter is transmitted to forward clutch (15). Forward clutch (15) transmits the power to counter gear A (18), and then, to counter shaft A (19).

2. Since 2nd speed clutch gear (32) is spline-connected to counter shaft C (27), the power is transmitted to counter gear C (26). 3. Counter gear C (26) transmits the power to output shaft gear (34), and then, to output shaft (35).

2. Counter shaft A (19) is spline-connected to counter gear B (20). 3. When 4th speed clutch (21) is engaged, the power will be transmitted to 4th speed clutch gear (23). 4. 4th speed clutch gear (23) transmits the power to counter shaft gear (27), counter gear C (26), and then, to output shaft gear (34). After that, the power is finally transmitted to output shaft (35).

80ZV-2 EU 32-13 32 Function & Structure Torque Converter and Transmission Group Power Flow Path in the Transmission

Reverse 1st speed power flow path

19

18 31 30 29 12

The torque converter and idle gear shown in this figure are actually identical to those shown in the forward speed diagrams. The idle gear is engaged with both the forward and reverse clutches. 80ZV32006

1. The power from the torque converter is transmitted to idle gear (12) and then to reverse clutch gear (29) where reverse clutch (30) is connected. The reverse clutch then transmits the power to counter gear D (31), counter gear A (18), and then, to counter shaft A (19). 2. After that, the power is transmitted to the output shaft via the same route as forward 1st speed.

Reverse 2nd, 3rd, and 4th speeds power flow paths Refer to the transmission routes of the above reverse 1st speed and the forward 2nd, 3rd, and 4th speeds.

80ZV-2 EU 32-14 32 Function & Structure Torque Converter and Transmission Group Hydraulic System Diagram

Hydraulic System Diagram Note Numbers below correspond to page 32-15.

Shift lever

Parking switch Declutch switch

Speed sensor

Downshift button

MCU

9 6

7 8

4th

T/M Oil pan

18

F

1st

5

15 3rd

13

25

3

R 2nd

17

14

16

4 19 23

10

24

21

20

22 1

2

80ZVE32014

80ZV-2 EU 32-15 32 Function & Structure Torque Converter and Transmission Group Hydraulic Circuit Diagram

Hydraulic Circuit Diagram Oil temp. sensor

Neutral position

25

0.5 MPa 11 (4.7 kgf/cm2) (67 psi)

10

M16 x1.5

P

T S 6 12

7 9

8

19 26

5

13

20 14 21 15

PF1/4 1.3±0.2 ~ 1.5±0.2 MPa (13±2 ~ 15±2 kgf/cm2) (185±28 ~ 213±28 psi)

0.3 MPa (3.5 kgf/cm2) (50 psi)

4

3

22 16

2 1

23 17

24 18

K85V2U32003

1. Transmission oil pan 2. Strainer 3. Torque converter gear pump 4. Line filter with bypass valve 5. Control valve 6. Clutch pressure regulator valve 7. Trimmer plug 8. Orifice (ø1.3) 9. Trimmer solenoid valve 10. Torque converter 11. T/C inlet relief valve 12. Orifice (ø1.2) 13. Forward clutch solenoid valve

14. Reverse clutch solenoid valve 15. 1st speed clutch solenoid valve 16. 2nd speed clutch solenoid valve 17. 3rd speed clutch solenoid valve 18. 4th speed clutch solenoid valve 19. Forward clutch 20. Reverse clutch 21. 1st speed clutch 22. 2nd speed clutch 23. 3rd speed clutch 24. 4th speed clutch 25. Torque converter oil cooler 26. Residual pressure preventive orifice

80ZV-2 EU 32-16 32 Function & Structure Torque Converter and Transmission Group Oil Flow

Oil Flow Oil flow in the torque converter line From torque converter gear pump to torque converter The oil fed from pump (3) flows through line filter (4) into control valve (5). In the clutch circuit, the oil flow rate is low, therefore, clutch pressure regulator valve (6) opens the torque converter port so that the oil flows into the torque converter circuit. At the inlet of the torque converter, there is inlet relief valve (11) in the case. If the oil pressure exceeds 0.5 MPa (4.7 kgf/cm2) (67 psi), the relief valve will be opened to drain oil into the transmission case.

From torque converter to cooling circuit

Oil flow to the clutch To forward and reverse clutches When the oil flows into the control valve, the oil pressure is adjusted to the specified pressure 1.3±0.2 ~ 1.5±0.2 MPa (13±2 ~ 15±2 kgf/cm2) (185±28 ~ 213±28 psi) by clutch pressure regulator valve (6). After that, the oil flows to forward clutch solenoid valve (13) and reverse clutch solenoid valve (14). Assume that the clutch is changed from "forward" to "reverse". When the clutch is changed to "reverse", reverse clutch solenoid valve (14) is turned on, and the oil flows into the reverse clutch piston chamber. At the same time, the forward clutch solenoid valve is turned off, and the oil in the forward clutch piston chamber is drained. The oil then flows through the clutch solenoid valve into the transmission case. Oil is also drained from the forward clutch piston chamber through the residual pressure prevention orifice in the clutch hub.

The oil returned from the torque converter flows into torque converter cooler (25) inside the radiator.

To speed clutch From cooler to lubrication circuit

The neutral position is available for forward/reverse. There is no neutral position for speed clutches.

The oil cooled by the cooler flows through the lubrication oil passages in the transmission housing to lubricate all the bearings and to cool the clutch plates. After that, the oil is drained into the oil pan.

Therefore, after engine starting, the oil fed from the pump is regulated to the specified pressure by the clutch pressure regulator valve, and then directed to one of the speed clutch piston chambers. Note The engine will not start if the shift lever is set to the forward or reverse position. In other words, the shift lever should be set to the neutral position to start the engine, therefore, the machine will not move the moment the engine is started. When the speed is changed, the oil flows in the same way as the forward/reverse clutch oil flow.

80ZV-2 EU 32-17 32 Function & Structure Torque Converter and Transmission Group T/C and T/M Oil Circulation

T/C and T/M Oil Circulation (S/N 9001~9100)

Transmission oil filter

Rear chassis Torque converter oil cooler

Radiator

Transmission control valve

Transmission Level gauge

80V2E32003

80ZV-2 EU 32-18 32 Function & Structure Torque Converter and Transmission Group T/C and T/M Oil Circulation (S/N 9101~)

Transmission Torque converter oil cooler oil filter

Rear chassis

Transmission control valve

Radiator

Transmission Level gauge

80V2E32011

80ZV-2 EU 32-19 32 Function & Structure Torque Converter and Transmission Group Control Valve

Control Valve

B 9

SKM6 G24D

A

A K WE6K- 22 -

18

15

13

16

B

Section B-B

17

14

Control valve

9

6

Stopper

Section A-A

1. — 2. — 3. — 4. — 5. — 6. Clutch pressure regulator valve 7. Trimmer plug 8. Orifice (ø1.3) 9. Trimmer solenoid valve

7

8

10. — 11. — 12. — 13. Forward clutch solenoid valve 14. Reverse clutch solenoid valve 15. 1st speed clutch solenoid valve 16. 2nd speed clutch solenoid valve 17. 3rd speed clutch solenoid valve 18. 4th speed clutch solenoid valve

80V2E32002

80ZV-2 EU 32-20 32 Function & Structure Torque Converter and Transmission Group Control Valve

System diagram

From torque converter pump

To torque converter

6

9

7

T.R

8 Drain

18 4th

13

15 1st

F

14

16

17 R 2nd

3rd

To forward clutch

To 3rd speed clutch

To reverse clutch

To 2nd speed clutch

To 1st speed clutch

To 4th speed clutch

80V2E32004

1. — 2. — 3. — 4. — 5. — 6. Clutch pressure regulator valve 7. Trimmer plug 8. Orifice (ø1.3) 9. Trimmer solenoid valve

10. — 11. — 12. — 13. Forward clutch solenoid valve 14. Reverse clutch solenoid valve 15. 1st speed clutch solenoid valve 16. 2nd speed clutch solenoid valve 17. 3rd speed clutch solenoid valve 18. 4th speed clutch solenoid valve

80ZV-2 EU 32-21 32 Function & Structure Torque Converter and Transmission Group Modulation Mechanism

Modulation Mechanism When forward/reverse or speed changing, 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. For such effects, the modulation mechanism controls the clutch oil pressure rising time as follows: An electrical signal from the MCU controls the trimmer operation. For information on the MCU refer to "Electrical Group" section.

80ZV-2 EU 32-22 32 Function & Structure Torque Converter and Transmission Group Modulation Mechanism

Clutch control oil pressure curve

ON

Solenoid valve

Electrical signals

For trimmer

OFF ON

For forward clutch

OFF ON

For reverse clutch

OFF

Main pressure Forward clutch pressure

Reverse clutch pressure

1.3±0.2 ~ 1.5±0.2 MPa (13±2 ~ 15±2 kgf/cm2) (185±28 ~ 213±28 psi)

0.3~0.4 MPa (3.5~4.0 kgf/cm2) (50~57 psi)

Clutch oil pressure

Time Pressure increase Specified Initial Lowholding oil pressure pressure feeding holding

80ZVE32018

Initial oil feeding*

Low-pressure holding

Pressure increase

0~0.05 sec.

0.2 sec.

Approx. 1 sec.

*Note: The initial oil feeding time depends on the capacity of the clutch piston chamber.

80ZV-2 EU 32-23 32 Function & Structure Torque Converter and Transmission Group Modulation Mechanism

Traveling at forward 1st speed Pressure holding

9

From torque converter pump

To torque converter

6

7

To each clutch solenoid valve 80ZVE32019

While the machine is traveling, the forward and 1st speed clutch solenoid valves are energized on, the clutch oil is flowing into each clutch piston chamber, and the clutch is kept engaged.

Solenoid valve

Electrical signals

ON For trimmer For forward clutch For reverse clutch

OFF ON OFF

The power of the trimmer solenoid valve (9), however, is off, and the clutch regulator valve (6) and trimmer plug (7) apply pressure to the modulator spring to keep the clutch pressure at the specified value 1.3±0.2 ~ 1.5±0.2 MPa (13±2 ~ 15±2 kgf/cm2) (185±28 ~ 213±28 psi).

ON OFF

Main pressure Forward clutch pressure Reverse clutch pressure

Clutch oil pressure Time

Specified pressure holding 80ZVE32020

80ZV-2 EU 32-24 32 Function & Structure Torque Converter and Transmission Group Modulation Mechanism

Changing from forward 1st speed to reverse 1st speed Releasing forward clutch and feeding initial oil to reverse clutch

Solenoid valve

Electrical signals

ON For trimmer For forward clutch For reverse clutch

OFF ON OFF ON OFF

Main pressure Forward clutch pressure Reverse clutch pressure

Clutch oil pressure Time

Initial oil feeding

80ZVE32021

Changing the shift lever from "forward" to "reverse", turns off the power of the forward clutch solenoid valve. The oil in the forward clutch piston chamber is immediately drained to release the clutch. On the other hand, power to the reverse clutch solenoid valve is turned on, and the oil flows into the reverse clutch piston chamber. After changing the shift lever, power to the trimmer solenoid valve is kept off for a short time, therefore the highpressure oil flows into the reverse clutch piston chamber to rapidly operate the piston. As a result, initial oil supply is quick, and time lag can be prevented.

80ZV-2 EU 32-25 32 Function & Structure Torque Converter and Transmission Group Modulation Mechanism

Trimmer engagement Low-pressure holding

9

From torque converter pump

To torque converter

6

Stopper

7

To each clutch solenoid valve 80ZVE32022

0.05 seconds after changing the shift lever, the power of trimmer solenoid valve (9) is turned on.

Solenoid valve

Electrical signals

ON For trimmer For forward clutch For reverse clutch

OFF

The oil in the trimmer plug chamber is drained, and trimmer plug (7) is returned by spring tension fully to the right. The modulator spring is released to reduce the pressure applied to regulator valve (6). The regulator valve may move fully to the right until it contacts the stopper screwed into the control valve housing. In this position more oil from the torque converter charge pump is drained. The main pressure and reverse clutch pressure, therefore, falls immediately.

ON OFF ON OFF

Main pressure Forward clutch pressure Reverse clutch pressure

Clutch oil pressure Time

Low-pressure holding

80ZVE32023

As a result, the shock at clutch engagement will be softened.

80ZV-2 EU 32-26 32 Function & Structure Torque Converter and Transmission Group Modulation Mechanism

Clutch engagement starting Pressure increase

9

From torque converter pump

To torque converter

6

7

8

To each clutch solenoid valve 80ZVE32024

To soften the shock, the clutch should slip during engagement.

Solenoid valve

Electrical signals

ON For trimmer For forward clutch For reverse clutch

OFF

When the power of the trimmer solenoid valve is turned off again after about 0.2 seconds, the drain port of the trimmer plug chamber is closed, and the oil is fed into the trimmer plug chamber. Pressure is applied to the trimmer plug and the spring to raise the clutch oil pressure. The oil flow rate to the trimmer plug chamber is limited by the orifice (8), therefore the trimmer plug (7) slowly shifts to the left. The clutch pressure, therefore, slowly rises. As a result, the clutch engagement is smooth and causes no shock.

ON OFF ON OFF

Main pressure Forward clutch pressure Reverse clutch pressure

Clutch oil pressure Time

Pressure increase

80ZVE32025

80ZV-2 EU 32-27 32 Function & Structure Torque Converter and Transmission Group Clutch Solenoid Valve

Clutch Solenoid Valve For forward/reverse and speed clutches After power-off (clutch disengaged status)

5 4 Clutch pressure regulator

1

2 6

A

Transmission C oil pan

B

Clutch piston chamber

3 80ZVE32026

1. Coil 2. Plunger 3. Push rod 4. Spring 5. Spool 6. Manual control push button When the power of the coil is turned off, spool (5), push rod (3), and plunger (2) are returned fully to the right, and the line from port A to port B is closed. The line between port B and C is opened, and the clutch is disengaged. Under such a condition, pressing manual control push button (6) (for emergency) opens the line between port A and B, and engages the clutch. Releasing the manual control push button returns the spool fully to the right, and disengages the clutch.

80ZV-2 EU 32-28 32 Function & Structure Torque Converter and Transmission Group Clutch Solenoid Valve

After power-on (clutch engaged status)

Clutch pressure regulator

A

Transmission C oil pan

B

Clutch piston chamber 80ZVE32027

When the power is supplied to the coil, the magnetic power attracts the plunger to the left, and the line between port A and B is opened. Pressure oil flows into the clutch piston chamber. The clutch is engaged.

80ZV-2 EU 32-29 32 Function & Structure Torque Converter and Transmission Group Clutch Solenoid Valve

For trimmer After power-off (high clutch pressure status)

Trimmer plug chamber

6

To transmission oil pan via trimmer spring chamber

80ZVE32028

When the power of the coil is turned off, the spring returns the spool to the right. The line between the trimmer plug chamber and the transmission oil pan is closed, therefore the clutch pressure is kept high. In this condition if the manual control push button (6) is pushed by hand main clutch pressure should be reduced to approximately 0~0.1 MPa (0~1 kgf/cm2) (0~98 psi).

80ZV-2 EU 32-30 32 Function & Structure Torque Converter and Transmission Group Clutch Solenoid Valve

After power-on (just after switching clutch)

Trimmer plug chamber

To transmission oil pan via trimmer spring chamber

80ZVE32029

When the power is supplied to the coil, the magnetic power attracts the plunger to the left, and the oil in the trimmer plug chamber is discharged into the transmission oil pan. The clutch pressure, therefore, falls. If debris were to stick the valve in this position pressure would remain low even if the power to the coil is turned off.

80ZV-2 EU 33-1 33 Check & Adjustment Torque Converter and Transmission Group

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

80ZV-2 EU 33-2 33 Check & Adjustment Torque Converter and Transmission Group Clutch Oil Pressure

Clutch Oil Pressure Measuring clutch oil pressure

T/C inlet oil pressure (PF1/2)

4th speed clutch oil pressure (PF1/4)

Forward clutch oil pressure (PF1/4)

1st speed clutch oil pressure (PF1/4) 3rd speed clutch oil pressure (PF1/4)

Reverse clutch oil pressure (PF1/4)

2nd speed clutch oil pressure (PF1/4)

80ZVE32030

WARNING Unexpected movement of the machine may cause an accident resulting in injury or death. To prevent such an accident during clutch oil pressure measurement, be sure to closely communicate with the person in the cab by giving signals to each other. Also use a gauge with a hose long enough to reach outside from the articulation area.

- Pressure gauge 2 MPa (20 kgf/cm2) (284 psi) with 2~3 m hose - Clutch oil pressure measurement value : 1.3±0.2 MPa (13±2 kgf/cm2) (185±28 psi) at engine idling speed (LI) 1.5±0.2 MPa (15±2 kgf/cm2) (213±28 psi) at engine maximum speed (HI) - Torque converter oil temperature : 50~80ºC (120~180ºF)

80ZV-2 EU 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 ....................................................... 42-16 Hydraulic Cylinder ................................................... 42-19 Loading System ...................................................... 42-22 Reducing Valve (for Pilot Pressure) ........................ 42-23 Pilot Valve (S/N 9001~9205) ................................... 42-24 Pilot Valve (S/N 9206~) ........................................... 42-30 Multiple Control Valve (KML28/2T102).................... 42-35 Adapter (Orifice) ...................................................... 42-46 Ride Control (OPT).................................................. 42-47 Steering System ...................................................... 42-56 Orbitrol® ................................................................... 42-57 Steering Valve (KVS25-A3.0/20) ............................. 42-64 Stop Valve ............................................................... 42-76 Reducing Valve (for Orbitrol®) ................................. 42-78 Steering Line Filter .................................................. 42-79 K-Lever (OPT) ......................................................... 42-80 Efficient Loading System......................................... 42-85 Fan Motor System ................................................... 42-89 Fan Motor Line ........................................................ 42-90 Reversing Fan Motor Line (OPT) ............................ 42-98 Secondary Steering ................................................. 42-103

80ZV-2 EU 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.

80ZV-2 EU 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.

80ZV-2 EU 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)

(1)

(2)

(1)

(2)

(1)

(2)

(1)

(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

80ZV-2 EU 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

M fixed

Bidirectional

M variable

Detent

Flow dividing valve

80ZV-2 EU 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

80ZV-2 EU 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

M

Internal combustion

M

Power source

Filter or strainer

Heater

Cooler

Pressure gauge

Temperature gauge

Flow meter

80ZV-2 EU 42-8 42 Function & Structure Hydraulic Group Hydraulic System Operation

Hydraulic System Operation Hydraulic system operation outline

Return oil from the cylinders flows through the valve to the oil cooler, return filter (12) and into the hydraulic tank.

The hydraulic system consists of the following systems: - Loading system - Steering system

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

- Efficient loading system - Fan motor system

Steering system - Ride control system (OPT) The steering system consists of the following components.

Loading system The loading system consists of the following components. All numbers base on page 92-4. - Hydraulic pump (1) - Unloader valve (22) - Line filter (81) - Check valve (32) - Reducing valve (38) - Pilot valve (16) - Multiple control valve (3) - Boom cylinders (5) - Bucket cylinder (6) Oil from pump (1) flows to pilot valve (16) through unloader valve (22), line filter (81), check valve (32) and reducing valve (38). Oil to pilot valve (16) is reduced to 3.5 MPa (36 kgf/cm2) (512 psi) by reducing valve (38). When the pilot control lever is operated, the pilot valve line is opened, and the oil pressure is generated depending on the position of the pilot control lever. The pilot pressure entering the oil pack to multiple control valve (3) moves the spool against its return spring. The spool press-in distance (displacement) depends on the pilot valve pressure. Oil from the loader pump is then directed through multiple control valve (3) to boom cylinders (5) and bucket cylinder (6).

- Hydraulic pump (1) - Steering valve (4) - Line filter (81) - Reducing valve (18) - Orbitrol® (14) - Stop valve (15) - Steering cylinder (8) Oil from pump (1) flows to Orbitrol® (14) through steering valve (4), line filter (81) and reducing valve (18). Oil to Orbitrol® (14) is reduced to 3.5 MPa (36 kgf/cm2) (512 psi) by reducing valve (18). A small amount of pilot oil supplied from Orbitrol® (14) controls steering valve (4) to realize steering operations. When the steering wheel is turned, oil at a flow rate proportional to the turning speed is sent from Orbitrol® (14) and supplied to the oil pack of steering valve (4). At this time, the pilot pressure is generated. The pilot pressure strokes the spool of steering valve (4), and supplies hydraulic oil at large flow rate proportional to the flow rate of the supplied pilot oil to the cylinder line. The excessive pilot oil flows through steering valve (4) to the other side of the pilot port. Shortly before the full turn, stop valve (15) activates, the pilot circuit is closed. While the steering wheel is not turned, almost all hydraulic oil from steering pump (1) is sent to the loading line by the action of the flow control spool.

80ZV-2 EU 42-9 42 Function & Structure Hydraulic Group Hydraulic System Operation Oil returns from steering cylinders (8) flows through steering valve (4) and oil cooler or cooler bypass valve (11). Finally it returns to the tank through return filter (12).

Efficient loading system The efficient loading system consists of the following components. - Hydraulic pump (1) - Pressure sensor (49) - Relief valve (62) - Check valve (63) - Solenoid valve (64) When the ELS switch is turned off, the oil discharged from the switch pump (front pump of (1)) flow into steering valve (4) P port. When the steering wheel is not turned, this oil is discharged from steering valve (4) P.B. port.

Fan motor system The fan motor system consists of the following components. - Hydraulic pump (1) - Unloader valve (22) - Fan motor (71) The cooling fan is driven by hydraulic motor (71). The pressure oil from unloader valve (22) flows into the port P of fan motor assy, enters the fan motor and flow control valve, and then turns fan motor (71). Three kinds of signals sent from the engine water temperature sensor (S/N 9001~9100), ECM (S/N 9101~), torque converter oil temperature sensor, and hydraulic oil temperature sensor, are input into the MCU as information to regulate the maximum fan revolution. The fan revolution is regulated by the oil amount supplied to fan motor (71). Oil amount supplied to fan motor (71) is changed in proportion as the engine revolution and the opening area of the flow control valve of fan motor (71).

On the other hand, the oil discharged from the main pump (center pump of (1)) opens the check valve, because cracking pressure of check valve (63) is less than the setting pressure of relief valve (62).

Ride control system (OPT)

The oil from switch pump and main pump are joined together and flow into multiple control valve (3) P port.

Refer to "Ride Control (OPT)" page 42-47 for the information.

When the ELS switch is turned on and the ELS operation condition set by the MCU is satisfied, solenoid valve (64) in the ELS valve is energized and the spool is moved. Therefore, the oil discharged from the main pump (center pump of (1)) opens relief valve (62) and all the hydraulic oil from the main pump goes to the hydraulic tank. But the oil from the steering valve P.B. port flow into multiple control valve (3) P port. Therefore when the ELS is operated, most of the engine power is applied to the wheels to exert maximum driving force by turning off the main pump and reducing the pump driving load on engine.

80ZV-2 EU 42-10 42 Function & Structure Hydraulic Group Layout of Hydraulic Units

Layout of Hydraulic Units

7

8

10

11

3

14 12

13

9

2

9

4

5

6

1 K80V2E42001

1. Multiple control valve 2. Pilot valve 3. Orbitrol® 4. Steering valve 5. Hydraulic pump (3 section) 6. Fan motor 7. Bucket cylinder

8. Boom cylinder 9. Steering cylinder 10. Reducing valve (Steering pilot) 11. T/C line filter 12. ELS valve 13. Secondary steering pump 14. Stop valve

80ZV-2 EU 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)

85 (22.7 US gal)

2

Filtration area (cm ) Return filter

16,900

Filtration particle size (µm)

28

Relief valve opening pressure (filter bypass) (MPa) (kgf/cm2) (psi) Suction strainer

Loading Pilot & brake Steering

0.1±0.02 (1.0±0.2) (14±2.8)

Filtration area (cm2)

1,640

Filtration particle size (µm)

105 2

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

1 (0.01) (0.14)

2

Discharge valve setting pressure (kPa) (kgf/cm ) (psi) Breather valve (oil filling port) (S/N 9001~9250)

29 (0.3) (4.3)

2

Filtration area (cm )

235

Filtration particle size (µm)

10

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

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

2

Suction valve setting pressure (kPa) (kgf/cm ) (psi) Breather valve (oil filling port) (S/N 9251~)

3.9 (0.04) (0.57)

2

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

29 (0.3) (4.3)

2

Filtration area (cm )

160

Filtration particle size (µm)

10

Hydraulic oil level check Before checking the hydraulic oil level, observe the following items: - Check that the machine is on level ground.

- Lower the boom to the lowest limit, and set the bucket level on the ground.

Bucket on ground Hydraulic tank

Oil level sight gauge

Check that the oil level is at the center of the oil level sight gauge.

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

85 L

Oil amount 85 L (22.7 US gal)

Cold level (22.7 US gal)

- Check the hydraulic oil level before operation (when oil is not warm).

80ZVE42004

80ZV-2 EU 42-12 42 Function & Structure Hydraulic Group Hydraulic Tank

Hydraulic Tank (S/N 9001~9250) 9

15

1 8

13

14 7 12 6

A-A 3

A

4 1

16

2

2

11

A

10

1. Hydraulic tank 2. Oil level sight gauge 3. Breather valve (tank cap) 4. Filter 5. Suction strainer 6. Return filter element 7. Relief valve 8. Spring 9. Cover

5

17

10. Drain plug 11. Inspection hole cover 12. Return pipe (for brake) 13. Return pipe (for pilot) 14. Vent pipe (to axle housing) 15. Temperature sensor 16. Oil level sensor 17. Lock bolt (S/N 9041~) 80V2E42002

80ZV-2 EU 42-13 42 Function & Structure Hydraulic Group Hydraulic Tank

Hydraulic tank breather valve (tank cap) (S/N ~9250) 1

3

2

4 5

6

A

7

7

a b c

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

Viewed from section A

70ZV42005

When the pressure inside the hydraulic tank drops below the outside air pressure, the outside air flows through filter element (2) and to valve assembly (4). 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 filter element (2). One cycle (down and up) of the boom applies pressure to the inside of the tank. Therefore 29 kPa (0.3 kgf/cm2) (4.3 psi) pressure is always applied to the inside of the hydraulic tank. The pressure applied to the inside of the hydraulic tank prevents the dust and dirt from being drawn into the tank and improves performance of the pump. The positive pressure pushes the oil to the pump reducing the possibility of pump cavitation. To release the internal pressure from the hydraulic tank, press downward on cover (1). 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.

80ZV-2 EU 42-14 42 Function & Structure Hydraulic Group Hydraulic Tank

Hydraulic Tank (S/N 9251~) (S/N 9351~)

Detail of B

1. Hydraulic tank 2. Oil level sight gauge 3. Breather valve (tank cap) 4. — 5. Suction strainer 6. Return filter element 7. Relief valve 8. Spring 9. Cover

10. Drain plug (S/N 9351~ Square socket head) 11. Inspection hole cover 12. Return pipe (for brake) 13. Return pipe (for pilot) 14. Vent pipe (to axle housing) 15. Temperature sensor 16. Oil level sensor 17. Lock bolt

80ZV-2 EU 42-15 42 Function & Structure Hydraulic Group Hydraulic Tank

Hydraulic tank breather valve (tank cap) (S/N 9251~)

When the pressure inside the hydraulic tank drops below the outside air pressure, the outside air flows through filter element (2) and to valve assembly (4). Suction valve (b) is then opened to let the air flow into the tank. When the air pressure inside the hydraulic tank rises to a certain point 29 kPa (0.3 kgf/cm2) (4.3 psi), Exhaust valve (a) is lifted (opened) so that the air can flow out of the tank through filter element (2).

PUSH

1

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

6

Therefore 29 kPa (0.3 kgf/cm2) (4.3 psi) pressure is always applied to the inside of the hydraulic tank.

2

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.

3

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

4

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.

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

The pressure is also applied to the axles.

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

80ZV-2 EU 42-16 42 Function & Structure Hydraulic Group Hydraulic Pump

Hydraulic Pump

9

8

2

4

3

5

4

12

1

5

2

4

1

6

2

13

1

14

14

14 10

7

11

10

7

10

11

7

11

80V2E42003

8. Oil seal 9. Snap ring 10. Pin 11. O-ring 12. Stud bolt / nut 13. Bolt 14. Bushing

1. Drive gear 2. Driven gear 3. Bracket 4. Gear case 5. Carrier 6. Cover 7. Wear plate

Hydraulic pump specifications Applicable circuit Theoretical discharge Maximum operation pressure Maximum speed

cm3/rev MPa (kgf/cm2) (psi)

Front

Center

Rear

For steering

For loading

For brake and pilot

80.2

32.2

25.3

20.6±0.5 (210±5) (2,986±71)

20.6±0.5 (210±5) (2,986±71)

11.8±0.5 (120±5) (1,706±71)

min-1 (rpm)

The triple gear pump is used for the steering, loading, brake and pilot.

2,500

80ZV-2 EU 42-17 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.

80ZV-2 EU 42-18 42 Function & Structure Hydraulic Group Hydraulic Pump

Hydraulic pump wear plate

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

General structure of pressure plate Suction

Discharge

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

Discharge High pressure area Backup ring

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

Hydraulic pump bushing lubrication

O-ring

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

Suction

Oil groove for lubricating bearing

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

Suction

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

Discharge

115ZV42006

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

80ZV-2 EU 42-19 42 Function & Structure Hydraulic Group Hydraulic Cylinder

Hydraulic Cylinder 19. Buffer ring 20. O-ring 21. Wear ring 22. Plug 23. O-ring 24. Bushing 25. Dust seal 26. Back ring 27. Piston packing

10. Square ring 11. Slipper ring 12. O-ring 13. O-ring 14. Backup ring 15. U-packing 16. Backup ring 17. Dust seal 18. Stop ring

1. Cylinder tube 2. Piston rod 3. Piston 4. Piston nut 5. Rod cover 6. Bushing 7. Bolt 8. Stop ring 9. Wear ring

Boom cylinder 24 25

11 21 10

4

9

3

16 14 2 1 19 15 13

6

5

8

17 18

12

7 80ZVE42006

: Piston nut (4): 3,923 N-m (400 kgf-m) (2,894 lb-ft) : Bolt (7): 471 N-m (48 kgf-m) (347 lb-ft)

Bucket cylinder 24 25

8 26 4 21 16 11 9

3 2 1

16 14 19 15 13 6 5 8 17

24 25

12

22,23

7 80ZV42020

: Piston nut (4): 4,903 N-m (500 kgf-m) (3,618 lb-ft) : Bolt (7): 686 N-m (70 kgf-m) (506 lb-ft)

80ZV-2 EU 42-20 42 Function & Structure Hydraulic Group Hydraulic Cylinder

Steering cylinder 19. Buffer ring 20. O-ring 21. — 22. — 23. — 24. Bushing 25. Dust seal 26. — 27. Piston packing

10. Square ring 11. Slipper ring 12. — 13. O-ring 14. Backup ring 15. U-packing 16. Backup ring 17. Dust seal 18. —

1. Cylinder tube 2. Piston rod 3. Piston 4. Piston nut 5. Rod cover 6. Bushing 7. — 8. Stop ring 9. Wear ring (S/N 9001~9008)

24 25

4

9 27 9

3

2

1

8 13 14 6 10 11 20 5 17

24 25

80V2E42004

: Piston nut (4): 930 N-m (94.8 kgf-m) (686 lb-ft) : Rod cover (5): 300 N-m (30.6 kgf-m) (221 lb-ft) (S/N 9009~9138) 24, 25

4

9 27 9

3

2

1

19

13 14 8

15 16 6

24, 25

20 5

17 K80ZV42007

: Piston nut (4): 930 N-m (94.8 kgf-m) (686 lb-ft) : Rod cover (5): 300 N-m (30.6 kgf-m) (221 lb-ft)

80ZV-2 EU 42-21 42 Function & Structure Hydraulic Group Hydraulic Cylinder (S/N 9139~)

24 25

4

9 27 9

3

2

1

19 13 14 15 16 6 20 8 5 17

24 25

80Z542003

: Piston nut (4): 930 N-m (94.8 kgf-m) (686 lb-ft) : Rod cover (5): 300 N-m (30.6 kgf-m) (221 lb-ft)

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

Pin hole (inner diameter x width)

Piston rod

ø80 x 165 (3.15 x 6.49)

Cylinder

ø80 x 130 (3.15 x 5.12)

Inner diameter x rod diameter x stroke Bucket cylinder

Pin hole (inner diameter x width)

Pin hole (inner diameter x width)

ø180 x ø90 x 533 (7.09 x 3.54 x 20.98)

Piston rod

ø100 x 120 (3.94 x 4.72)

Cylinder

ø100 x 120 (3.94 x 4.72)

Inner diameter x rod diameter x stroke Steering cylinder

ø150 x ø75 x 788 (5.91 x 2.95 x 31.02)

ø80 x ø45 x 405 (3.15 x 1.77 x 15.94)

Piston rod

ø45 x 60 (1.77 x 2.36)

Cylinder

ø45 x 60 (1.77 x 2.36)

80ZV-2 EU 42-22 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

Oil from the loader pump is then directed through the valve to the cylinder.

Pilot valve

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

Valve (for safety lock) Reducing valve

From brake line

Oil packs

Multiple Oil packs control valve

From steering valve Cooler

P Return filter

85V2E42004

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

80ZV-2 EU 42-23 42 Function & Structure Hydraulic Group Reducing Valve (for Pilot Pressure)

Reducing Valve (for Pilot Pressure) Pressure adjustment stud Locknut PPDB-LAN CXCD-XAN

Ball

CXCD-XAN

Passage Y (T)

(P) (TA) (ACCR)

(PARKING)

(ACCF)

(PA) (Z1)

(Z)

T

Orifice 2

From front brake accumulator circuit

(Z2)

(PPI)

Tank Valve assembly

Note: Valve is shown rotated 180º from normal.

C

A Orifice 1

A

B

Passage Z

B

Plunger

Pilot oil circuit

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

T Hydraulic circuit diagram

80V2E42014

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

80ZV-2 EU 42-24 42 Function & Structure Hydraulic Group Pilot Valve (S/N 9001~9205)

Pilot Valve (S/N 9001~9205) Float/Down

Raise (Detent)

White (Female) (for port 3 solenoid) Roll back (Detent) Blue (Female) (for port 2 solenoid)

Dump

From Top 18.20

16.20

White (Male) (for port 4 solenoid)

A For bucket control

B For boom control

T

P

A (Port 1, 2)

1

2

3

4

From Bottom

B (Port 3, 4)

K115V2U42003

80ZV-2 EU 42-25 42 Function & Structure Hydraulic Group Pilot Valve (S/N 9001~9205) (S/N 9001~9200) Dump

Roll back (Detent)

Float (Detent) Down

Raise (Detent)

1

2 7

21

21

20

20

19

19

18

18

3 9

4 6

Identifying mark

8 10

10

2 5 Identifying mark

8

9 10

10

11

13 22

23

25

12

13

23

22

To tank port

14 15

16

15

16

24

From pump port

14

17 Port1 Port2 To/from MCV oil packs

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

80ZV-2 EU 42-26 42 Function & Structure Hydraulic Group Pilot Valve (S/N 9001~9205) (S/N 9201~9205) Dump

Roll back (Detent)

Float (Detent) Down

Raise (Detent)

1

2 7

21

21

20

20

19

19

18

18

3 9

4 6

Identifying mark

8 10

10

2 5 Identifying mark

8

9 10

10

11 12 23 22

23

22

To tank port

14 15

16

15

16

24

From pump port

14

17 Port1

Port2

Port3

To/from MCV oil packs

To/from MCV oil packs

For bucket control (Section A-A)

For boom control (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. —

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

80ZV-2 EU 42-27 42 Function & Structure Hydraulic Group Pilot Valve (S/N 9001~9205)

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

20

Pilot valve operation (modulated position) 3 Predetent section

10 10

12

12

22 14

23 14

15 24

16

17

Lever is in the neutral position 85V2E42009

T

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 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.

80ZV-2 EU 42-28 42 Function & Structure Hydraulic Group Pilot Valve (S/N 9001~9205)

21 19

1

20

18

3

Predetent section

10

10

25 13 22

23

15

16

17

17

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

Lever is shifted from the neutral 85V2E42010

When lever (1) is shifted from the neutral, push rod (10) and spring seat (23) are pushed down at the same time, the value of secondary pressure spring is changed. Spool (17) is forced down by 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.

(S/N 9001~9200 only) In addition, spring seat (13) and spring (25) are installed inside of push rod (10) in the "Boom Float" or "Bucket Dump". When lever (1) is shifted more than a desired angle, spring (25) makes contact with the bottom of push rod (10) inside diameter. The inclination of second pressure changed by this spring force. Then, to be sure the multiple control valve spool is fully stroked, spring (25) and spring seat (13) are used. This allow 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.

80ZV-2 EU 42-29 42 Function & Structure Hydraulic Group Pilot Valve (S/N 9001~9205)

Pre-detent and detent magnet solenoid

1 21 20

19 3

21 19 20

2 18

3

7 8 18

3

9

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

10 T

P T Actuation of electromagnetic detent

P

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). 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.

80ZV-2 EU 42-30 42 Function & Structure Hydraulic Group Pilot Valve (S/N 9206~)

Pilot Valve (S/N 9206~) Float/Down

Raise (Detent)

White (Female) (for port 3 solenoid) Roll back (Detent) Blue (Female) (for port 2 solenoid)

Dump

18.20

White (Male) (for port 4 solenoid)

16.20

A

B

For bucket control

For boom control

P T 1

2

2

A 1

2

3

4

(Port 1, 2)

4

B (Port 3, 4)

90Z542003

80ZV-2 EU 42-31 42 Function & Structure Hydraulic Group Pilot Valve (S/N 9206~)

Dump

Roll back (Detent)

Float (Detent) Down

Raise (Detent)

1

2 7

21

21

20

20

19

19

18

18

3 9

4 6

8

Identifying mark

8

10

10

10

2 5 Identifying mark 9 10 11 12 23

22

23

16

22

14

14 15

16 From pump port

To tank port

15 24

17

Port1

Port2

Port3

To/from MCV oil packs

To/from MCV oil packs

For bucket control (Section A-A)

For boom control (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. — 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

80ZV-2 EU 42-32 42 Function & Structure Hydraulic Group Pilot Valve (S/N 9206~)

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

20

Pilot valve operation (modulated position) 3 Predetent section

10 10

12

12

22 14

23 14

15 24

16

17

Lever is in the neutral position 90Z542006

T

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).

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.

80ZV-2 EU 42-33 42 Function & Structure Hydraulic Group Pilot Valve (S/N 9206~)

19

1

21 20

18

3

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.

Predetent section

10

10

22

23

15

16

17

17

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

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.

80ZV-2 EU 42-34 42 Function & Structure Hydraulic Group Pilot Valve (S/N 9206~)

Pre-detent and detent magnet solenoid 1 21 20

19

21 19 20

3 2 18

18

3

7 3

8 9

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

10

T P

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.

80ZV-2 EU 42-35 42 Function & Structure Hydraulic Group Multiple Control Valve (KML28/2T102)

Multiple Control Valve (KML28/2T102)

7 8 3

C

C

B

B 2

P

A

A

1 9

A-A

4

Bucket Spool

6

B-B

4

10

Boom Spool

6

5

C-C

70ZV42011

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 (G 1/4)

80ZV-2 EU 42-36 42 Function & Structure Hydraulic Group Multiple Control Valve (KML28/2T102)

(ROD) B1 A1 (HEAD)

Bucket

Multiple control valve specifications

(PB)

Pi2 (ROD) B2 A2 Boom (HEAD) Pb2

B2R Pa2

Model

KML28/2T 102

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)

Hch B1R A1R

Pb1

Pa1 Bch

P

MR

(Pi1)

Hydraulic line

T

70ZV42012

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".

Over load relief valve installation point Make-up valve installation point

Bucket Boom Bucket Boom

Rod side

Installed

Bottom side

Installed

Rod side

Non-installed

Bottom side

Non-installed

Rod side

Installed

Bottom side

Installed

Rod side

Installed

Bottom side

Non-installed

80ZV-2 EU 42-37 42 Function & Structure Hydraulic Group Multiple Control Valve (KML28/2T102)

Multiple control valve main relief valve 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.

Main relief valve operation

Adjusting screw

Poppet

Filter

Chamber A Tank port Pump port

Sleeve Adjusting screw

Poppet

Filter

Plunger

Orifice 1

Chamber A Tank port Pump port

Lock nut

Sleeve

Orifice 2

Plunger 70ZV42013

1. When the oil pressure is at the set point or below - The pressurized oil from the pump flows in to the chamber A through the orifice 1, and the plunger is pressed against the sleeve by the pressure area difference of the plunger and the spring force. Also the sleeve completely closes the pump port by the pressure area difference of the sleeve between the pump port side and chamber A side. 2. 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 clearance between the body and sleeve. 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.

80ZV-2 EU 42-38 42 Function & Structure Hydraulic Group Multiple Control Valve (KML28/2T102) 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, plunger, or clogging of the filter. Always clean the filter during overhaul of the relief valve.

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 locknuts when finished with adjustment. Only set pressures in accordance with setting specifications.

Multiple control valve overload relief valve (with make-up function) (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 high and the oil pressure will be greatly increased, the overload relief valve returns the oil to the tank to protect the cylinders and pipes from breakage.

80ZV-2 EU 42-39 42 Function & Structure Hydraulic Group Multiple Control Valve (KML28/2T102)

Overload relief valve operation

Chamber B

A

When the oil pressure is at the preset valve or less The pressurized oil from the cylinder is sent to the chamber B through the hole A of the piston, and the plunger is pressed against the sleeve by the spring force.

Sleeve

To tank

Filter

Also the sleeve completely closes the cylinder port by the pressure area difference of the sleeve between the cylinder port side and the chamber B side.

Cylinder

When the oil pressure exceeds the preset valve

Piston

Plunger

Poppet

When the oil pressure in the cylinder line rises above the pressure set by the spring, the poppet is moved to the right and opens the port. Then the oil in the chamber B flows to the tank through clearance between the body and sleeve.

Spring

Sleeve To tank

Spring

As a result, the pressure in the chamber B rapidly lowers and the plunger is moved right. Then the plunger opens the port to the tank port and the pressurized oil in the cylinder port escapes to the tank port.

Cylinder

Make-up valve operation Piston

Plunger

Chamber B Poppet

X From tank

Spring

Sleeve

Y

Cylinder

70ZV42014

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 sleeve is moved to the right by the pressure area difference of the sleeve between the right and left (Y-X). The sleeve opens the port and the oil flows to the cylinder port. It prevents a vacuum (negative pressure) in the cylinder. Note The make-up valve function is non-adjustable.

80ZV-2 EU 42-40 42 Function & Structure Hydraulic Group Multiple Control Valve (KML28/2T102)

Multiple control valve make-up valve

Adjusting set pressure

(Installed on the rod side of the boom circuit) Chamber B

A

Sleeve

Adjusting screw

To tank

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.

Cylinder

Lock nut Piston

The make-up valve is installed in the circuit between the control spool and boom cylinder.

Plunger

Poppet

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.

Spring 70ZV42015

Make-up valve operation 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)

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.

80ZV-2 EU 42-41 42 Function & Structure Hydraulic Group Multiple Control Valve (KML28/2T102)

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

A1

From pilot valve

D

B1

Pb1

Pa1 Spool

From C pump

- When the control lever is set to the "Bucket Roll Back" position, the pilot pressure is applied on the left oil pack (Pa1), the spool moves to the right, and spool shoulder (C) closes the center bypass line. As a result, the oil from the pump opens 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.

70ZV42016

80ZV-2 EU 42-42 42 Function & Structure Hydraulic Group Multiple Control Valve (KML28/2T102) 2. "Bucket Dump" position

E D

A1

B1

Pb1

Pa1 Spool

C

From pilot valve

From pump 70ZV42017

- When the control lever is set to the "Bucket Dump" position, the pilot pressure is applied on the right oil pack (Pb1), the spool moves to the left, and spool shoulder (C) closes the center bypass line. As a result, the oil from the pump opens 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), make-up valve (E) opens so that the oil in the tank port flows into the rod side of the cylinder.

80ZV-2 EU 42-43 42 Function & Structure Hydraulic Group Multiple Control Valve (KML28/2T102)

Multiple control valve boom spool Boom spool operation 1. "Boom Raise" position

A2

D

B2

Pb2

Pa2 From pilot valve

Spool

From pump

C

70ZV42018

- When the control lever is set to the "Boom Raise" position, the pilot pressure is applied on the left oil pack (Pa2), the spool moves to the right, and spool shoulder (C) closes the center bypass line. As a result, the oil from the pump opens 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.

80ZV-2 EU 42-44 42 Function & Structure Hydraulic Group Multiple Control Valve (KML28/2T102) 2. "Boom Down" position

E

A2

D

B2

Pb2

Pa2 Spool

C

From pilot valve

From pump 70ZV42019

- When the control lever is set to the "Boom Down" position, the pilot pressure is applied on the right oil pack (Pb2), the spool moves to the left, and spool shoulder (C) closes the center bypass line. As a result, the oil from the pump opens 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), make-up valve (E) opens so that the oil in the tank port flows into the rod side of the cylinder.

80ZV-2 EU 42-45 42 Function & Structure Hydraulic Group Multiple Control Valve (KML28/2T102) 3. "Boom Float" position

A2

B2

Pb2

Pa2 Spool

From pilot valve

From pump 70ZV42020

- When the control lever is pushed downward beyond the "Boom Down" position to the "Boom Float" position, the spool moves fully to the left by the pressure oil from the Pb2. - As a result of this, all ports (i.e., pump port, cylinder rod end port and cylinder bottom 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.

80ZV-2 EU 42-46 42 Function & Structure Hydraulic Group Adapter (Orifice)

Adapter (Orifice)

ø1.0 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.

80ZV-2 EU 42-47 42 Function & Structure Hydraulic Group Ride Control (OPT)

Ride Control (OPT) Ride control hydraulic circuit 3 2

Capacity: 5.7 L Gas charging pressure: 1.96±0.1 MPa (20±1 kgf/cm2) (284.2±14.5 psi)

1 SP2

A

From multiple control valve

T

B (16) (17) (18)

(11)

(15) (13)

P

(14) Pilot lamp

F13 Ride control switch

MCU

SP1 (G3/4)

Hydraulic circuit Electrical circuit

1. Valve assembly (11) Charge switching spool (12) Reducing valve (13) Check valve (14) Solenoid valve (15) Flow control spool (16) Main spool (17) Orifice (18) Depressure valve (for accumulator circuit) 2. Accumulator 3. Boom cylinder

(12) 7.4±0.3 MPa (75±3 kgf/cm2) (1,073±43 psi)

From MCV pump port To MCV tank port

70V2U42007

Ride control function Ride control reduces fore and aft pitching motion to the machine in roading by using the boom cylinder and hydraulic circuit with the accumulator. Ride control can be operated or released by turning the ride control switch ON/OFF. Turn the ride control switch ON, and when the machine travelling speed reaches more than 7 km/h (4.3 mph), solenoid valve (14) comes to ON by a signal from the MCU, then the ride control works. When the machine travelling speed goes down to 5 km/ h (3.1 mph) or slower, no signal transferred from the MCU, as a result, the ride control does not work.

80ZV-2 EU 42-48 42 Function & Structure Hydraulic Group Ride Control (OPT)

Ride control operation Preparation mode (ride control switch is OFF) 3 2

Capacity: 5.7 L Gas charging pressure: 1.96±0.1 MPa (20±1 kgf/cm2) (284.2±14.5 psi)

1 SP2

A

From multiple control valve

T

B (16) (17) (18)

(11)

(15) (13)

P

(14) Pilot lamp

F13 Ride control switch

MCU

SP1 (G3/4)

Hydraulic circuit Electrical circuit

The oil from the pump is reduced to 7.4 MPa (75 kgf/ cm2) (1,073 psi) by reducing valve (12) through charge switching spool (11). The oil flows into accumulator (2) through check valve (13), and also flows into the lower part of main spool (16) through solenoid valve (14), flow control spool (15) and orifice (17). Although the accumulator pressure applies to the upper part of main spool (16), the main spool is being kept by spring force at the lower part. In this condition, the ride control does not work because the both ports of the boom cylinder are closed.

(12) 7.4±0.3 MPa (75±3 kgf/cm2) (1,073±43 psi)

From MCV pump port To MCV tank port

70V2U42007

80ZV-2 EU 42-49 42 Function & Structure Hydraulic Group Ride Control (OPT)

Running mode (ride control switch is ON) 3 2

Capacity: 5.7 L Gas charging pressure: 1.96±0.1 MPa (20±1 kgf/cm2) (284.2±14.5 psi)

1 SP2

A

From multiple control valve

T

B (16) (17) (18) (15)

(11)

(13) P

(14) Pilot lamp

F13 Ride control switch

Hydraulic circuit

MCU

SP1 (G3/4)

(12) 7.4±0.3 MPa (75±3 kgf/cm2) (1,073±43 psi)

Running mode

Electrical circuit

The ride control switch is ON, and when the machine travelling speed reaches more than 7 km/h (4.3 mph) solenoid valve (14) comes to ON by a signal from the MCU. When solenoid valve (14) is switched, the accumulator pressure applies to the upper part of charge switching spool (11) and the pump port is closed by pressing the spool down. Pressurized oil in the lower part of main spool (16) is drained to the tank through solenoid valve (14). As a result, main spool (16) is switched by the accumulator pressure, and the hydraulic line between the boom cylinder bottom side and the accumulator is connected. Then the accumulator absorbs the oil pressure fluctuations in the boom cylinder bottom side. On the other hand, the hydraulic line between the boom cylinder rod side and tank port is connected.

From MCV pump port To MCV tank port

K80V2J42009

Flow control spool (15) and orifice (17) control the switching speed of main spool (16), and reduce the momentary motion of the boom cylinder by switching the main spool when there is pressure difference in the hydraulic circuit between the accumulator and boom cylinder bottom side.

80ZV-2 EU 42-50 42 Function & Structure Hydraulic Group Ride Control (OPT)

Ride control valve assembly Outline drawing

(14)

A

From pump

1

(11)

(11)

P

(14)

(12)

(12)

KAYABA INDUSTRY CO,LTD TOKYO JAPAN

(18) B

B

(14)

T

SP2

SP1

To accumulator

(18) A

(13)

B

(15)(16) Boom cylinder bottom side

Boom cylinder rod side

A (15)(16)

(14)

K80V2J42020

1. Ride control valve assembly (11) Charge switching spool installation section (12) Reducing valve installation section (13) Check valve installation section (14) Solenoid valve (15) Flow control spool installation section (16) Main spool installation section (18) Depressure valve (for accumulator circuit)

80ZV-2 EU 42-51 42 Function & Structure Hydraulic Group Ride Control (OPT) Section drawing

(11) P

(12) 1 21

(14)

22 23 To accumulator

(18) SP1

SP2

T

(13) (17)

A

B

(13)

B-B (15) (16)

A-A

Preparation mode K80V2J42021

1. Ride control valve (11) Charge switching spool (12) Reducing valve (13) Check valve (14) Solenoid valve (15) Flow control spool (16) Main spool (17) Orifice (18) Depressure valve (for accumulator circuit) 2. — 3. — 4. — 5. — 6. — 7. — 8. —

9. — 10. — 11. — 12. — 13. — 14. — 15. — 16. — 17. — 18. — 19. — 20. — 21. Lock nut 22. Adjusting screw 23. Lock nut

80ZV-2 EU 42-52 42 Function & Structure Hydraulic Group Ride Control (OPT)

(11) P

(12) 1 21 (14) 22 To accumulator

23 SP1

SP2

T

(18) (13) (17)

A

B

(13) (15)

B-B

(16)

A-A

Running mode K80V2J42010

80ZV-2 EU 42-53 42 Function & Structure Hydraulic Group Ride Control (OPT)

Solenoid valve

T

P

2

T

3

(ACC)

4 1

A 5

B Z Capacity: 5.7 L Gas charging pressure: 1.96±0.1 MPa (20±1 kgf/cm2) (284.2±14.5 psi) SP2

P A

T

B

T

A

B

T

P

Viewed from Z

P

7.4±0.3 MPa (75±3 kgf/cm2) (1,073±43 psi) From pump To tank 70V2U42008

1. Body 2. Spool 3. Solenoid 4. Push rod 5. Pin

Specification Voltage

DC 24 V

Current

1A

Resistance

24 

80ZV-2 EU 42-54 42 Function & Structure Hydraulic Group Ride Control (OPT)

T

P

2

T

3

(ACC)

4 1

A

B 5

Z

P A

B

T Viewed from Z

When push rod (4) is pushed manually K80V2J42011

WARNING When the push rod (4) of the solenoid valve is pushed manually, even if no ride control switch is ON, the ride control hydraulic circuit changes to the running mode. As a result, the boom will go down if raised. It may cause serious injury or death. Before pushing the push rod (4), it is necessary to put the machine on the level ground and lower the attachment on the level ground.

80ZV-2 EU 42-55 42 Function & Structure Hydraulic Group Ride Control (OPT)

Accumulator (for ride control)

7 2

4

1

3 13 10

12 11 5 8 9 6

85V2E42017

1. Body 2. Hydraulic cap 3. Gas cap 4. Piston 5. V-O ring 6. Back up ring 7. Wear ring 8. O ring 9. Back up ring 10. Gas valve 11. Gas valve O ring 12. Gas valve guard 13. Bolt

Accumulator function While the ride control operates, the accumulator absorbs fluctuation of the boom cylinder bottom pressure by air cushion function of the nitrogen gas charged in the cylinder. The cylinder contains N2 (Nitrogen) gas at 1.96 MPa (20 kgf/cm2) (284.2 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) (284.2)

Capacity (L)

5.7

80ZV-2 EU 42-56 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

LH

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

Steering valve To loading line

To Orbitrol®

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.

P

Oil cooler

Finally it returns to the tank through the return filter.

Return filter

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

80ZV-2 EU 42-57 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® structure 1. Spool 2. Sleeve 3. Stator 4. Rotor

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

Valve part

8

6 7

T L Valve

1 2

R

P

5

3 4

Rotor

4

3

85V2E42018

80ZV-2 EU 42-58 42 Function & Structure Hydraulic Group Orbitrol® - Spool (1) and sleeve (2) as a set form a rotary-type directional change-over valve. Spool (1) in this valve is linked to the steering wheel by means of a spline.

Orbitrol® specification Model

- When the steering wheel is not being turned, spool (1) and sleeve (2) are held in the neutral position by centering spring (6); the oil groove of the spool does not match the oil hole of the sleeve, so the flow route of oil is totally closed. - When the steering wheel is turned, the oil groove of the spool matches the oil hole of the sleeve, opening the oil passage, permitting oil to flow.

Rotor part

1

2

Oil groove To tank To steering valve To steering valve Oil hole From reducing valve (pump) 70ZV42023

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

ND-K2-D

Theoretical discharge (cm3/rev)

120

Operation pressure MPa (kgf/cm2) (psi)

3.5 (36) (512)

80ZV-2 EU 42-59 42 Function & Structure Hydraulic Group Orbitrol®

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

T

2

8

L Oil hole

6 7

R

T

Oil groove

L

1 2

R

P

5

70ZV42025

3 4

85V2E42019

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

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

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

80ZV-2 EU 42-60 42 Function & Structure Hydraulic Group Orbitrol®

Turn (When the steering wheel is being turned)

8 6 1

T

6 7

T L

2

L

2 Oil hole

5 1

R Oil groove

R

P

To steering valve Pa port From steering valve Pb port

From reducing valve (pump)

3 4

85V2E42020

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. Sleeve (2) is directly linked to the rotor by means of cross pin (7) and drive shaft (5); it is also fixed. - When the steering wheel begins to be turned, rotary force is applied to spool (1), which then pushes and compresses centering spring (6) set in the slit; the oil groove of the spool matches the oil hole of the sleeve, and opens the hydraulic circuit. - As a result, all four ports (pump, tank and oil pack on right and left side of steering valve) are opened, allowing the oil to flow and rotating the rotor.

80ZV-2 EU 42-61 42 Function & Structure Hydraulic Group Orbitrol®

Orbitrol® feed-back mechanism operation

Spool

Sleeve

Cross pin

Drive shaft To steering valve Pa port From steering valve Pb port

P

Stator

Rotor

K80V2J42003

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

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

80ZV-2 EU 42-62 42 Function & Structure Hydraulic Group Orbitrol®

Steering speed and flow rate control Low steering speed

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

High steering speed

1 3 Small displacement angle

Large displacement angle

Hydraulic pump oil amount and steering force

2

70ZV42028

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

- 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.

80ZV-2 EU 42-63 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)

1

1

Rotor (rotation) Stator (fixed)

Locus of rotor center

1 7

2

6

3

6

4

2

7

3

5

4

5

2

7

6

3

5

4

1 2

7

6

3

5

4

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

- Inside the rotor there is a stator with 7 internal gears that is fixed to the housing and a 6-tooth rotor that is engaged with the stator. - Half of the chamber formed by the stator and the rotor is connected to the high-pressure side and the other half to the low-pressure side. When high-pressure oil flows into the chamber, the rotor is forced to turn in the direction that will expand the area of the chamber (by means of pressure difference). - When overrunning the power assist capacity of the rotor due to very fast rotation or turning the steering wheel vigorously, rotation of the sleeve and spool takes place by means of the cross pin. - With this rotation, and at the same time due to the relationship of the position between the sleeve port and the housing port, the position of oil flowing into the rotor part is gradually delayed in sequence.

70ZV42029

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

80ZV-2 EU 42-64 42 Function & Structure Hydraulic Group Steering Valve (KVS25-A3.0/20)

Steering Valve (KVS25-A3.0/20)

To loading line

From steering pump

2

C

7

P ®

To Orbitrol main pressure reducing valve

Detail of C (S/N 9116~)

3

Pc

A

A

B

To loading line

P.B.

B Pilot operating port

Pilot operating port

6

T 1

To tank port

To cylinder port

To cylinder port

B

A

Section A - A

4

4

Pb

Pa

1

5

Section B - B K80V2U42002

1. Steering spool 2. Flow control spool 3. Main relief valve 4. Overload relief valve (with make-up valve) 5. Pilot orifice (with filter) 6. Check valve 7. Casing

80ZV-2 EU 42-65 42 Function & Structure Hydraulic Group Steering Valve (KVS25-A3.0/20) 1. Steering spool A

B

Pa

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.

Pb T

P.B.

2. Flow control spool

Orifice

Pc

P

Hydraulic line 85V2E42022

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

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

KVS25-A3.0/20

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)

80ZV-2 EU 42-66 42 Function & Structure Hydraulic Group Steering Valve (KVS25-A3.0/20)

Steering valve operation Neutral position (steering spool in "Neutral") To loading line

2

A

B

1

85V2E42023

- 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 0.72 MPa (7.3 kgf/cm2) (104 psi), flow control spool (2) is moved to the right due to the pressure difference between chambers A and B. Thus the flow control spool is opened, and all the oil from the steering pump is sent to the loading line.

80ZV-2 EU 42-67 42 Function & Structure Hydraulic Group Steering Valve (KVS25-A3.0/20)

Left turn position

To From loading line pump

2

From steering valve (pilot)

Check valve

To tank

1 Variable throttle section

85V2E42024

- 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 0.72 MPa (7.3 kgf/cm2) (104 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.

80ZV-2 EU 42-68 42 Function & Structure Hydraulic Group Steering Valve (KVS25-A3.0/20) - 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 PA

PB

- 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

85V2E42025

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 0.3 MPa (3.1 kgf/ cm2) (44 psi).

80ZV-2 EU 42-69 42 Function & Structure Hydraulic Group Steering Valve (KVS25-A3.0/20)

Steering valve flow control plunger To loading line From pump Spring

PA PB B

Variable throttle To loading line From pump To steering line

PA PB

To steering line

85V2E42026

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 0.72 MPa (7.3 kgf/cm2) (104 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.

80ZV-2 EU 42-70 42 Function & Structure Hydraulic Group Steering Valve (KVS25-A3.0/20)

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

To loading line

From pump Flow control spool Filter

A B

Steering spool

From cylinder

To tank

To cylinder

85V2E42027

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.

80ZV-2 EU 42-71 42 Function & Structure Hydraulic Group Steering Valve (KVS25-A3.0/20)

When the pressure exceeds the preset value

To loading line

From pump Flow control spool

A B

Steering spool

To tank

85V2E42028

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.

80ZV-2 EU 42-72 42 Function & Structure Hydraulic Group Steering Valve (KVS25-A3.0/20)

Steering valve overload relief valve Force

B

A

Make-up function

Overload relief function

To tank 85V2E42029

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.

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.

80ZV-2 EU 42-73 42 Function & Structure Hydraulic Group Steering Valve (KVS25-A3.0/20)

Overload relief valve operation Chamber B

A

Make-up valve operation

Sleeve

To tank

Filter

X From tank

Sleeve

Y Cylinder Cylinder

80ZV42014

80ZV42016

When the oil pressure is at the preset valve or less

When the overload relief valve on one side of the cylinder port is actuated, the plunger in the steering 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.

Piston

Plunger

Poppet

Spring

The pressurized oil from the cylinder is sent to the chamber B through the hole A of the piston, and the plunger is pressed against the sleeve by the spring force. Also the sleeve completely closes the cylinder port by the pressure area difference of the sleeve between the cylinder port side and the chamber B side. Sleeve To tank

Spring

Cylinder

Piston

Plunger

Chamber B

Poppet Spring 80ZV42015

When the oil pressure exceeds the preset valve When the oil pressure in the cylinder line rises above the pressure set by the spring, the poppet is moved to the right and opens the port. Then the oil in the chamber B flows to the tank through clearance between the body and sleeve. As a result, the pressure in the chamber B rapidly lowers and the plunger is moved right. Then the plunger opens the port to the tank port and the pressurized oil in the cylinder port escapes to the tank port.

When the pressure at the cylinder port becomes less than tank pressure, the sleeve is moved to the right by the pressure area difference of the sleeve between the right and left (Y-X). The sleeve opens the port and the oil flows to the cylinder port. It prevents a vacuum (negative pressure) in the cylinder.

80ZV-2 EU 42-74 42 Function & Structure Hydraulic Group Steering Valve (KVS25-A3.0/20)

Steering pilot circuit and its operation

From pump Orbitrol®

Reducing valve

To tank

Steering valve Filter To tank

From cylinder

To cylinder Stop valve

A

B

Stop valve

End cover

End cover

Flow amp notch Pilot orifice To tank Pilot line

K85V2J42003

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.

80ZV-2 EU 42-75 42 Function & Structure Hydraulic Group Steering Valve (KVS25-A3.0/20)

Return spring force

Return spring

Pilot oil

Hydraulic force

Pilot pressure

Flow amplifier notch and pilot orifice

End cover Pilot orifice Flow amp notch

Flow amp. notch opening

Pilot line K80V2J42012

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.

80ZV-2 EU 42-76 42 Function & Structure Hydraulic Group Stop Valve

Stop Valve

17.0 mm (S/N ~9214) 14.5 mm (S/N 9215~9250) 16.0 mm (S/N 9251~)

17 (0.67")

(Full stroke)

From Orbitrol®

A B

To steering valve

7

3

8

2

1

6

DR

11

13

10

12

5

4

14

9

95V2E42038

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

B

A

DR

97ZV42042

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

80ZV-2 EU 42-77 42 Function & Structure Hydraulic Group Stop Valve

Stop valve function

Stopper (bolt) Spool

Port B To steering valve

Stop valve operation Port A From Orbitrol®

P Installed on front chassis

Check valve Installed on rear chassis 90V2U42003

A stop valve is provided to reduce the impact caused to the chassis steering stopper block when the machine is making a full turn while the hydraulic pressure of the steering cylinder is still working.

B

Pb

A

Pa

90V2U42004

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

80ZV-2 EU 42-78 42 Function & Structure Hydraulic Group Reducing Valve (for Orbitrol®)

Reducing Valve (for Orbitrol®)

Spring

(T)

Sleeve

Tank Plunger Pump

Passage Z

(A)

TS

B A

B A Passage Y

(TS)

T

Hydraulic circuit diagram

(B) Orbitrol®

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

90ZV42012

This oil is supplied from the Orbitrol® to the steering valve pilot port, and moves the spool. Set pressure 3.5 MPa (36 kgf/cm2) (512 psi)

80ZV-2 EU 42-79 42 Function & Structure Hydraulic Group Steering Line Filter

Steering Line Filter

From pump (steering valve)

To reducing valve

FILTER

3

1

4

2

5 70ZV42040

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

1. Case 2. Nipple 3. Strainer 4. O-ring 5. O-ring Line filter

Rear chassis Reducing valve

Rear chassis

Stop valve

Front Installation position for steering pilot line filter 80V2E42005

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

80ZV-2 EU 42-80 42 Function & Structure Hydraulic Group K-Lever (OPT)

K-Lever (OPT) Hydraulic circuit [K-Lever handle]

1 4 2 Horn switch

3

R N F

95V2U42009

1. K-Lever 2. Arm rest 3. Forward/Reverse changeover switch (on K-Lever) 4. Downshift button (on K-Lever) Solenoid valve

K-Lever switch

When the K-Lever system is turned on, it allows quick easy steering, directional control, and down shifting on one joystick type lever. On the other hand, the steering can be applied by use of the steering wheel and it overrides the K-Lever system.

K-Lever

The transmission forward and reverse (F/R) changeover switch and the downshift button are built into the KLever. This allows the operator to change the direction and speed of the machine without releasing the KLever. The K-Lever handle is connected to a potentiometer. This potentiometer changes the input voltage from 2.5 V DC down to 0 V DC, or from 2.5 V DC up to 5 V DC and is interpreted as input voltage at the MCU (machine control unit). 2.5 V DC is input for no steering action. Raising or lowering the voltage creates steering input.

Solenoid valve

80V2U42008

80ZV-2 EU 42-81 42 Function & Structure Hydraulic Group K-Lever (OPT)

Hydraulic line diagram

Solenoid valve assembly Orbitrol®

X

A

B

P

T

P

T

R

L

120 cm3/rev

L

R

Stop valve

Stop valve

A

A B

B

DR

DR

A

Pb

3.5 MPa (512 psi) at 0 L/min B

B

Pa

T

A P.B.

Steering valve

95 m

Reducing valve

G

PC

P

95V2U42010

80ZV-2 EU 42-82 42 Function & Structure Hydraulic Group K-Lever (OPT)

Hydraulic line

3

View A-A

2

A

1 A

4

80V2U42009

1. Orbitrol® 2. Solenoid valve assembly 3. Reducing valve 4. Stop valve

80ZV-2 EU 42-83 42 Function & Structure Hydraulic Group K-Lever (OPT)

Solenoid valve assembly (1/2)

P Port PF1/8

4 T P A

A

B Port

T Port

A Port A-A

2

PF1/8

PF1/8

4

4

5

1 "T Port"

"B Port" PF3/8-PF3/8

30

30

PF3/8-PF3/8

"A Port"

"P Port" PF3/8-PF3/8

3

B

PF3/8-PF3/8

A

PF1/8

4 80V2U42010

1. Block 2. Solenoid valve assembly 3. Adapter 4. Plug 5. Elbow adapter

80ZV-2 EU 42-84 42 Function & Structure Hydraulic Group K-Lever (OPT)

Solenoid valve assembly (2/2)

5

11

13

2

4

3

6

14

9 8

10

12

1

7

95V2U42014

1. Solenoid 2. Socket bolt 3. O-ring 4. O-ring 5. Guide 6. O-ring 7. Screw (spool centering adjuster) 8. O-ring 9. O-ring 10. Socket bolt 11. O-ring 12. Nut 13. O-ring 14. Socket bolt

DANGER Always shut the engine off prior to making any adjustments to the spring tensioning screw number 7. Involuntary movement of the steering can result when this is misadjusted.

Adjustment method If the desired steering speed cannot be achieved through changing the mA or DC V in the MODM, loosen lock nut number 12 and adjust screw number 7 only slightly. This is a very sensitive adjustment, and very little screw movement is needed to make a significant change. Do not over loosen as hazardous involuntary movement of the steering will take place if this is too loose. It must be adjusted so as to keep the spool held in the center position.

80ZV-2 EU 42-85 42 Function & Structure Hydraulic Group Efficient Loading System

Efficient Loading System Efficient loading system outline

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

Fast

Therefore most of the engine power is applied to the wheels to exert maximum driving force by turning off the main pump and reducing the pump driving load on engine. Slow and higher driving force

In addition, as for the loading operation, it becomes easy to operate slightly by reducing the quantity of total oil to the loading circuit, and is improved the performance of operating when excavating and scooping.

When excavating and scooping Switch pump

Multiple control valve

Steering valve

Main pump

Boom Bucket

ELS valve

Fuel efficient mode switch is also installed at the instrument panel when operating at the time of fuel saving driving. If the combination of ELS switch and fuel efficient mode switch is selected properly, it can be able to improve the fuel consumption without reducing the operation efficiency. In addition, the height range of the boom that ELS operates can be set up to the arbitrary height depending on setting of the variable kickout sensor.

Hydraulic tank

When raising the boom Switch pump

Main pump

Multiple control valve

Steering valve

Boom Bucket

The operation condition of ELS The ELS switch ON

ELS valve

Hydraulic tank Concept of the ELS operation

85V2E42054

Shift lever

Forward position

Machine speed

Less than 5 km/h

Boom height

The setting position of the variable kickout sensor is less than it.

80ZV-2 EU 42-86 42 Function & Structure Hydraulic Group Efficient Loading System

Mounting of the ELS valve 4 Multiple control valve P line

3 ELS valve

(PG1) From main pump

Center pin

(A)

(P)

Steering valve P.B. line

(PG2) (T) To hydraulic tank

1

2

Rear chassis

Hydraulic line

P 2 PG2

4

PG1 A

1 Axle center line

T

3

Detail of ELS valve section

80V2E42006

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

80ZV-2 EU 42-87 42 Function & Structure Hydraulic Group Efficient Loading System

Mounting of the variable kickout sensor 5

8 2 3

Apply grease at area

1 Detail of grease applying

A Boom

9

4

2

5,8

6

When the boom is horizontal

Chassis

3 1,7 1

Detail of A 85V2E42056

1. The variable kickout sensor 2. Link 3. Plate 4. Plate 5. Shaft 6. Ball bearing 7. O-ring 8. Spring pin 9. Rod

80ZV-2 EU 42-88 42 Function & Structure Hydraulic Group Efficient Loading System

Efficient loading system operation While the ELS is not operating

4

While the ELS is operating

4

Multiple control valve P line

3

From main pump

Multiple control valve P line

3

Steering valve P.B.line

From main pump

Steering valve P.B.line

To hydraulic tank

2

1

2

1

80V2E42007

80V2E42008

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

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

On the other hand, the oil discharged from the main pump opens the check valve, because cracking pressure of check valve (3) is less than the setting pressure of the relief valve (2).

After that, the setting pressure of relief valve drops to the hydraulic tank pressure level.

Cracking pressure of check valve (3) 0.2 MPa (2 kgf/cm2) (29 psi) Setting pressure of relief valve (2) 20.6 MPa (210 kgf/cm2) (2,987 psi) The oil from switch pump and main pump are joined together and flow into the multiple control valve P port. Therefore it can be able to operate the boom and bucket at normal speed. In addition, pressure sensor (4) is installed in the discharged side of the main pump and detects oil pressure of loading line and sends the signal to the MCU.

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

80ZV-2 EU 42-89 42 Function & Structure Hydraulic Group Fan Motor System

Fan Motor System Mounting of fan motor (S/N 9273~)

T1 L 2

T1 L 2

T2 L 1

T2 Bolt (SEALOCK MEC procesing)

1 2

80V2E42020

1. Fan motor 2. Fan : T1: 93.7 N-m (9.55 kgf-m) (69 lb-ft) T2: 73.5 N-m (7.50 kgf-m) (54 lb-ft) L1: Screw lock agent (Loctite® 262) L2: With lubrication oil (Engine oil or gear oil)

80ZV-2 EU 42-90 42 Function & Structure Hydraulic Group Fan Motor Line

Fan Motor Line Fan revolution (min-1)

Engine coolant: High temperature [94ºC (201.2ºF)]

1,500 Stepless control range

1,050

Middle range temperature [60~80ºC (160~180ºF)]

(500)

Low temperature [below 60ºC (160ºF)]

0

725 (Hibernate mode) 800

1,200

(1,392) Engine revolution (min-1)

(1,938) Values inside ( ) are offered as reference.

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

Fan motor (1)

Cooling fan

Flow control valve (2)

28.0 cm3/rev

Flow control solenoid (3)

B

E

MCU

D A C

To return filter

T

P

TC

Fan motor assy Hydraulic circuit diagram

From unloader valve 70V2E42019

80V2E42017

The cooling fan is driven by the hydraulic motor. The pressure oil from the unloader valve flows into the port P of fan motor assembly, enters fan motor (1) and flow control valve (2), and then, turns fan motor (1). Three kinds of signals sent from the engine water temperature sensor (S/N 9001~9100), ECM (S/N 9101~), torque converter oil temperature sensor, and hydraulic oil temperature sensor, are input into the MCU as information to regulate the maximum fan revolution. The fan revolution is regulated by the oil amount supplied to fan motor (1). Oil amount supplied to fan motor (1) is changed in proportion as the engine revolution and the opening area of flow control valve (2). The opening area is regulated by the pilot pressure to flow control valve (2) that is changed by electric current value from MCU to flow control solenoid (3).

80ZV-2 EU 42-91 42 Function & Structure Hydraulic Group Fan Motor Line

Number of revolutions of fan (min-1)

1,050

Solenoid output current F for control of the fan revolution Flow control solenoid [mA]

Flow control solenoid [mA]

Flow control solenoid [mA]

About 400

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

1,500

0 0 115 ( C) 94 ( C) 110 (239) ( F) (201.2) ( F) (230) T T/M T E/G The signal of the engine The signal of the torque coolant temperature converter oil temperature 80 (176)

90 95 ( C) (194) (203) ( F) T H/D The signal of the hydraulic oil temperature

Control of the fan revolutions 80V2E42018

When the input electric current value to flow control solenoid (3) is maximum (approximately 400 mA), the fan revolution is minimum value (1,050 min-1) because bypass oil amount at flow control valve (2) is increased. When this value is minimum (0 mA), the fan revolution is maximum value (1,500 min-1) because bypass oil amount at flow control valve (2) is decreased. When the engine water temperature is low, the electric currents value from the MCU to flow control solenoid (3) is big. As a result, bypass oil amount from port P to fan motor (1) line becomes big, and then the fan revolution becomes low. When the torque converter oil temperature is 110ºC (230ºF) or less and the hydraulic oil temperature is 90ºC (194ºF) or less, the fan revolution is controlled only by engine water temperature.

In normal condition, fan revolution is regulated by engine water temperature. But when the torque converter oil temperature exceeds 110ºC (230ºF) or the hydraulic oil temperature exceeds 90ºC (194ºF), in each signal input into a MCU from the engine water temperature, torque converter oil temperature and hydraulic oil temperature sensors, the lowest signal in the electric current value is chosen (the fan revolution becomes high to lift the cooling performance), and the control electric current is input into flow control solenoid (3).

80ZV-2 EU 42-92 42 Function & Structure Hydraulic Group Fan Motor Line

Hydraulic circuit (fan motor normal rotation) Fan motor (4) Flow control solenoid (3)

MB

MA

Fan motor assy

MCU (Engine water temp. sensor T/C oil temp. sensor Hydraulic oil temp. sensor) Flow control valve (2)

Brake circuit

Safety valve (1)

TC

P

T

Relief valve

Unloader valve

M

TS

Hydraulic tank

Hydraulic circuit diagram

K80V2J42017

Safety valve (with suction function)

If the oil pressure at fan motor (4) inlet port comes to negative pressure, cavitation may generate.

When the pressure oil from the hydraulic pump is supplied to the inlet port P, the pressure in the MA side circuit of the fan motor will increase. The starting torque for the fan motor is generated, and the motor starts to rotate. The oil in the MB side circuit of the fan motor returns to the hydraulic tank via the outlet port T.

In this case, oil from the tank-return circuit is supplied to fan motor (4) inlet port through the safety valve to prevent cavitation.

When engine stops, the pressurized oil from the pump is not supplied to fan motor (4) inlet port, as a result, the fan motor revolution speed gradually decreases.

Suction function

Oil supply is stopped, however the fan is still turning by the inertial force.

80ZV-2 EU 42-93 42 Function & Structure Hydraulic Group Fan Motor Line

To prevent generation of negative pressure, the safety valve opens so that the oil in the tank port flows into the fan motor inlet port.

Safety function When starting engine, pump discharge pressure may rise extremely high.

Flow control valve

B Fan motor revolution

This condition generates negative pressure at the motor inlet port.

A C

Q0

Q1

To prevent the fan motor line from damages, the relief valve is installed.

Oil amount supplied to motor

If the pump discharge pressure exceeds the set pressure, the relief valve relieves the pressurized oil to the tank port.

Flow control valve (2) supplies the pump discharge amount necessary to fan motor (4) and returns excess oil to the tank.

85V2E42038

Fan motor revolution rises in proportion to oil amount (Q) supplied to fan motor (4). When the amount of oil supplied to fan motor (4) is Q1, the fan rotates with B min-1. To reduce noise from fan and also energy loss, it is necessary to keep fan revolution constantly with necessary fan revolution, regardless of the oil amount supplied to the fan motor. Oil amount in A-B-C area returns to the tank. For this purpose, flow control valve (2) is installed in the line. Even when oil amount to the fan motor changes from Q0 to Q1, the fan revolution is kept from A to C min1 constantly.

80ZV-2 EU 42-94 42 Function & Structure Hydraulic Group Fan Motor Line

Flow control valve Proportional solenoid valve

Pump Throttle (D)

Command current

P Throttle section (E)

B

C A

MB

Adjusting screw

Main spool (dummy)

MA

T

Spring for flow control valve K70V2J42006

Fan motor revolution

Flow control solenoid valve

A

temperature sensor, are input into the MCU as information to change fan revolution. The regulated maximum number of revolutions varies depending on the input electric current value from the MCU to flow control solenoid (3).

C Stepless control range

A’

When oil amount supplied to port P is Q0 or more in the figure, pressure difference (PA-PB) at the flow control spool grows bigger than installation load of it.

C’ High temp.

Low temp.

Q0

In this motor, upstream pressure of throttle is led to A side and downstream pressure is led to B side of flow control spool. When the pressurized oil from the pump flow into P port, the pressure difference generated before and after the throttle section works on the spring of the flow control spool.

Q1

Oil amount supplied to motor 70V2U42006

Flow control solenoid valve (3) (proportional pressure solenoid) is used in the fan motor line. In addition three kinds of signals sent from the engine water temperature sensor (S/N 9001~9100), ECM (S/N 9101~), torque converter oil temperature sensor, and the hydraulic oil

After that, because flow control spool is opened (PT) to discharge excess oil to tank line (the shaded region shown in the figure), the fan revolution is kept from A to C min-1 constantly. The proportional flow control valve is installed on this motor. It is possible for this motor to change the fan revolutions from A-C to A’-C’ range consecutively by changing the command current as shown in figure.

80ZV-2 EU 42-95 42 Function & Structure Hydraulic Group Fan Motor Line

Fan motor

Port Tc

c

Port P

Port T EF connector (Flow control sol.)

C A

B

B

C

A

Z

K80V2J42022

Fan motor specifications Displacement capacity Rating

28±1 cm3/rev (1.7 in3/rev)

Pressure

12.8 MPa (131 kgf/cm2) (1,863 psi)

Speed

1,650 min-1

Flow

66 L/min (17.6 gal/min)

Speed Control method control

Continuous variable control with solenoid valve

80ZV-2 EU 42-96 42 Function & Structure Hydraulic Group Fan Motor Line

Fan motor structure

B-B 20

2

3

4

5

17

14

15

21

6

1

18 10 11

9

16 7

8

A-A

13

19

12

C-C K70V2J42008

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 10. Sub bearing 11. Oil seal

12. End cover 13. Center spring 14. Spring for safety valve 15. Safety valve with suction function 16. Variable flow control valve 17. Flow control spool 18. Spring 19. Main spool (dummy) 20. Flow control solenoid valve 21. Filter

80ZV-2 EU 42-97 42 Function & Structure Hydraulic Group Fan Motor Line

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.

Y

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

F3

ri F3

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

85V2E42043

This force pushes thrust plate (3) fixed at a certain angle  for the output shaft (1), and it is divided into two component force F2 and F3.

F1

D

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.

P

F3

Resultant force of this torque (T= (F3 x ri)) goes through a piston as turning force and turns cylinder block (5).

F2

3

5

4

85V2E42044

4 5

Y

6

1

Supply side

3 Discharge side

Y

85V2E42045

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

80ZV-2 EU 42-98 42 Function & Structure Hydraulic Group Reversing Fan Motor Line (OPT)

Reversing Fan Motor Line (OPT) Reversing fan motor function

Functional limitation conditions: When either one of the following temperature exceeds the preset upper limit(s), the cooling fan reverse rotation function does not work.

Switch

1. Signal of engine water temperature > 94ºC (201.2ºF) 2. Signal of torque converter oil temperature > 115ºC (239ºF) 3. Signal of the hydraulic oil temperature > 95ºC (203ºF) K70V2J42013

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

80ZV-2 EU 42-99 42 Function & Structure Hydraulic Group Reversing Fan Motor Line (OPT)

Fan motor This figure is shown the optional reversing fan motor.

ER connector (Reversing sol.)

Port P Port Tc

Port T

Z

EF connector (Flow control sol.)

C

A

B

B

C Z

Fan motor specifications Displacement capacity Rating

28±1 cm3/rev (1.7 in3/rev)

Pressure

12.8 MPa (131 kgf/cm2) (1,863 psi)

Speed

1,650 min-1

Flow

66 L/min (17.6 gal/min)

Speed Control method control

Continuous variable control with solenoid valve

A 85V2E42041

80ZV-2 EU 42-100 42 Function & Structure Hydraulic Group Reversing Fan Motor Line (OPT)

Fan motor structure

B-B

20

17

14

15

23

21 2

3

4

5

6

1

18

10

11

16

22

24

19

9 7

8

13

A-A

12

C-C 85V2E42042

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 10. Sub bearing 11. Oil seal 12. End cover

13. Center spring 14. Spring for safety valve 15. Safety valve with suction function 16. Variable flow control valve 17. Flow control spool 18. Spring 19. Main spool 20. Flow control solenoid valve 21. Filter 22. Selector valve (*) 23. Reversing solenoid (*) 24. Spring (*) (*) Optional parts for reversing fan motor

80ZV-2 EU 42-101 42 Function & Structure Hydraulic Group Reversing Fan Motor Line (OPT)

Reversing fan control chart Reversing control

Normal control ON

Reversing solenoid valve

OFF

FVR1 Flow control solenoid valve output current Fv Flow control solenoid valve

FVR2

t FV1

t FV1

t FV1

t FV2

t FV2

t AR2

t AR1

t AR2 ON

Reversing fan switch

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

t FV1

16

t FV2

18

t AR1

1,800

t AR2

60

F VR1

approx. 400

F VR2

0

85V2E42047

80ZV-2 EU 42-102 42 Function & Structure Hydraulic Group Reversing Fan Motor Line (OPT)

Hydraulic circuit (Reverse rotation) Fan motor (4)

Selector valve (6)

Fan motor assy

Flow control solenoid (3) MB

MA

Reverse solenoid (5)

To MCU (Reversing cooling fan switch)

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

Flow control valve (2)

Brake circuit

Safety valve (1)

TC

P

T

Relief valve

M

Unloader valve

TS

Hydraulic tank

Hydraulic line (reverse revolution)

K80V2J42018

When the cooling fan reversal switch is "ON", reverse solenoid valve (5) is magnetized. The solenoid valve spool moves to the left. Oil from the pump pushes selector valve (6) to the left. As a result, the fan motor turns into reverse.

80ZV-2 EU 42-103 42 Function & Structure Hydraulic Group Secondary Steering

Secondary Steering Secondary steering motor and pump

Magnetic switch

Pressure sensor

Hydraulic pump To battery relay

Steering valve

Hydraulic circuit Electrical circuit Check valve K80V2U42003

Speed sensor Pilot lamp

To steering valve

F13 MCU

To loading line Pressure sensor

Check valve

Check valve G1 G1/2

+24 V

Secondary steering motor and pump

M

G1 G1/2

10 cm3/rev

G3/8

11.7MPa (119.3 kgf/cm2) (1696 psi)

To brake and pilot line

80.2 32.2 25.3 cm3/rev cm3/rev cm3/rev

M

G1/4 TS

Magnetic switch (on motor and pump) Steering pump

Hydraulic line Electrical circuit

Secondary steering circuit 80V2E42011

80ZV-2 EU 42-104 42 Function & Structure Hydraulic Group Secondary Steering

Secondary steering operation In normal operation, the oil from the steering pump flows into the steering valve through the check valve. And the signal of the pressure sensor is always sent to the MCU. With some problems, as the steering hydraulic pressure goes down while the engine is running, the pressure sensor signal becomes less than the preset value at the MCU more than 1 sec. In this condition, if the machine speed is more than 2 km/h, the MCU sends a signal to the magnetic switch. As a result, the secondary steering motor and pump is driven. Then it is ready to steer the machine. Pressure sensor preset value Steering hydraulic pressure ON: at 0.3 MPa (3 kgf/cm2) (44 psi) or lower OFF: at 0.4 MPa (4 kgf/cm2) (58 psi) or higher

The signal from MCU to magnetic switch

Machine speed signal

ON

Machine speed

OFF

1

2

(km/h)

85V2E42051

80ZV-2 EU 42-105 42 Function & Structure Hydraulic Group Secondary Steering

Secondary steering motor and pump CW rotation

Magnetic switch

Relief valve

+24 V

Motor

+24 V

Pump

Relief valve 11.7 MPa (119.3 kgf/cm2)

Customer's power connection

Customer's MCU connection

M

10

Customer's ground connection Electric/Hydraulic schematic 80V2E42013

Secondary steering motor and pump Model

ND-K2-D

Discharge (cm3/rev)

10

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

11.7 (119.3) (1,696)

85V2E42052

80ZV-2 EU 42-106 42 Function & Structure Hydraulic Group

MEMO

80ZV-2 EU 43-1 43 Check & Adjustment Hydraulic Group

43 Check & Adjustment Hydraulic Group Loading/Steering Circuit Relief Valve/Ride Control Circuit Reducing Valve (OPT) ................................................................................ 43-2 Hydraulic Cylinder ................................................... 43-14 Stop Valve ............................................................... 43-16

80ZV-2 EU 43-2 43 Check & Adjustment Hydraulic Group Loading/Steering Circuit Relief Valve/Ride Control Circuit Reducing Valve (OPT)

Loading/Steering Circuit Relief Valve/Ride Control Circuit Reducing Valve (OPT) Loading circuit relief valve setting pressures WARNING Unexpected movement of the machine may cause an accident resulting in injury or death. Therefore, to provide repair service with the engine running, be sure to observe the following items : - Park the machine on level ground. - Apply the parking brake. - Block the tires with chocks to prevent the tires from moving. - Determine the signals between the service man. - Prohibit any person from walking into dangerous areas. - Near articulation areas of the machine - Under the machine - Around the engine - In front of or behind the machine

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

CAUTION Be careful, you may get burned if the high pressure oil spouts out. To prevent such an accident, be sure to release the residual pressure from the pipe, and open the cap of the hydraulic tank before removing the plug from the pressure measurement port. Releasing residual pressure from tank and pipes Keep the bottom surface of the bucket horizontal, and stop the engine when the bucket is approximately 30 cm (1 ft.) above the ground. Tilt down the bucket until it comes in contact with the ground. Place the bucket control lever in the roll back position, and then lower the boom. Push down on, then open the cap of the hydraulic tank to release the residual pressure.

Measurement instruments Pressure gauge 30 MPa (300 kgf/cm2) (5,000 psi) (for loading line with 3 m (10 ft.) hose) 5 MPa (50 kgf/cm2) (1,000 psi) (for pilot line) with 2~3 m (6~10 ft.) hose Note For safety purpose, route the gauge to an area where it may be safely read by the person doing the test.

Standard measurement value Loading line main relief pressure (at maximum speed) MPa (kgf/cm2) (psi)

20.6±0.5 (210±5) (2,986±71)

Loading line overload relief pressure (at idling speed) MPa (kgf/cm2) (psi)

23.5±0.5 (240±5) (3,413±71)

Pilot line

MPa (kgf/cm2) (psi)

3.5 (36) (512)

Hydraulic oil temperature: 50±5ºC (120±9ºF)

80ZV-2 EU 43-3 43 Check & Adjustment Hydraulic Group Loading/Steering Circuit Relief Valve/Ride Control Circuit Reducing Valve (OPT)

Gauge port

Valve assembly Gauge port location

Port size

(5)

Main relief pressure (1), (2), (3) Overload relief pressure

Pilot line pressure (Reducing valve)

(PPI)

(1), (2), (3) G (PF) 1/4 with O-ring

(Z2)

(4)

(1), (2), (3)

(Z)

(Z1)

(PA) ACF

(ACCF)

(ACCR)

(PARKING) (TA)

(4) G (PF) 3/8 with O-ring

(T)

(P)

(4), (5) (5) G (PF) 1/4 with O-ring

Reducing valve (for pilot)

Bucket cylinder 85V2E43001

(1)

(2)

80ZVE43001

Multiple control valve

(3)

Main relief valve Overload relief valve

Overload relief valve 70ZVE43002

80ZV-2 EU 43-4 43 Check & Adjustment Hydraulic Group Loading/Steering Circuit Relief Valve/Ride Control Circuit Reducing Valve (OPT)

Measuring loading circuit main relief pressure 1. Unload the bucket.

Adjusting main relief pressure

Adjusting screw

2. Press the brake pedal, and set and confirm the transmission shift lever is at the neutral position. 3. Set and confirm the parking brake is at the "ON" position. 4. Press the brake pedal, and lower the boom to the lowest limit.

Lock nut Main relief valve 70ZV43004

5. Attach the pressure gauge 30 MPa (300 kgf/cm2) (5,000 psi) to the bucket cylinder bottom side (2). 6. Set the declutch ON/OFF switch to ON. Press down the brake pedal all the way to the floor to avoid the “fuel saving mode at idle time”. Note In the “fuel saving mode at idle time”, the engine is not activated promptly and may not reach the maximum revolution. 7. Move the bucket control lever to the roll back position. Hold the lever at that position. 8. Increase the engine speed to the maximum, and measure and record the pressure using the pressure gauge.

Loosen the lock nut and adjust the pressure by the adjusting screw. Turn clockwise the adjusting screw to raise the set pressure, or turn counterclockwise the adjusting screw to lower the set pressure.

IMPORTANT At the completion of check and adjustment of main relief valve pressure, be sure to tighten the lock nut.

80ZV-2 EU 43-5 43 Check & Adjustment Hydraulic Group Loading/Steering Circuit Relief Valve/Ride Control Circuit Reducing Valve (OPT)

Measuring loading circuit overload relief pressure

Adjusting overload relief pressure

1. Attach the pressure gauge to the port ((2) for the bottom side, (1) for the rod side, (3) for the both sides).

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.

Adjusting screw Overload relief valve 70ZV43005

2. Move the bucket control lever to the roll back position.

Loosen the lock nut and adjust the pressure by the adjusting screw.

3. Place the shift lever to the forward position. Note Avoid “Hibernate mode” during the measurement. In the “Hibernate mode”, the engine speed is decreased to 725 min-1 at idling under the following conditions: - when the transmission shift lever is placed at “N” position, - the engine coolant temperature is higher than 60ºC (140ºF), and - the engine speed is held at 950 min-1 or less for 10 seconds. 4. Keep the engine speed at low idle. 5. Hold the bucket control lever at the roll back position and record the pressure. Bucket cylinder rod side 1. Keep the boom horizontal. 2. Move the bucket control lever to the dump position, hold and then measure and record the pressure.

Turn clockwise the adjusting screw to raise the set pressure, or turn counterclockwise the adjusting screw to lower the set pressure.

IMPORTANT At the completion of check and adjustment of overload relief valve pressure, be sure to reset the main relief valve to the original condition.

80ZV-2 EU 43-6 43 Check & Adjustment Hydraulic Group Loading/Steering Circuit Relief Valve/Ride Control Circuit Reducing Valve (OPT)

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 port (4) or (5).

Adjusting screw

WARNING

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. Place the shift lever to the forward position. Note Avoid “Hibernate mode” during the measurement. In the “Hibernate mode”, the engine speed is decreased to 725 min-1 at idling under the following conditions: - when the transmission shift lever is placed at “N” position, - the engine coolant temperature is higher than 60ºC (140ºF), and - the engine speed is held at 950 min-1 or less for 10 seconds. 3. Keep the engine speed at low idle (when the brake line pressure is normal) and then measure and record the pressure.

80ZV-2 EU 43-7 43 Check & Adjustment Hydraulic Group Loading/Steering Circuit Relief Valve/Ride Control Circuit Reducing Valve (OPT)

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

CAUTION Be careful, you may get burned if the high pressure oil spouts out. To prevent such an accident, be sure to release the residual pressure from the pipe, and open the cap of the hydraulic tank before removing the plug from the pressure measurement port. Releasing residual pressure from tank and pipes Keep the bottom surface of the bucket horizontal, and stop the engine when the bucket is approximately 30 cm (1 ft.) above the ground. Tilt down the bucket until it comes in contact with the ground. Place the bucket control lever in the roll back position, and then lower the boom. Push down on, then open the cap of the hydraulic tank to release the residual pressure.

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

Measurement instruments Pressure gauge 15 MPa (150 kgf/cm2) (3,000 psi) (for ride control line) with 3 m (10 ft.) hose Note For safety, route the gauge to an area where it may be safely read by the person doing the test.

Reference

Standard measurement value

From pump

1

(11)

P

(12)

Ride control line pressure (reducing valve) MPa (kgf/cm2) (psi)

7.4±0.3 (75±3) (1,067)

KAYABA INDUSTRY CO,LTD TOKYO JAPAN

Plug SP1

Hydraulic oil temperature: 50±5ºC (120±9ºF)

(18)

B

B T

SP2

Gauge port

To accumulator A

Gauge port location

B

(15)(16) Boom cylinder bottom side

Boom cylinder rod side

K80V2J43001

Reducing pressure

SP1

Port size G (PF) 3/4 with O-ring

80ZV-2 EU 43-8 43 Check & Adjustment Hydraulic Group Loading/Steering Circuit Relief Valve/Ride Control Circuit Reducing Valve (OPT)

Measuring ride control circuit reducing pressure

Adjusting reducing valve pressure

P

1 21 23 (18)

22

Reducing valve section Depressure valve section

70V2U43001

85V2E43003

1. Loosen lock nut (23) and depressure valve (18) for releasing internal pressure from accumulator circuit. : Valve (18): 7 N-m (0.7 kgf-m) (10 lb-ft) : Lock nut (23): 13.6 N-m (1.4 kgf-m) (5 lb-ft)

Loosen lock nut (21) and adjust the pressure by adjusting screw (22). : Lock nut (21): 29 N-m (3.0 kgf-m) (22 lb-ft) Turn clockwise the adjusting screw to raise the set pressure, or turn counterclockwise the adjusting screw to lower the set pressure.

2. Attach the pressure gauge to the gauge port SP1.

IMPORTANT : Plug SP1: 165 N-m (16.8 kgf-m) (121 lb-ft) 3. Keep the engine speed at low idle and then measure and record the pressure.

At the completion of check and adjustment of reducing valve pressure, be sure to tighten the lock nut.

80ZV-2 EU 43-9 43 Check & Adjustment Hydraulic Group Loading/Steering Circuit Relief Valve/Ride Control Circuit Reducing Valve (OPT)

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

CAUTION Be careful, you may get burned if the high pressure oil spouts out. To prevent such an accident, be sure to release the residual pressure from the pipe, and open the cap of the hydraulic tank before removing the plug from the pressure measurement port. Releasing residual pressure from tank and pipes Keep the bottom surface of the bucket horizontal, and stop the engine when the bucket is approximately 30 cm (1 ft.) above the ground. Tilt down the bucket until it comes in contact with the ground. Place the bucket control lever in the roll back position, and then lower the boom. Push down on, then open the cap of the hydraulic tank to release the residual pressure.

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

Measurement instruments Pressure gauge 30 MPa (300 kgf/cm2) (5,000 psi) (for 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 Steering line main relief pressure (at maximum speed) MPa (kgf/cm2) (psi)

20.6±0.5 (210±5) (2,986±71)

Steering line overload relief pressure (at idling speed) MPa (kgf/cm2) (psi)

24.5 +1.0 0 (250 +100 ) (3,555 +1420 )

Pilot line MPa (kgf/cm2) (psi)

3.5 (36) (512)

Hydraulic oil temp : 50±5ºC (120±9ºF)

80ZV-2 EU 43-10 43 Check & Adjustment Hydraulic Group Loading/Steering Circuit Relief Valve/Ride Control Circuit Reducing Valve (OPT)

Gauge port

Steering valve Gauge port location

Port size

Main relief pressure (1), (2)

G (PF) 1/4 with O-ring

(3)

Rc (PT 1/8)

Overload relief valve

Overload relief pressure Reducing pressure

Steering cylinder

Steering cylinder

Main relief valve

(2)

70ZV43008

(1)

70ZV43007

Reducing valve

(A)

(3)

(B)

115ZV43006

80ZV-2 EU 43-11 43 Check & Adjustment Hydraulic Group Loading/Steering Circuit Relief Valve/Ride Control Circuit Reducing Valve (OPT)

Measuring steering circuit main relief pressure 1. Unload the bucket. 2. Press the brake pedal, and set and confirm the transmission shift lever is at the neutral position. 3. Set and confirm the parking brake is at the "ON" position. 4. Press the brake pedal.

7. In case the pressure gauge is installed to (1), steer the machine to the left until the front and rear chassis contact each other. Continue to hold the steering wheel fully turned. Note Because the stop valve is installed into the steering line, oil pressure does not reach the set point when the steering is fully turned. When measuring oil pressure, be sure to apply the articulation stopper or screw the stopper (bolt) in until the front and rear chassis contact each other.

WARNING Steering cylinder

(2)

If the machine begins to move with the articulation stopper applied, it may cause an accident resulting in injury or death. After the measurement, be sure to disconnect and store the articulation stopper. 8. Increase the engine speed to high idle, and measure and record the pressure.

(1)

70ZV43007

Adjusting steering line main pressure

5. Attach the pressure gauge to the gauge port ((1) or (2)). 6. Set the declutch ON/OFF switch to ON. Press down the brake pedal all the way to the floor to avoid the “fuel saving mode at idle time”.

Lock nut Adjusting screw

Note In the “fuel saving mode at idle time”, the engine is not activated promptly and may not reach the maximum revolution. Steering valve

Main relief valve 70ZV43009

Loosen the lock nut and adjust the pressure by the adjusting screw. Turn clockwise the adjusting screw to raise the steering line main pressure.

80ZV-2 EU 43-12 43 Check & Adjustment Hydraulic Group Loading/Steering Circuit Relief Valve/Ride Control Circuit Reducing Valve (OPT)

Measuring steering circuit overload relief pressure

Stopper (bolt)

Port B To steering valve

Adjusting overload relief pressure

Port A From Orbitrol®

Lock nut

Spool

Adjusting screw Installed on front chassis

Check valve 70ZV43005

Installed on rear chassis 90V2U42003

1. Attach the pressure gauge to the port ((1) for the left turn, (2) for the right turn). 2. Adjust the main relief valve pressure to 25.5 MPa (260 kgf/cm2) (3,697 psi) + 1/4 additional turn, so the pressure is above the overload relief pressure.

Loosen the lock nut and adjust the pressure by the adjusting screw. Turn clockwise the adjusting screw to raise the set pressure, or turn counterclockwise the adjusting screw to lower the set pressure.

WARNING 3. Steer the machine until the front and rear chassis contact each other. Continue to hold the steering wheel fully turned. Note Because the stop valve is installed into the steering line, oil pressure does not reach the set point when the steering is fully turned. When measuring oil pressure, be sure to apply the articulation stopper or screw the stopper (bolt) in until the front and rear chassis contact each other. 4. Place the shift lever to the forward position. Note Avoid “Hibernate mode” during the measurement. In the “Hibernate mode”, the engine speed is decreased to 725 min-1 at idling under the following conditions: - when the transmission shift lever is placed at “N” position, - the engine coolant temperature is higher than 60ºC (140ºF), and - the engine speed is held at 950 min-1 or less for 10 seconds. 5. Keep the engine speed at low idle, and measure and record the pressure. Raise the engine speed to 1,000 min-1 if fail to do.

If the machine begins to move with the articulation stopper applied, it may cause an accident resulting in injury or death. After the measurement, be sure to disconnect and store the articulation stopper.

IMPORTANT At the completion of check and adjustment of overload relief valve pressure, be sure to reset the main relief valve to the original condition.

80ZV-2 EU 43-13 43 Check & Adjustment Hydraulic Group Loading/Steering Circuit Relief Valve/Ride Control Circuit Reducing Valve (OPT)

Measuring pilot circuit relief pressure (reducing pressure)

5. Hold the bucket control lever at the roll back position and record the pressure.

Adjusting pilot line pressure

Adjusting screw Lock nut

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 port (3). (S/N 9029~) Gauge port plug width across flat: 5 mm (0.2 in) 2. Keep the engine speed at low idle and record the pressure. 3. Place the shift lever to the forward position. Note Avoid “Hibernate mode” during the measurement. In the “Hibernate mode”, the engine speed is decreased to 725 min-1 at idling under the following conditions: - when the transmission shift lever is placed at “N” position, - the engine coolant temperature is higher than 60ºC (140ºF), and - the engine speed is held at 950 min-1 or less for 10 seconds. 4. Keep the engine speed at low idle and record the pressure.

80ZV-2 EU 43-14 43 Check & Adjustment Hydraulic Group Hydraulic Cylinder

Hydraulic Cylinder Cylinder natural drift

Measurement procedure 1. Unload the bucket.

WARNING Standing under the boom or bucket during service work is dangerous. An accident resulting in injury or death may be caused. To prevent such an accident, be sure to lock the boom and bucket control levers in the cab, securely support the boom, and remove the starter key. In addition, hang a "DO NOT OPERATE!" tag on the steering wheel.

2. Keep the boom and bucket horizontal. 3. Set the parking brake switch to the "ON" position. 4. Lock the boom and bucket control levers using the safety lock. 5. Stop the engine. 6. Mark the cylinder rod at a point 100~150 mm (4~6 in) away from the cylinder head cover.

Measurement instrument

7. Measure the accurate distance from the cylinder head cover to the vinyl tape. This is distance "A" mm (in). Measure the distance again 5 minutes later. This is distance "B" mm (in).

- Scale 150~300 mm (1 ft.) - Stop watch

Cylinder drift (mm/min) A – B (mm) (in) = -------------(in/min) 5 (min)

- Black vinyl "electrician's" type Note Warm-up the hydraulic oil before measuring cylinder drift.

Standard measurement value Boom cylinder (mm/min) (in/min)

3 (1/8) or less

Bucket cylinder (mm/min) (in/min)

4 (5/32) or less

80ZV-2 EU 43-15 43 Check & Adjustment Hydraulic Group Hydraulic Cylinder Reference

Mark (Vinyl tape) Scale

70ZV43012

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.

80ZV-2 EU 43-16 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 33.8~38.7 mm (1.33~1.52 in)

Reference dimension 13.7~27.5 mm (0.54~1.08 in)

Stopper (bolt) length

Clearance between machine body and stopper

80ZVE43003

80ZVE43002

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 "13.7~27.5 mm (0.54~1.08 in)" shown in the table below.

38

37

36

Clearance between machine body and stopper (mm) (in)

13.7 (0.54)

20.6 (0.81)

27.5 (1.08)

Stopper (bolt) length (mm) (in)

33.8 (1.33)

36.2 (1.42)

38.7 (1.52)

*The target value should be the articulation angle "37º". - After adjustment, turn the steering wheel slowly at a rate of 5 sec or more per turn, and confirm the clearance between the machine body and the stopper. - When adjustment is completed, tighten the lock nut of the stopper (bolt). : 90 N-m (9.2 kgf-m) (67 lb-ft)

80ZV-2 EU 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 Accumulator ............................................................ 52-9 In-Line Filter ............................................................ 52-10 Brake Valve ............................................................. 52-11 Service Brake .......................................................... 52-15 Parking Brake.......................................................... 52-18 Parking Brake Manual Release............................... 52-21 Parking Brake Spring Chamber............................... 52-23 Brake Circuit Check Valve....................................... 52-24 Pressure Sensor (for stop lamp and declutch) ........ 52-25

80ZV-2 EU 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 brake is the internal expansion drum 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 unloader valve (22), and accumulated in accumulator (33) provided for the front and rear wheels. When brake valve (23) is depressed, the pressure oil in the accumulator enters the disc brake piston chamber for the front and rear wheels, pushes the piston, and generates braking power.

Parking brake The internal expansion type drum brake for parking is applied by spring chamber (55). Spring chamber (55) operates when the pressure oil inside the spring chamber returns to the tank while the power is not supplied to solenoid valve (35) (that is, while the parking switch is ON).

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.

80ZV-2 EU 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 brake is the internal expansion drum type.

2

3

1

5

6

4

80V2E52001

1. Accumulator 2. Solenoid valve (for parking) 3. Brake valve 4. Parking brake 5. Spring chamber (for parking brake) 6. Unloader valve

80ZV-2 EU 52-4 52 Function & Structure Brake Group Unloader Valve

Unloader Valve (S/N 9001~9039)

To accumulator

B-B

6 To tank

24

22

21

23

To fan motor

7

8 9

B

20

A

Filter

3

18

5

17 Pilot port (accumulator feedback port)

B

16 A-A

10

1

19

4

15 11

12

14

13

2

A

From pump Fan motor port

Pump port

Tank port

T

Accumulator port

2

Fan motor port

AC

Pilot port (accumulator feedback port)

Rc 1/8

Tank port

Pilot port (accumulator feedback port)

Accumulator port

P Pump port

Outline drawing

Hydraulic circuit diagram

1. Body 2. Spring 3. Spool 4. O-ring 5. Plug 6. Orifice 7. Orifice 8. O-ring

PP

9. Plug 10. Plug 11. Governor plunger 12. Spring 13. O-ring 14. Plug 15. Pilot valve 16. Spring seat

17. Spring 18. Spring 19. O-ring 20. Plug 21. Adjusting screw 22. Lock nut 23. Packing 24. Cap 80ZV52010

80ZV-2 EU 52-5 52 Function & Structure Brake Group Unloader Valve (S/N 9040~)

To accumulator

6

B-B

To tank

To fan motor

21 22

8

7

20

B

25 19

26 18

9

10 1

A

17

3 16 Filter

4 15

12

11

Pilot port (accumulator feedback port)

B

2

5

13

A-A

From pump

A

Fan motor port

Accumulator port

14

T

Pump port

2

Fan motor port Pilot port (accumulator feedback port)

AC

Tank port

PP

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

80ZV-2 EU 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. Body (1) is equipped with ports (pump, fan motor, accumulator, pilot and tank). Spool (3) which opens and closes the pump port to the fan motor port, orifice (6) which regulates the flow rate to the accumulator port with high priority, and the pressure governor mechanism which controls the pressure on the accumulator port side are built in the unloader valve.

Unloader valve operation While the unloader valve is not operating, spool (3) is pushed back by spring (2) and the pump port to the fan motor port is closed. Oil flowing from the pump port is sent to the accumulator port through orifice (6), and the pressure at the accumulator port increases accordingly. When an excess flow rate is generated, spool (3) moves to the fan motor port side and the excess flow rate flows out to the port to the fan motor. The pressure at the accumulator port is transferred to the inside of the pressure governor through orifice (7). When the pressure at the accumulator port increases and exceeds the load of springs (17)(18) applied on pilot valve (15), the pilot valve opens and increase of the pressure at the accumulator port stops (cut-out pressure). At this time, the pressure in the accumulator connected to the pilot port pushes governor plunger (11), and continuously releases the pilot valve. When the pressure in the accumulator decreases and the spring attached to the pilot valve pushes back the governor plunger, the pilot valve is closed and the pressure at the accumulator port starts to increase again (cut-in pressure). Setting pressure

OFF

11.8±0.5 MPa (120±5 kgf/cm2) (1,706±71 psi)

ON

6.9±1.0 MPa (70±10 kgf/cm2) (995±142 psi)

80ZV-2 EU 52-7 52 Function & Structure Brake Group Valve Unit

Valve Unit 4

Note Unloader valve (PI) "Feed back" signal is acquired from front brake accumulator.

Loading line pilot valve

(PPI)

(Z)

(Z1)

(Z2) (PA)

ACF

(ACCF)

Spring chamber for parking brake

(ACCR) (PI)

(PARKING)

(TA)

Unloader valve "feed back" signal.

(P) Tank

Pump port (from unloader valve)

(T)

2

1

3

High pressure test ports

P=Pump supply T=Tank circuit PI=Pump feedback to unloader (From ACCF circuit) ACCR=Accumulator circuit-rear ACCF=Accumulator circuit-front PPI=Pilot valve 85V2E52002

A

P

B

WARNING

ACCR

3

4

A

B

ACCF To parking brake ACF Rc1/8

PI

1 B

2 P

T

B A

PA G3/8

T

Z2 G1/4

ACF T Rc1/8 G1/2

Z PPI TA Z1 G1/4 G3/8 G3/8 G1/4

85V2E52003

1. Solenoid valve for parking brake 2. Reducing valve [3.5 MPa (36 kgf/cm2) (512 psi)] (Serves as pressure for loading pilot control and park brake) 3. Check valve Accumulator low pressure sensor 4. Set value by MCU [3.9±0.5 MPa (40±5 kgf/cm2) (569±71 psi)]

Injection Hazard High pressure test ports contain accumulator pressure [11.8 MPa (1,706 psi)] that can escape from these 2 plugs. Depress brake pedal 80~100 times to completely discharge the brake accumulators prior to removing these test plugs. 135ZV52035

80ZV-2 EU 52-8 52 Function & Structure Brake Group Valve Unit

Accumulator low pressure sensor Parking brake solenoid valve

Reducing valve

Pressure sensor Valve unit K80V2U52002

2

A

1

3

View A 1: Power (+) 2: Output (+) 3: Common

(V) 5 4 3 2 1

0

10 (102) (1422)

20 (204) (2844)

30 35 MPa 2 (306) (351) (kgf/cm ) (4351) (4991) (psi)

95V2E52095

80ZV-2 EU 52-9 52 Function & Structure Brake Group Accumulator

Accumulator

11 3

5

7

6

4

6

7

Stroke 169 mm (6 5/8 in)

5

1

2

11

8 9 10

80V2E52002

1. Cylinder 2. Top cover 3. Oil port 4. Piston 5. O-ring 6. T-ring 7. Backup ring 8. Core 9. Packing 10. Cap 11. Spring pin

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. Accumulator specifications Maximum operating pressure MPa (kgf/cm2) (psi)

11.8±0.5 (120±5) (1,706±71)

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

2.94±0.1 (30±1) (427±14)

Nitrogen gas capacity L (gal)

1.5 (0.396)

80ZV-2 EU 52-10 52 Function & Structure Brake Group In-Line Filter

In-Line Filter

From unloader valve

To combination valve

FILTER

1

3

4

2

5 70ZV42040

1. Case 2. Nipple 3. Strainer

4. O-ring 5. O-ring

Combination valve In-line filter

Accumulator

Unloader valve

80V2U52001

This 95 micron filter protects the brake manifold and related valves from contamination.

become lodged & may not blow out with compressed air, but may release later & cause erratic valve troubles.

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

It is called out as item #81 in the brake diagram.

80ZV-2 EU 52-11 52 Function & Structure Brake Group Brake Valve

Brake Valve 34

B

35

33

32

36

37

41

32

43

A 28

25

39

38

40

42

52

44 45 A-A

46

47

49

31

26

51 16 50

15

27

14

48

A 17

18 29

22 19

20

13 23

30

21 Rear brake port

Accumulator port 5

10 2

12

Tank port

6 Front brake port

11 Accumulator port

2 5 3

1

6

4 8

1. Body 2. Spool 3. Spring seat 4. Snap ring 5. Plunger 6. Spring 7. Plug 8. O-ring 9. C-ring 10. Orifice 11. O-ring

Pressure sensor port

B 9

B-B

7

12. Body 13. Cover 14. Oil seal 15. Plate 16. C-ring 17. Spool input 18. Spring seat 19. Retainer 20. Bolt 21. Spring 22. Spring

23. Case 24. — 25. Seat 26. Dust cover 27. Mounting plate 28. Pedal bush 29. Bolt 30. Spring washer 31. Pedal 32. Roller

33. Spacer 34. Pedal pin 35. L-pin 36. Washer 37. Pin 38. Shaft 39. Spacer 40. Joint 41. Pin 42. Boot

80V2E52003

43. Snap ring 44. Shaft 45. Bolt 46. Washer 47. Nut 48. Plate 49. Spring 50. Screw 51. Nut 52. Pedal cover

80ZV-2 EU 52-12 52 Function & Structure Brake Group Brake Valve

Brake valve performance chart

Pedal pressing force (F)

N (kgf) (lbf)

334 (34.1) (75.0)

300 (30.6) (67)

200 (20.4) (45) 100 (10.2) (22) 72.3 (7.4) (16.3)

55.5 (5.7) (12.5) ( ) 0

3.9

5

10

15

18.5 19

15

18.5 19

Pedal stroke

Output oil pressure (Brake port)

MPa (kgf/cm2) (psi) 4 (40) (580)

4.06 (41) (589)

2 (20) (290)

( ) 0

3.9 5

10

Pedal stroke K80V2U52001

80ZV-2 EU 52-13 52 Function & Structure Brake Group Brake Valve

Brake valve outline

While the valve is not operating

The brake valve is integrated into the pedal converts the pump oil pressure into the pressure corresponding to the pedal pressing force, and transmits it to the brake.

B

The brake valve is the tandem type, and consists of two independent systems. When the right side pedal is depressed, the movement of right side pedal is transmitted to a left side pedal by the linkage and brake is applied. But when the left side pedal is depressed, only left pedal is worked.

32

The valve is the closed center type (in which the import is closed while the pedal is released). High pressure is always applied on the in-port side to improve the responsiveness during operation. 17 22 21

Accumulator

Accumulator

A1

B1 Rear brake 2

A2

5 6 B2 Front brake 2 5 B

6

Tank T

Pressure sensor port B-B

80V2E52005

80ZV-2 EU 52-14 52 Function & Structure Brake Group Brake Valve

While the valve is operating Between spool input (17) and spools (2) in the brake valve, spring (21) which converts pedal pressing force into output oil pressure is installed.

When the brake pedal is pressed, spool input (17) is pushed by way of roller (32).

In addition, two spools (2) are installed for series in the center of the main body of the brake valve. Plungers (5) which transmit the control oil pressure to spool as the hydraulic reactive force are built in each spool.

Spool input (17) lets each spool (2) drop down by way of spring (21). When spool (2) are pushed down, at first the passage from out-port B1, B2, and pressure sensor port to the tank port are shut down.

While the valve is not operating, each spool is returned to the non-operation position by spring (6).

When spool (2) are pushed down further, the passages from in-ports A1, A2 to out-ports B1, B2 are opened and pressure oil from the accumulator is sent to the brake piston chamber to apply the brake.

As a result, the passages from out-ports B1, B2, and pressure sensor port to tank port are opened, and the pressure inside the brake piston chamber becomes equivalent to the pressure in the tank. In addition, oil sent from the pump is stored in the accumulator, and sent to the in-ports A1 and A2. But the passages from in-ports A1, A2 to out-ports B1, B2 and pressure sensor port are shut down by each spool (2), and high pressure oil from the accumulator is maintained.

Pressure oil of in-ports A1, A2 side act on plunger (5) inside each spool (2) through the orifices and works as the hydraulic reactive force to return spool (2) upward. When the sum of hydraulic reactive force and spring load (6) becomes balanced with spring load (21), it returns spool (2) to shut down the passages A1-B1 and A2-B2 to hold the pressure. By this operation, the load of springs (21)(22) by deflection are transmitted to the operator as pedal pressing force and the pressure in proportion to the pedal pressing force is obtained.

While the valve is releasing When the brake pedal is released, spool input (17) is pushed back by spring (22). The compressed spring (21) is extended, and each spool (2) is returned upward to the non-operation position by the sum of hydraulic reactive force and spring load (6). After the passages from out-ports B1,B2 and pressure sensor port to in-ports A1, A2 is shut down by spool (2), the pressure of out-ports B1,B2 and pressure sensor port is opened to tank port, and then the brake operation is released.

80ZV-2 EU 52-15 52 Function & Structure Brake Group Service Brake

Service Brake Service brake operation 10

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.

3

1 Brake oil inlet port

9

Since friction plate (6) rotating with axle shaft (9) via disc gear (7) is placed between brake backing plate (8) and steel plate (5), it makes the rotation speed of the axle shaft decrease or makes it stop.

7 6 2 12 11 8

When stepping on the brake pedal, the brake oil from the brake oil inlet enters the brake piston chamber through the oil passage of the axle housing extension and internal gear hub (2), and presses brake piston (4) to the left. Then, the brake piston presses steel plate (5) against friction plate (6).

Axle housing

5 4

80ZVE52004

1. Wheel hub 2. Internal gear hub 3. Internal gear 4. Brake piston 5. Steel plate 6. Friction plate 7. Disc gear 8. Brake backing plate 9. Axle shaft 10. O-ring (for brake piston) 11. O-ring (for gear hub) 12. Air bleeder nipple The service brake is an enclosed wet-type single-plate hydraulic brake, and is incorporated in the axle housing. This type of service brake ensures good braking power and protects the brakes from mud or sand.

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.

80ZV-2 EU 52-16 52 Function & Structure Brake Group Service Brake

Service brake friction plate

0.82 mm (0.032 in) or more

Detailed drawing of groove 70V2U52002

1. Plate 2. Lining The friction plate has linings (paper material) on the contact faces on both sides.

Service brake steel plate

Upper Internal gear

Spring pin

Steel plate Installation procedure 80ZV52011

80ZV-2 EU 52-17 52 Function & Structure Brake Group Service Brake

Brake circuit air bleeding procedure

Bleeding air from brake pipes and axle housing hubs

WARNING Unexpected movement of the machine may cause a severe accident. To prevent such an accident, take the following safety measures when performing air bleeding with the engine running. - Park the machine on level ground. - Apply the parking brake. - Block the tires with chocks to prevent the wheel from moving. - Determine the signals between the persons related to this work for engine starting to prevent an accident. - When moving up the boom, install a safety column under the boom. - Apply the articulate stopper.

IMPORTANT Before bleeding the service brakes, it is important to remove all air from the brake valve manifold block, and all related valves. These include the reducing valve and park brake valve. Failure to do this correctly will result in unsatisfactory brake modulation. Perform the following to do this: 1. Verify that the wheels are securely blocked, and the articulation lock is in the "locked" position. 2. Charge accumulator to full pressure, then shut off engine, and complete procedure. 3. 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 this back to the normal position when finished.

Air bleeder nipple

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. 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)

80ZV-2 EU 52-18 52 Function & Structure Brake Group Parking Brake

Parking Brake 5

6

B-B 5 A

5

Drum rotational direction for traveling in reverse

6

B

B

3

C 4 1 C D

D A

2 Adjusting screw rotational direction for brake shoe expansion A-A

4

D-D

C-C 80ZVE52005

1. Support plate 2. Brake shoe 3. Brake lining 4. Adjusting screw 5. Cam shaft 6. Lever The parking brake is a propeller shaft braking drum type, and is connected to the transmission output shaft.

80ZV-2 EU 52-19 52 Function & Structure Brake Group Parking Brake

Parking brake operation

Parking brake operation chart Parking switch

Parking switch ON

+

Oil

OFF

Solenoid valve for parking

Spring chamber

Bracket Bracket Pin Link ON OFF Lever (6)

Transmission

Parking brake

Parking brake operation (switch ON)

80ZVE52006

Turning on (pulling out) the parking switch turns off the power of the solenoid valve (shown in the figure). Oil is discharged from the spring chamber to the tank, and the spring in the spring chamber pulls parking brake lever (6). Since lever (6) is connected to cam shaft (5), the cam shaft rotates when the lever is pulled up. The rotation of the cam shaft causes the shoes on both sides of the cam to expand. As a result, the rotating brake drum is stopped.

ON

OFF

Solenoid valve

Power-off

Power-on

Spring chamber

Oil discharge

Oil feeding

Parking brake

Braking

Released

80ZV-2 EU 52-20 52 Function & Structure Brake Group Parking Brake

Parking brake solenoid valve Spring chamber (brake actuator) B

Reducing valve

Solenoid

Knob

P

T Seat face A

Seat face B

Manual release (counterclockwise rotation)

Spool

B

Tank

P T Hydraulic circuit diagram

Solenoid valve operation

Solenoid valve specifications Voltage

Amp

a 0

a

Volt

Varistor 95ZV42079

While the parking switch is ON (that is, while the power is not supplied to the solenoid), the seat face A is closed and the seat face B is open. As a result, the spring chamber port is connected to the tank, and the parking brake is applied. When the parking switch is set to OFF (that is, when the power is supplied to the solenoid), the spool is pushed to the left, the seat face A is open, and the seat face B is closed. As a result, the oil from the reducing valve enters the spring chamber, and the parking brake is released. Note The varistor (variable resistor) is used for the solenoid coil to protect the circuit.

DC 24 V

Current

0.92 A

Resistance

26.2 

85V2E52007

80ZV-2 EU 52-21 52 Function & Structure Brake Group Parking Brake Manual Release

Parking Brake Manual Release Solenoid valve for parking brake

Rear chassis

Valve assembly

Front

Installation position 80V2E52006

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. Note 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.

80ZV-2 EU 52-22 52 Function & Structure Brake Group Parking Brake Manual Release Method 2

Method 1

Parking brake spring chamber (actuator)

Lever Valve assembly

Link Pin ON

Link

OFF Rope or wire Prybar (used as nail puller-carpentry)

70ZVE52006

Solenoid valve for parking brake

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.

Knob

Turn it counterclockwise.

85V2E52009

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 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.

- 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 prybar to control the spring force of the spring chamber, then remove the pin when it releases.

80ZV-2 EU 52-23 52 Function & Structure Brake Group Parking Brake Spring Chamber

Parking Brake Spring Chamber 2

11

7 4 5

13

12

1

6 3

8

9

10

14

Oil

65ZV52018

1. Cylinder tube 2. Piston rod 3. Piston 4. Rod cover 5. Cap 6. Spring 7. Bushing 8. U-packing 9. O-ring 10. Wear ring 11. Dust seal 12. Filter 13. Set screw 14. Set screw

1,736 N (177 kgf) (390.2 lbf)

1,079 N (110 kgf) (242.5 lbf)

160 (6.299)

60 stroke (2.362)

(Installation length) 220 (8.661)

99 (3.898)

(Free length) 319 (12.559) Spring specification [mm(in)]

70ZVE52003

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.

80ZV-2 EU 52-24 52 Function & Structure Brake Group Brake Circuit Check Valve

Brake Circuit Check Valve

Poppet (T)

(P) (TA)

Pump supply through reducing valve

Seat face

(PARKING)

A

(ACCR)

(ACCF) (PA) (Z1)

(Z2)

(ACF)

(Z)

B (ACCF) Reducing valve

(PPI)

Note Valve is shown rotated 180º from normal.

Accumulator

Valve assembly

A

B

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 80V2E52008

80ZV-2 EU 52-25 52 Function & Structure Brake Group Pressure Sensor (for stop lamp and declutch)

Pressure Sensor (for stop lamp and declutch) Pressure sensor (for declutch) Refer to "Electrical Group: "Adjustable declutch preset switch" page 62-48".

Pressure sensor (for stop lamp) This pressure sensor that set valve is controlled by the MCU is installed between the brake valve and the front brake. When the brake pedal is depressed and the pressure increases to the set value of the MCU, the stop lamp turns on.

Left brake valve

Set value: S/N 9001~9100: 0.51 MPa (5.2 kgf/cm2) (74.0 psi) S/N 9101~: 0.26 MPa (2.6 kgf/cm2) (37.0 psi)

Pressure sensor for stop lamp and declutch

80V2E52007

80ZV-2 EU 52-26 52 Function & Structure Brake Group Pressure Sensor (for stop lamp and declutch)

Pressure sensor (stop lamp) (S/N 9001~9250)

2

A

1

3

View A 1: Power (+) 2: Output (+) 3: Common

85V2E52012

(V) 5

Output voltage

4 3 2 1

0

1 (10) (140)

2 (20) (285)

3 (30) (435)

4 (40) (570)

5 (50) (715)

MPa (kgf/cm2) (psi)

Pressure 65V2E52003

80ZV-2 EU 52-27 52 Function & Structure Brake Group Pressure Sensor (for stop lamp and declutch)

Pressure sensor (stop lamp) (S/N 9251~)

A

GND

Vout

Vdd

View A K80V2U52003

(V) 5

4

Output voltage

3

2

1

0

1.08* (11)(157)

4.31* (44)(625) Pressure

5.4 (55)(783)

MPa (kgf/cm2)(psi) *: Calibration point

K80V2U52004

80ZV-2 EU 52-28 52 Function & Structure Brake Group

MEMO

80ZV-2 EU 53-1 53 Check & Adjustment Brake Group

53 Check & Adjustment Brake Group Brake Circuit Oil Pressure ....................................... 53-2 Service Brake .......................................................... 53-6 Parking Brake.......................................................... 53-9

80ZV-2 EU 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)

ACF

(ACCF)

(ACCR)

(PARKING) (TA)

(T)

(P)

ACF port

Valve assembly

85V2E53001

WARNING

Injection Hazard Depress brake pedal 80~100 times to completely discharge the brake accumulators prior to removing these test plugs. 135ZV52035

Brake line main pressure is regulated by the unloader valve.

80ZV-2 EU 53-3 53 Check & Adjustment Brake Group Brake Circuit Oil Pressure

Unloader valve setting pressure measurement

Unloader valve setting pressure adjustment (S/N 9001~9039)

Measurement instrument

24 22 21

Fan motor port

Hydraulic pressure gauge 20 MPa (200 kgf/cm2) (3,000 psi)

Gauge port ACF port on valve assembly Rc (PT) 1/8

Standard measurement value Pump port 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)

Measurement procedure

Unloader valve 70ZV53001

(S/N 9040~)

21 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.

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. : ACF port plug: 11.3 N-m (1.15 kgf-m) (8.3 lb-ft)

Pump port Unloader valve

K115ZV53002

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).

1. Remove cap nut (24) and loosen lock nut (22).

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).

2. Adjust the pressure by adjusting screw (21). Turn the screw clockwise to raise the pressure.

Note If the pressure gauge is not available, refer to the pressure value displayed on the MODM. Refer to "Brake Main pressure 1" "Brake Main pressure 2" of MODM "Input/Output Monitor" page 62-85 and 9258 for information.

: Nut (22): 16.7 N-m (1.7 kgf-m) (12.3 lb-ft) : Nut (24): 78.5 N-m (8.0 kgf-m) (57.86 lb-ft)

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.

80ZV-2 EU 53-4 53 Check & Adjustment Brake Group Brake Circuit Oil Pressure

Brake valve oil pressure

Brake valve oil pressure measurement Measurement instrument

19

Force

Gauge port 15 0 m m

Remove air bleeder nipple fitting on the axle housing, and then install the pressure gauge to the bleeder position.

45

Pe

da

la ng

le

Hydraulic pressure gauge 10 MPa (105 kgf/cm2) (1,500 psi)

Size of air bleeder port: Rc (PT) 3/8 (In case of the bleeder valve: M10 X 1.0)

80V2E53001

Air bleeder nipple fitting [59 N-m (6.0 kgf-m) (43 lb-ft)]

85ZVE53001

Measurement procedure 1. Check to be sure the brake valve is fully released. 2. Press down the brake pedal to check that the oil pressure rises in proportion to the pedal angle. 3. Release the brake pedal to check that the oil pressure drops to zero in proportion to the pedal angle. In addition, visually check for brake oil leakage. Note If the pressure gauge is not available, refer to the pressure values displayed on the MODM. Refer to "Brake Pedal Output Oil Pressure" of MODM "Input/Output Monitor" page 62-85 and 92-58 for information.

80ZV-2 EU 53-5 53 Check & Adjustment Brake Group Brake Circuit Oil Pressure

Brake valve performance

Output oil pressure (brake port)

MPa (kgf/cm2) (psi) 4 (40) (580)

4.06 (41) (589)

2 (20) (290)

0

10

3.9 5

15

Pedal stroke

18.5 19 ( ) K80V2U53001

Refer to the curve shown in the above figure. When the measured value does not match the performance curve, check the following points. Possible cause Malfunctioning brake valve

Solution Repair or replacement

Brake line oil pressure low (Pump, reducing valve malfunction)

Check and repair

IMPORTANT After measuring oil pressure, be sure to tighten the air bleeder valve. Also be sure to bleed air.

80ZV-2 EU 53-6 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.

IMPORTANT

WARNING Separate the test course by using rope etc. and keep persons away from the test course. In addition, post persons in several positions near the course to warn others and avoid an accident while checking the service brake performance. Condition

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 14 m (15.5 yard) or shorter Possible causes of extremely long braking distance Possible cause Low brake line pressure

Solution

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.

Check and repair

Friction plate wear

Check and repair

Brake valve malfunction

Check and repair

Note The brake performance check condition and standard measurement value are based on the law and the regulation in Japan. When checking the service brake performance, follow the law and/or local regulation in your country, state, or province.

2. Set the parking brake switch to the "OFF" position. 3. Set the declutch switch to OFF, and then depress the brake pedal all the way to the floor. 4. Set the shift lever to 2nd reverse speed. 5. Gradually increase the engine speed. The machine should not move at the maximum engine speed. Possible cause of machine moving during brake performance check. Possible cause Low brake line pressure

Solution Check and repair

Friction plate wear

Check and repair

Brake valve malfunction

Check and repair

80ZV-2 EU 53-7 53 Check & Adjustment Brake Group Service Brake

Service brake friction plate wear measurement

A

Slide caliper

A

Brake backing plate Steel plate Friction plate

80ZVE53002

WARNING Oil inlet port Internal gear

Steel plate

Brake backing plate 70V2U53001

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.

80ZV-2 EU 53-8 53 Check & Adjustment Brake Group Service Brake

Measurement procedure

Cautions on installing brake discs

Turn the planetary gear so that the oil supply plug is positioned at 10º from the top. Check that the teeth of steel plate are as shown in the figure in page 53-7 (only one section of the plate circumference is as shown in the figure).

A B

Insert calipers to the inner steel plate to measure the dimension A. Note During measurement, be sure the service brake is applied. The wear limit for dimension A is 15.1 mm (0.59 in). Note that dimension A is 17.4 mm (0.69 in) when the plate is new and unused. Note To aid quick measurement on the front axle-raise the front of the machine so the front tires clear the ground by about 25 mm (1 in). This allows easy rotation of the wheel to align the gear teeth.

Wheel hub

Brake piston

80V2E53003

When only the friction plate or the steel plate is to be replaced, if the brake piston is installed as it is, the brake may drag and the brake disc may seize. Push back the brake piston by loosening the air bleeder nipple before replacing a friction plate or a steel plate. - After pushing back the piston, confirm dimension A from the piston end face to the wheel hub end face.

IMPORTANT Wheel bearings must be adjusted correctly to get an accurate measurement for dimension A. Dimension should be equal at top and bottom. A: 100.25~101.40 mm (3.95~3.99 in) Note Piston stroke B 1.15~3.40 mm (0.045~0.134 in) - After finishing the installation work, bleed air completely from the brake line.

80ZV-2 EU 53-9 53 Check & Adjustment Brake Group Parking Brake

Parking Brake Parking brake performance check

Method 2

Method 1

If no test course available as described "Method 1", carry out the following method.

IMPORTANT

WARNING Unexpected movement of the machine may cause an accident resulting in injury or death. Before starting brake performance check, be sure to observe the following items: - Check that there is enough clearance for brake performance check around the machine. - During performance check, prohibit any person to walking near the machine.

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

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. Test course 1/5 slope (Approx. 11º 19') 2. Bucket empty 3. Parking switch ON

WARNING

Standard measurement value 1. Set the parking brake switch to the "ON" position. No movement on 1/5 slope. Possible cause of machine moving during brake performance check

2. Disconnect the cable connector of parking brake solenoid valve. 3. Set the parking brake switch to the "OFF" position.

Possible cause

Solution

Clearance between brake drum and shoe too large

Clearance adjustment

Improperly adjusted spring chamber link

Check and adjustment

Broken spring chamber spring

Check and repair

Parking brake solenoid valve malfunction

Check and repair

Note The brake performance check condition and standard measurement value are based on the law and the regulation in Japan. When checking the service brake performance, follow the law and/or local regulation in your country, state, or province.

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.

80ZV-2 EU 53-10 53 Check & Adjustment Brake Group Parking Brake

Possible cause

Solution

Clearance between brake drum and shoe too large

Clearance adjustment

Improperly adjusted spring chamber link

Check and adjustment

Broken spring chamber spring

Check and repair

Parking brake solenoid valve malfunction

Check and repair

Parking brake clearance adjustment Drum rotational direction for traveling in reverse

B

B

Brake lining Brake shoe

A D

D A

Adjusting screw rotational direction for brake shoe expansion

D-D

Adjusting screw

A-A 80ZV53002

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.

80ZV-2 EU 53-11 53 Check & Adjustment Brake Group Parking Brake

Adjustment procedure

Brake lining abrasion check

Shoe

Rivet

Abrasion limit

B

Inspection hole 2nd propeller shaft

Lining

Position of adjusting screw

Approx. 8º

Wear limit B : 0.8 mm (0.03 in) 80ZV53004

Rivet

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.

Brake shoe

A

For replacement of shoe assembly refer to Section 54. 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".

80ZV-2 EU 53-12 53 Check & Adjustment Brake Group

MEMO

80ZV-2 EU 62-1 62 Function & Structure Electrical Group

62 Function & Structure Electrical Group 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 Engine Start Circuit.................................................. 62-14 Power Generating/Charging Circuit......................... 62-22 ECM (Engine Controller) ......................................... 62-23 Transmission Control Circuit and Monitor Circuit .... 62-37 Instrument Panel and Switch................................... 62-57 MODM ..................................................................... 62-65 Electrical Detent Circuit ........................................... 62-104 Diode ....................................................................... 62-111

80ZV-2 EU 62-2 62 Function & Structure Electrical Group How to Use Electrical Wiring Diagram

How to Use Electrical Wiring Diagram Example 10

6

10 9

8

7

5

1

6

5

20 19 18 17 16

4

3

2

1

15 14 13 12 11 21

40 39

32 31

40

36

35

31

WIDTH LAMP RELAY

RIDE CONTROL NEUTRAL RELAY RELAY

BACK LAMP RELAY

HORN RELAY

MCU FAULT RELAY

B

RB B611

LgSb YV H133 E214

RL SbP H610 E220

RL LB H128 E219

GW GL H127 B501

R R D114 D114

Br Lg D112 D103

G L D102 D002

R Lg D111 D103

G G D107 D107

RB

A520 C201 H129

1

2

1

2

1

2

1

2

LgW L A405 D001 1

2

LgW E218

1

2

(BLACK)

(BLACK)

(BLACK)

(BLACK)

(BLACK)

(BLUE)

F5

F0

F6

F7

F8

F9

(1) (2)

H1

10

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

5

E520 E108 F004 LgL W LgSb 36

E804 WY

E601 BrR

35

31

(3)

The address method is used for electrical wiring diagrams. For this method, a symbol is attached to each connector and connector terminal in order to easily locate the other terminal where the other end of the cable is connected. Example 1 Symbol under (or above) connector, such as F6: Shows the address of the connector. Example 2 Symbol at the multi-terminal connector, such as 1 and 10: Shows the terminal number and the numbering direction.

95ZV62001

Example 3 Checking the other connector terminal where F704 RL (item (3)) is connected: 1. F704 Shows that the terminal is connected to the 4th terminal of the F7 connector. Check the description in the 4th terminal of the F7 connector (F704), it shows that the F704 terminal is connected to H128. This means that the 4th terminal of the F7 connector is connected to the 28th terminal of the H1 connector. 2. RL Shows the color of the wire "RL" represents that the insulation color is red, and "L" represents a blue stripe is on the red insulation.

80ZV-2 EU 62-3 62 Function & Structure Electrical Group Utilisation des schémas des câblages électriques (FRANÇAIS)

Utilisation des schémas des câblages électriques (FRANÇAIS) Exemple 10

6

10 9

8

7

5

1

6

5

20 19 18 17 16

4

3

2

1

15 14 13 12 11 21

40 39

32 31

40

36

35

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

RB

A520 C201 H129

1

2

1

2

1

2

1

2

B

LgW E218

LgW L A405 D001 1

2

Relais de défaillance du contrôleur

1

2

(Noir)

(Noir)

(Noir)

(Noir)

(Noir)

(Blue)

F5

F0

F6

F7

F8

F9

(1) (2)

H1

10

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

5

E520 E108 F004 LgL W LgSb 36

35

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.

80ZV-2 EU 62-4 62 Function & Structure Electrical Group Verwendung des elektrischen Schaltplans (DEUTSCH)

Verwendung des elektrischen Schaltplans (DEUTSCH) Beispiel 10

6

10 9

8

7

5

1

6

5

20 19 18 17 16

4

3

2

1

15 14 13 12 11 21

40 39

32 31

40

36

35

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

RB

A520 C201 H129

1

2

1

2

1

2

1

2

Reglerfehlerrelais

B

LgW L A405 D001 1

2

LgW E218

1

2

(Schwarz)

(Schwarz)

(Schwarz)

(Schwarz)

(Schwarz)

(Blau)

F5

F0

F6

F7

F8

F9

(1) (2)

H1

10

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

5

E520 E108 F004 LgL W LgSb 36

35

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.

80ZV-2 EU 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

6

10 9

8

7

5

1

6

5

20 19 18 17 16

4

3

2

1

15 14 13 12 11 21

40 39

32 31

40

36

35

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

RB

A520 C201 H129

1

2

1

2

1

2

1

2

B

LgW E218

LgW L A405 D001 1

2

Relè del controller d’ errore

1

2

(Nero)

(Nero)

(Nero)

(Nero)

(Nero)

(Blu)

F5

F0

F6

F7

F8

F9

(1) (2)

H1

10

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

5

E520 E108 F004 LgL W LgSb 36

35

E804 WY

E601 BrR 31

(3)

Per gli schemi elettrici si utilizza il metodo degli indirizzi, in base al quale a ciascun connettore e a ogni suo contatto viene associato un simbolo che permette di identificare agevolmente il contatto cui 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.

80ZV-2 EU 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

6

10 9

8

7

5

1

6

5

20 19 18 17 16

4

3

2

1

15 14 13 12 11 21

40 39

32 31

40

36

35

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

RB

A520 C201 H129

1

2

1

2

1

2

1

2

B

LgW E218

LgW L A405 D001 1

2

Relé de fallos del controlador

1

2

(Negro)

(Negro)

(Negro)

(Negro)

(Negro)

(Azul)

F5

F0

F6

F7

F8

F9

(1) (2)

H1

10

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

5

E520 E108 F004 LgL W LgSb 36

35

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.

80ZV-2 EU 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

6

10 9

8

7

5

1

6

5

20 19 18 17 16

4

3

2

1

15 14 13 12 11 21

40 39

32 31

40

36

35

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

RB

A520 C201 H129

1

2

1

2

1

2

1

2

B

LgW E218

LgW L A405 D001 1

2

Relé de controlo de falha

1

2

(Preto)

(Preto)

(Preto)

(Preto)

(Preto)

(Azul)

F5

F0

F6

F7

F8

F9

(1) (2)

H1

10

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

5

E520 E108 F004 LgL W LgSb 36

35

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.

80ZV-2 EU 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

YL

YW

YR

YB

YO

GL

GW

GR

GB

GO

SbW

SbR

Sb

B O Lg (black) (orange) (light green)

Y (yellow)

Y

YG

G (green)

GY

G

Sb (sky blue)

SbY

SbG

Br (brown)

BrY

BrG

Br

BrL

BrW

BrR

BrB

L (blue)

LY

LG

LBr

L

LW

LR

W (white)

WY

WG

WBr

WL

W

R (red)

RY

RG

RBr

RL

B (black)

BY

BG

O (orange)

OY

OG

OSb

Lg (light green)

LgY

LgG

LgSb

P (pink) Gy (grey)

GyY

Sb

P (pink)

SbO

SbLg

SbP

LB

LO

LLg

LP

WR

WB

WO

RW

R

RB

RO

RLg

BL

BW

BR

B

BO

BLg

OL

OW

OR

OB

O

LgL

LgW

LgR

LgB

PG

PL

PW

GyG

GyL

GyW

GyR

VW

VR

LgBr

V (violet)

Insulation color Stripe color

70ZV62001

V (violet)

YGy

YV

WP

WV RGy

BP

BV

Lg

PB GyB

Gy (grey)

P GyO

Gy V

80ZV-2 EU 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

M

80ZV-2 EU 62-10 62 Function & Structure Electrical Group Sensor Mount

Sensor Mount

1 5

6

2

3

4

5

6 1

1. Machine speed sensor 2. T/C oil temperature sensor 3. Air cleaner sensor 4. E/G coolant temperature sensor (S/N 9001~9100) 5. Hydraulic oil level sensor 6. Hydraulic oil temperature sensor

80V2E62001

80ZV-2 EU 62-11 62 Function & Structure Electrical Group Fuse

Fuse The following fuses are provided to protect electrical circuits. Fusible link 70 A x 2, 30 A x 1 Fuse box 15 fuses x 2 (for chassis and cab) 1 fuse x 1 (for engine controller ECM) (For installation positions, refer to "Electrical Equipment Layout".)

CAUTION Possible burn hazard. Before replacing a fuse, be sure to turn off the starter switch.

IMPORTANT Replace a fuse with the same capacity. If a fuse blows immediately after replacement, the electric system is defective. Locate the defective part, and then repair it.

Fuse box For chassis

Fuse No.

Fuse capacity (A)

1

20A

LIGHTING HEAD LIGHT

2

15A

R. WORK LIGHT

SPARE

3

10A

BOOM KICKOUT BUCKET LEVELER

30A

4

15A

TURN SIGNAL

SPARE

5

30A

PARKING BRAKE MCU (MACHINE)

20A

6

15A

F. WORK LIGHT

SPARE

7

10A

AIR SUS. SEAT (OPT)

8

15A

SPARE

9

15A

SPARE

10

15A

4WAY FLASHER HORN ROOM LAMP RADIO

11

10A

SPARE

12

15A

PREHEAT

13

5A

BUZZER MONITOR LAMP

14

5A

NEUTRAL RELAY

15

5A

BATTERY RELAY ECM (ENGINE)

Protective circuit

15A SPARE 5A

For cab

Fuse No.

Fuse box for cab

Fuse box for chassis

80V2E62004

Fuse capacity (A)

Protective circuit

16

5A

SPARE

17

5A

SPARE

18

5A

R. WIPER / WASHER

19

10A

F. WIPER / WASHER

20

10A

MODM

21

15A

SPARE

22

3A

DC-DC CONVERTER

23

10A

SPARE

24

10A

SPARE

25

20A

SPARE

26

5A

AIRCON

27

5A

AIRCON

28

10A

AIRCON

29

20A

AIRCON

30

20A

SPARE

SPARE 20A SPARE 15A SPARE 10A SPARE 5A

80ZV-2 EU 62-12 62 Function & Structure Electrical Group Fuse For engine controller (ECM)

Fuse No.

Fuse capacity (A)

36

30A

Protective circuit ECM (ENGINE)

80ZV-2 EU 62-13 62 Function & Structure Electrical Group Fuse

Fusible link

Problems caused by blown fusible link Fuse damaged

Fusible link Cover

Box for fusible link

Fusible link

(900) [W5]

(086) W

12V

(015) (065) WR1.25 F15 WR

R1 BR B AC R2 C

F13

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".

IMPORTANT

(013) (Lg) (1)

BATTERY RELAY

When replacing fusible link, you may want to disconnect the battery negative terminal to avoid arcing out a circuit and damaging wire. If so, after you reconnect battery, do following : 1. Turn on key 2. Press throttle pedal fully down and up 3 times in 5~6 seconds. 3. Turn off key switch.

STARTER B C

[R5] x 6 (910 ~ 915)

MAGNETIC S/W (702) [R5] (701) [BW5]

RL1.25 (703)

WG (704)

VOLTAGE RELAY

NR

F13

(013) (Lg)

(705) (WG)

(707) WL

CHARGE LAMP L

20

70A

R E

ALTERNATOR

20

M

100

M SECONDARY STEERING PREHEAT LAMP PUMP (720) (BG)

15

(706) WL1.25

B

(2)

AIR HEATER

15

(012) BW HEATER

RELAY B

- The same conditions as "During engine operation". - Engine can be started.

70A (1)

- Horn [and opt. flasher] will operate. - All the others will not operate and the machine can not be operated. - Engine will not stop automatically but can be stopped with starter switch OFF.

WV (700)

70A

(014) G1.25

MCU

5A

(063) WR1.25

5A

(064) G1.25

30A

(708) WP

5A

F14

F12 (012) BW

15A

(062) BW

BATTERY

ECM (39)

During engine stop - All the electrical circuit will not function. - Engine can not be started.

70ZV62010

100

30A (060) (901) W [W5]

During engine operation - Engine will stop automatically. - All the power for all electrical circuit will be OFF.

Fuse element

12V

Problem (symptom)

ACC’

E

TO PILOT LAMP

Fusible link location

80V2U62080

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.

80ZV-2 EU 62-14 62 Function & Structure Electrical Group Engine Start Circuit

Engine Start Circuit Engine start circuit diagram Starter switch

B BR ACC R1 R2 C PREHEAT OFF ON START

MCU

F N R

1

D04

12V

B18

30A

B12

Fusible link

12V

Battery

ECM

B11

Diode unit

F15

5A

D11

E04 E12 E03 E11

F14

E24

Shift lever F/R position

E05 E06 E17

5A

23A D12 D05 (1)

D10

70A

D03

Battery relay

Starter motor B C

+24 V

Magnetic switch 3

4

2

1

Voltage relay

Neutral relay F13

* When shift lever is in F/R position: OFF When shift lever is in N position: ON

Charge lamp

+24 V (F5) (2) 70A

B

MCU E24 L

R E

Alternator

80V2U62081

Neutral starter

Shift lever neutral (N) position

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.

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.

80ZV-2 EU 62-15 62 Function & Structure Electrical Group Engine Start Circuit When the starter switch is turned to the START position, the start command current flows from the starter switch terminal C to the neutral relay, the magnetic switch and the voltage relay. As a result, the magnetic switch turns ON, the starting current flows in the starter motor, and the engine starts.

Shift lever forward/reverse (F/R) position While the shift lever is located in the F or R position, the power is not supplied to the neutral relay coil, and the main contact is OFF. As a result, the starting current from the starter switch terminal C does not flow in the magnetic switch, and the engine does not start.

80ZV-2 EU 62-16 62 Function & Structure Electrical Group Engine Start Circuit

Starter switch

Off Enables insertion and removal of the starter key. All the electrical circuits (except the horn and hazard flasher [OPT.]) will be turned off. On Supplies power to the charge, lamp, and monitor circuits. Start Starts the engine.

Starter switch Control box

Preheat Preheats the intake air to ensure smooth starting in cold weather.

Starter switch location 85V2E62002

Preheat

35º

OFF

30º

ON 35º Start

B

AC

C

R1

BR R2

W3 W5

Preheat

B

AC

WB x 2

Off

R2

C

G

On

R1

To heater relay

WR x 2

BR AC

To battery relay

BBG G

R1 BR

B

From battery

BW

Connection table

R2

C

BW WR WR BG WB WB

1.25

G

W5 W3

To neutral relay

Start

85V2E62013

80ZV-2 EU 62-17 62 Function & Structure Electrical Group Engine Start Circuit

ECM safety features The ECM is equipped with safety functions that are designed to limit engine revolution (min-1) in certain situations. The “zero point” of the pedal is recalibrated every time the key switch is turned to the “ON” position, so that the pedal operation positions are consistent. (Pedal angle relative to engine revolution (min-1) point.) This permits the ECM to see the signal and set the engine revolution (min-1) appropriately. This function is set to turn “on” 1 second after the key is set to the “ON” position, then adjustment is completed in 3 seconds and this function is turned “off”. Note There is no indication on the instrument panel or MODM that this function turns either “on” or “off” because there is no engine abnormality to call out or indicate. Effect on the machine (a) If the throttle pedal is applied while turning the key switch to the start position, the engine maximum speed will only increase to 80% of high idle. (b) If the throttle pedal is applied while the engine is starting, this function will turn “ON” 1 second after releasing the pedal and engine speed will only increase 80% of high idle.

Battery relay

Terminals for coil energizing current (4 mm)

Moving contact Main contacts

BR

Coil for energizing

Terminals for main current (8 mm) 95ZV62017

When the starter switch is placed to the ON position or the start position, the battery relay is turned on. When the starter switch is set to the OFF position, the alternator stops generating power, and the battery relay is automatically turned off so that the electrical circuits will not function. If the battery relay was not used, a large amount of current would be directly sent through the starter switch when it is turned on. However, use of the battery relay reduces the amount of current because this relay needs only a small amount of current to energize it.

Battery relay operation

These safety features protect engine parts from high speed damage due to low oil pressure while the engine is cold and oil is beginning to circulate through the engine.

Starter switch From charge circuit

AC

B

Battery relay (B)

To main circuit

(E)

Battery

To avoid these troubles, the following steps are important; 1. Wait one second before turning the key from the “ON” to the “START” position. 2. Do not step on the pedal while the engine is starting, nor just after the engine starts.

Suppression diode

85V2E62014

Battery relay Rated voltage

DC 24 V

Minimum operating voltage

20 V or less

Release voltage

9 V or less

When current flows from the starter switch terminal AC, the coil will be energized, and the moving contact will lower to close the main contact. As a result, current will flow from the battery to the main circuit.

80ZV-2 EU 62-18 62 Function & Structure Electrical Group Engine Start Circuit

Alternator R terminal wire 12V

Diode unit 12V

30A

Battery (1)

ECM F15

R1 BR B AC R2 C

WR

(2) (3)

5A

WP

WV

(2)(3): Diode unit

WR WP

5A

5A

F13

F14

F12

15A

Suppression diode Charge circuit

B

WV:To battery relay WR:To starter switch terminal AC (VIA F15) and to ECM WP:To alternator

From alternator R terminal

Neutral relay

Diode storage section 70ZV62017

70V2U62005

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 AC stops flowing and the coil is demagnetized. Then the charging circuit from the alternator is shut down. However the alternator is still generating power and the load dump surge may be generated. This may damage the related circuits and equipment. In order to prevent this trouble, this circuit (1) is provided to hold the battery relay in the "ON" position.

The diode unit is incorporated in the milky white connector near the battery relay. It is provided for the following purpose. 1. Diode (2) This diode is provided to prevent the roundabout current from the alternator to the ECM. If this diode is not provided (or is defective), the ECM does not turn OFF and the engine cannot be stopped. 2. Diode (3) This diode is provided to prevent the roundabout current from the starter switch AC to the alternator R terminal.

80ZV-2 EU 62-19 62 Function & Structure Electrical Group Engine Start Circuit

3

SbP

4

RL

2

L

1

G

Neutral relay

Internal connection dia. Body black 85V2E62016

Position of shift lever

Between 1 and 2

Between 3 and 4

Starting

F or R

Not energized

OFF

Impossible

N

Energized

ON

Possible

The structures of the neutral relay, engine idle selection relay, engine torque selection relay, engine oil pressure switch relay, horn relay, width lamp relay and the head lamp relay are identical to each other. Note The illustrations show the de-energized condition. When the shift lever is in the N position while the starter switch is kept at the start position, the neutral relay is magnetized and electric current flows from the battery to the neutral relay / magnetic switch / voltage relay through the starter switch terminal C.

Rating

DC 24 V

Operating voltage

16 V or less

Reset voltage

2.4 V or more

Coil resistance

320 

80ZV-2 EU 62-20 62 Function & Structure Electrical Group Engine Start Circuit

Magnetic switch

Rating 24V x 200A

M

C

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.

80ZV-2 EU 62-21 62 Function & Structure Electrical Group Engine Start Circuit

Voltage relay

Note The illustrations show the de-energized condition.

(S/N 9001~9038)

Once the engine is started, the alternator starts generating electric power. 1

2

3

When electric current is supplied from the alternator R terminal to the voltage relay, the voltage relay is magnetized and is turned OFF.

2

Consequently the magnetic switch turns OFF and no electric current flows to the starter motor terminal C, disengaging the starter motor.

3 1

4

4 70ZV62020

Voltage relay Contact point closed

6V

Contact point open

8V

(S/N 9039~) Blue

K70V2J62005

Voltage relay Contact point closed

6V

Contact point open

8V

80ZV-2 EU 62-22 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

<Load>

For rotor coil initial excitation

Battery

Load circuit operation

Starter switch

Voltage adjustment

Battery charge

For battery relay 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.

80ZV-2 EU 62-23 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

E

J3 (086) 3 [W ]

(036) 3 [G ]

F36 30A

4

1

3

2

B E

J2 (015) WR

F15

39 43

21

44

(730) (BrR)

STOP

(013) (Lg)

F13

(731) WARNING (BrB)

26 32

45

THROTTLE PEDAL THROTTLE OPENING SENSOR

41 BrW(733) YV (734) BLg (735)

IDLE S/W OFF IDLE

9 23

49

42 GyY (736)

IDLE

GyW(737)

(161)W

(E15)

22 (751) GyR

E/G OIL PRESS. EP

(752) GyR

1

11 S2H S2L

DIAGNOSTIC S/W BrG(738)

RESISTOR B

INC/DEC S/W INC

PG (739)

(m)

PW (740)

(060) W

24 25

DEC

46 47 37

BL (741) RLg(206) AI TC

CAN

S2S 2

34

10 20

SbY(209)

Sb (205)

S2H S2L S2S (YL) (747) (Y0) (748)

B C D E F G

13

A

31

DATA LINK E CONNECTOR

19

3

ECM

E/G ECM connection diagram

85V2U62006

80ZV-2 EU 62-24 62 Function & Structure Electrical Group ECM (Engine Controller)

Monitor lamp test

ON Key switch OFF

Approx. 2 sec

ON Engine warning lamp

Yellow

OFF

Lights when abnormality occurs.

ON Engine stop lamp OFF

Red

70V2U62010

STOP

(S/N 9001~9100) Engine warning lamp Engine stop lamp K85V2E62001

When the starter switch is set to ON, two engine monitor lamps (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.

80ZV-2 EU 62-25 62 Function & Structure Electrical Group ECM (Engine Controller)

Failure diagnosis

The diagnosis for the engine failure should be done by the following steps.

Engine diagnostic switch (option)

Step 1. Starter switch key "OFF" Step 2. Diagnostic switch "ON" Step 3. Starter switch key "ON"

Diag. switch Inc./Dec. switch (Part Number : 35010-60130) (Part Number : 35010-60180)

The engine warning lamp flashes with these conditions. To diagnose the engine failure, convert the flashing pattern to the 3-digit fault code. The following shows how to convert the flashing pattern to the 3-digit fault code. G R L W

Note These code are quickly retrievable with Cummins Quickcheck hand held analyzers or with the MODM on the machine.

R G Y

Cable assembly (Part Number : 33191-49150) 70ZV62069

This switch is used to check the engine failure when any one of the engine warning lamps is turned on.

Refer to the "QUANTUM FAULT CODE INFORMATION" for details. The following steps show how to finish the diagnosis for the engine failure. Step 1. Diagnostic switch "OFF" Step 2. Starter switch key "OFF"

PREHEAT

OFF

ON

START

K80V2J62009

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

Fault code (continued)

70V2U62012

80ZV-2 EU 62-26 62 Function & Structure Electrical Group ECM (Engine Controller)

Failure diagnostic chart ON Key switch OFF ON Diagnostic switch OFF

[When there is no fault code] ON Engine warning lamp Yellow

OFF ON

Engine stop lamp

STOP

Red

OFF

[When there is fault code] 1 sec

1 sec

ON Engine warning lamp Yellow

OFF ON

Engine stop lamp

STOP

Red

OFF

100's digit

1 sec

10's digit

1 sec

1's digit

Fault code

[Example: Failure code 131] Accelerator pedal position sensor circuit-shorted high.

1 sec

1 sec

ON Engine warning lamp Yellow

OFF ON

Engine stop lamp

STOP

Red

OFF

1

3

1

Following page explains more. 70V2U62013

80ZV-2 EU 62-27 62 Function & Structure Electrical Group ECM (Engine Controller)

Increment decrement switch (option)

- Adjusting the engine idle revolution

Diag. switch Inc./Dec. switch (Part Number : 35010-60130) (Part Number : 35010-60180)

G R L W

R G Y

Cable assembly (Part Number : 33191-49150) 70ZV62069

The switch is used for ; 1. Checking the history of the engine failures 2. Adjusting the engine idle revolution - Checking the history of the engine failures When the diagnostic switch is ON (Starter switch key "ON"), the lights will continue to flash the same fault code until the system is advanced to the next active fault code. To go to the second fault code, move the increment / decrement switch to "+", then release it. You can also go back to the previous fault code by moving the switch to "-", then releasing it. To check the third or fourth fault code, move the switch to "+", then release it when all active fault codes have been viewed. Moving the switch to "-" will go back to the first fault code. Refer to the section of the diagnostic switch for converting the flashing pattern to 3-digit fault code. Refer to the "Quantum fault code information" for details.

When the diagnostic switch is OFF (Starter switch key "ON"), the engine idle revolution can be adjusted in 25 rpm by using the increment / decrement switch (650 rpm  800 rpm  1,000 rpm). Move the increment / decrement switch to "+", then release it, to increase the engine idle revolution to 1,000 min-1 (rpm). To decrease the engine idle revolution, move this switch to "-", then release it. As a result the engine idle revolution is adjusted as 650 min-1 (rpm). The engine idle revolution is not changed to over 1,000 min-1 (rpm) or to below 650 min-1 (rpm) even though this switch is moved to "+" or "-".

80ZV-2 EU 62-28 62 Function & Structure Electrical Group ECM (Engine Controller)

EG111 Red

Engine Control Module (ECM) - critical internal failure.

EG113 Yellow

Engine Timing Actuator Circuit - shorted high.

EG114 Yellow

Engine Timing Actuator Circuit - shorted low.

EG115 Red

Engine Speed / Camshaft Position Sensor Circuit - lost both of two signals from the magnetic pickup sensor.

EG121 Yellow

Engine Speed / Position Sensor Circuit - lost one of two signals from the magnetic pickup sensor.

EG122 Yellow

Intake Manifold Pressure Sensor #1 Circuit - shorted high.

EG123 Yellow

Intake Manifold Pressure Sensor #1 Circuit - shorted low.

EG124 Yellow

Intake Manifold Pressure - above normal operation.

EG131 Red

Accelerator Pedal Position Sensor Circuit - shorted high.

EG132 Red

Accelerator Pedal Position Sensor Circuit - shorted low.

EG133 Red

Remote Accelerator Pedal Position Sensor Circuit - shorted high.

EG134 Red

Remote Accelerator Pedal Position Sensor Circuit - shorted low.

EG135 Yellow

Engine Oil Pressure Sensor Circuit - shorted high.

EG141 Yellow

Engine Oil Pressure Sensor Circuit - shorted low.

EG143 Yellow

Engine Oil Pressure Low - warning.

EG144 Yellow

Engine Coolant Temperature Sensor Circuit - voltage above normal or shorted high.

EG145 Yellow

Engine Coolant Temperature Sensor Circuit - voltage below normal or shorted low.

EG146 Yellow

Engine Coolant Temperature High - warning.

EG151 Red

Engine Coolant Temperature High - critical.

EG153 Yellow

Intake Manifold Air Temperature Sensor Circuit - voltage above normal or shorted high.

EG154 Yellow

Intake Manifold Air Temperature Sensor Circuit - voltage below normal or shorted low.

EG155 Red

Intake Manifold Air Temperature Sensor High - critical.

EG166 Yellow

Rack Position Sensor #1 Circuit - shorted high.

EG172 Red

Rack Actuator Position #1 Circuit - grounded circuit.

QST30 (135ZV-2)

QSK19 (115ZV-2)

QSX15 (95ZV-2)

QSM11 (92ZV-2)

QSM11 (90ZV-2)

QSC8.3 (85ZV-2)

DESCRIPTION

QSC8.3 (80ZV-2)

FAULT CODE/ LAMP

QSB6.7 (70ZV-2) (70TMV-2)

These codes show the fault codes for the engine failure displayed on the MODM error log monitor, or checked by the diagnostic switch (option).

Please note that not all are used in the 80ZV-2 machine application. Refer to Cummins Engine troubleshooting fault codes list for more information.

QSB4.5 (60ZV-2)

Quantum fault code information

EG173 Yellow

Rack Actuator - mechanically stuck open.

EG184 Yellow

Engine Control Module Identification Input State Error.

EG185 Yellow

Engine Control Module Network Communication Error.

EG187 Yellow

Sensor Supply Voltage #2 Circuit - shorted low.

EG212 Yellow

Engine Oil Temperature Sensor Circuit - shorted high.

EG213 Yellow

Engine Oil Temperature Sensor Circuit - shorted low.

EG214 Red

Engine Oil Temperature High - Critical.

EG221 Yellow

Ambient Air Pressure Sensor Circuit - shorted high.

EG222 Yellow

Ambient Air Pressure Sensor Circuit - shorted low.

EG227 Yellow

Sensor Supply Voltage #2 Circuit - shorted high.

EG231 Yellow

Engine Coolant Pressure Sensor Circuit - shorted high.

EG232 Yellow

Engine Coolant Pressure Sensor Circuit - shorted low.

EG233 Yellow

Engine Coolant Pressure Low - warning.

EG234 Red

Engine Speed High - critical.

EG238 Yellow

Sensor Supply Voltage #3 Circuit - shorted low.

EG254 Red

Fuel Shutoff Valve Circuit - shorted low.

EG255 Yellow

Fuel Shutoff Valve Circuit - shorted high.

EG259 Red

Fuel Shutoff Valve - stuck open.

EG261 Yellow

Fuel Temperature High - warning.

EG263 Yellow

Fuel Temperature Sensor Circuit - shorted high.

EG265 Yellow

Fuel Temperature Sensor Circuit - shorted low.

EG266 Red

Engine Fuel Temperature - data valid but above normal operational range - most severe level.

EG271 Yellow

Fuel Control Actuator Circuit - shorted low.

EG272 Yellow

Fuel Control Actuator Circuit - shorted high.

EG281 Yellow

Injection Pump Mechanical System - signal not in range from ECM.

EG284 Yellow

Engine Speed / Position Sensor #1 (Crankshaft) Supply Voltage Circuit - shorted low.

EG285 Yellow

SAE J1939 Data Link Multiplexing PGN Timeout Error.

QST30 (135ZV-2)

QSK19 (115ZV-2)

QSX15 (95ZV-2)

QSM11 (92ZV-2)

QSM11 (90ZV-2)

QSC8.3 (85ZV-2)

QSC8.3 (80ZV-2)

DESCRIPTION

QSB6.7 (70ZV-2) (70TMV-2)

FAULT CODE/ LAMP

QSB4.5 (60ZV-2)

80ZV-2 EU 62-29 62 Function & Structure Electrical Group ECM (Engine Controller)

EG286 Yellow

SAE J1939 Data Link Multiplexing Configuration Error.

EG287 Red

SAE J1939 Multiplexing Accelerator Pedal Sensor System Error.

EG295 Yellow

Ambient Air Pressure Sensor Circuit - data incorrect.

EG299 Yellow

Engine stopped not using Starter Switch.

EG311 Yellow

Injector Solenoid Valve Cylinder #1 Circuit - grounded circuit.

EG312 Yellow

Injector Solenoid Valve Cylinder #5 Circuit - grounded circuit.

EG313 Yellow

Injector Solenoid Valve Cylinder #3 Circuit - grounded circuit.

EG314 Yellow

Injector Solenoid Valve Cylinder #6 Circuit - grounded circuit.

EG315 Yellow

Injector Solenoid Valve Cylinder #2 Circuit - grounded circuit.

EG319 Yellow

Real Time Clock - power Interrupt.

EG321 Yellow

Injector Solenoid Valve Cylinder #4 Circuit - grounded circuit.

EG322 Yellow

Injector Solenoid Valve Cylinder #1 Circuit - open circuit.

EG323 Yellow

Injector Solenoid Valve Cylinder #5 Circuit - open circuit.

EG324 Yellow

Injector Solenoid Valve Cylinder #3 Circuit - open circuit.

EG325 Yellow

Injector Solenoid Valve Cylinder #6 Circuit - open circuit.

EG331 Yellow

Injector Solenoid Valve Cylinder #2 Circuit - open circuit.

EG332 Yellow

Injector Solenoid Valve Cylinder #4 Circuit - open circuit.

EG334 Yellow

Coolant Temperature Sensor Circuit - data erratic, intermittent, or incorrect.

EG341 Yellow

Engine Control Module - data lost.

EG342 Red

Engine Control Module - out of calibration.

EG343 Yellow

Engine Control Module - warning internal hardware failure.

EG346 Yellow

Engine Control Module - warning software error.

EG351 Yellow

Injector Power Supply.

EG352 Yellow

Sensor Supply Voltage #1 Circuit - shorted low.

EG378 Yellow

Fueling Actuator #1 Circuit - open circuit.

EG379 Yellow

Fueling Actuator #1 Circuit - grounded circuit.

EG386 Yellow

Sensor Supply Voltage #1 Circuit - shorted high.

QST30 (135ZV-2)

QSK19 (115ZV-2)

QSX15 (95ZV-2)

QSM11 (92ZV-2)

QSM11 (90ZV-2)

QSC8.3 (85ZV-2)

QSC8.3 (80ZV-2)

DESCRIPTION

QSB6.7 (70ZV-2) (70TMV-2)

FAULT CODE/ LAMP

QSB4.5 (60ZV-2)

80ZV-2 EU 62-30 62 Function & Structure Electrical Group ECM (Engine Controller)

EG387 Yellow

Accelerator Pedal Position Sensor Supply Voltage Circuit - shorted high.

EG394 Yellow

Timing Actuator #1 Circuit - open circuit.

EG395 Yellow

Timing Actuator #1 Circuit - grounded circuit.

EG396 Yellow

Fueling Actuator #2 Circuit - open circuit.

EG397 Yellow

Fueling Actuator #2 Circuit - grounded circuit.

EG398 Yellow

Timing Actuator #2 Circuit - open circuit.

EG399 Yellow

Timing Actuator #2 Circuit - grounded circuit.

EG415 Red

Engine Oil Pressure Low - critical.

EG418 Yellow

Water in Fuel Indicator High - maintenance.

EG419 Yellow

Intake Manifold Boost Pressure Imbalance.

EG423 Yellow

Fuel Timing Pressure or Timing Actuator Stuck.

EG428 Yellow

Water in Fuel Sensor Circuit - shorted high.

EG429 Yellow

Water in Fuel Sensor Circuit - shorted low.

EG431 Yellow

Accelerator Pedal Idle Validation Circuit - data incorrect.

EG432 Red

Accelerator Pedal Idle Validation Circuit - out of calibration.

EG433 Yellow

Intake Manifold Pressure Sensor Circuit - data incorrect.

EG434 Yellow

Voltage to ECM less than 6 V

EG435 Yellow

Engine Oil Pressure Switch Circuit - data incorrect.

EG441 Yellow

Battery #1 Voltage Low - warning.

EG442 Yellow

Battery #1 Voltage High - warning.

EG443 Yellow

Accelerator Pedal Position Sensor Supply Voltage Circuit - shorted low.

EG449 Yellow

Fuel Pump Delivery Pressure High - warning.

EG451 Yellow

Injector Metering Rail #1 Pressure Sensor Circuit - shorted high.

EG452 Yellow

Injector Metering Rail #1 Pressure Sensor Circuit - shorted low.

EG465 Yellow

Turbocharger #1 Wastegate Control Circuit - shorted high.

EG466 Yellow

Turbocharger #1 Wastegate Control Circuit - shorted low.

EG482 Yellow

Fuel Pressure Low - warning.

QST30 (135ZV-2)

QSK19 (115ZV-2)

QSX15 (95ZV-2)

QSM11 (92ZV-2)

QSM11 (90ZV-2)

QSC8.3 (85ZV-2)

QSC8.3 (80ZV-2)

DESCRIPTION

QSB6.7 (70ZV-2) (70TMV-2)

FAULT CODE/ LAMP

QSB4.5 (60ZV-2)

80ZV-2 EU 62-31 62 Function & Structure Electrical Group ECM (Engine Controller)

EG483 Yellow

Injector Metering Rail #2 Pressure Sensor Circuit - shorted high.

EG484 Yellow

Injector Metering Rail #2 Pressure Sensor Circuit - shorted low.

EG485 Yellow

Injector Metering Rail #2 Pressure High - warning.

EG486 Yellow

Injector Metering Rail #2 Pressure Low - warning.

EG488 Yellow

Intake Manifold Temperature High - warning.

EG491 Yellow

Turbocharger #2 Wastegate Control Circuit - shorted high.

EG492 Yellow

Turbocharger #2 Wastegate Control Circuit - shorted low.

EG496 Yellow

Engine Speed / Position Sensor #2 (Camshaft) Supply Voltage.

EG524 Yellow

OEM Alternate Droop Switch Validation - data incorrect.

EG527 Yellow

Auxiliary Input / Output #2 Circuit - shorted high.

EG528 Yellow

OEM Alternate torque validation switch - data incorrect.

EG529 Yellow

Auxiliary Input / Output #3 Circuit - shorted high.

EG546 Yellow

Fuel Delivery Pressure Sensor Circuit - shorted high.

EG547 Yellow

Fuel Delivery Pressure Sensor Circuit - shorted low.

EG551 Yellow

Accelerate Pedal Idle Validation Circuit - shorted low.

EG553 Yellow

Injector Metering Rail #1 Pressure High - warning level.

EG554 Yellow

Fuel Pressure Sensor Error.

EG559 Yellow

Injector Metering Rail #1 Pressure Low - data valid but below normal operational range - moderately severe level.

EG596 Yellow

Electrical Charging System Voltage High - warning level.

EG598 Red

Electrical Charging System Voltage Low - critical level.

EG689 Yellow

Crankshaft Engine Speed Signal Error.

EG731 Yellow

Mechanical Timing Misalignment.

EG753 Yellow

Crankshaft Position Sensor and Camshaft Position Sensor - data erratic, intermittent, or in correct.

EG757 Yellow

Electronic Control Module Data Lost.

EG758 Yellow

Injector Metering Rail #2 Pressure Malfunction.

EG778 Yellow

Engine Speed Sensor (Camshaft) - data erratic, intermittent, or incorrect.

EG951 None

Cylinder Power Imbalance Detected.

QST30 (135ZV-2)

QSK19 (115ZV-2)

QSX15 (95ZV-2)

QSM11 (92ZV-2)

QSM11 (90ZV-2)

QSC8.3 (85ZV-2)

QSC8.3 (80ZV-2)

DESCRIPTION

QSB6.7 (70ZV-2) (70TMV-2)

FAULT CODE/ LAMP

QSB4.5 (60ZV-2)

80ZV-2 EU 62-32 62 Function & Structure Electrical Group ECM (Engine Controller)

EG1117 None

Power Lost with Ignition ON - data erratic, intermittent, or incorrect.

EG1358 Yellow

Accelerator Pedal Position Sensor 1 Circuit - voltage above normal or shorted high.

EG1359 Yellow

Accelerator Pedal Position Sensor 1 Circuit - voltage below normal or shorted low.

EG1361 Yellow

Remote Accelerator Pedal Position Sensor 1 Circuit - voltage below normal or shorted low.

EG1376 Orange

Engine Camshaft Speed / Position Sensor - data erratic, intermittent, or incorrect.

EG1595 Yellow

Remote Accelerator Pedal Position Sensor 1 Circuit - voltage above normal or shorted high.

EG1597 Orange

Engine Control Module Critical Internal Failure - bad intelligent device or component.

EG1845 Orange

Water in Fuel Indicator Sensor Circuit - voltage above normal or shorted to high source.

EG1846 Orange

Water in Fuel Indicator Sensor Circuit - voltage below normal or shorted to low source.

EG1852 Yellow

Water in Fuel Indicator - data valid but above normal operational range moderately severe level.

EG1911 Yellow

Injector Metering Rail 1 Pressure - above normal operating range.

EG2185 Yellow

Sensor Supply Voltage #4 Circuit - shorted high.

EG2186 Yellow

Sensor Supply Voltage #4 Circuit - shorted low.

EG2215 Yellow

Fuel Pump Delivery Pressure - data valid but below normal operational range moderately severe level.

EG2249 Yellow

Fuel Pump Delivery Pressure Sensor Circuit - shorted low.

EG2261 Orange

Fuel Pump Delivery Pressure - data valid but above normal operational range least severe level.

EG2262 Orange

Fuel Pump Delivery Pressure - data valid but below normal operational range least severe level.

EG2265 Yellow

Fuel Priming Pump Control Signal Circuit - shorted high.

EG2266 Yellow

Fuel Priming Pump Control Signal Circuit - shorted low.

EG2311 Yellow

Fueling Actuator #1 Circuit Error - condition exists.

EG2321 None

Engine Speed Sensor #1 - data erratic, intermittent, or incorrect.

EG2322 None

Engine Speed Sensor #2 - data erratic, intermittent, or incorrect.

EG2697 Orange

Accelerator Pedal Position Sensor Circuit and Idling Position Detection Switch Circuit - data erratic, intermittent, or incorrect.

EG2963 None

Engine Coolant Temperature High - warning.

EG2964 None

Intake Manifold Temperature High - warning.

EG2973 Yellow

Intake Manifold Pressure Sensor Circuit - data erratic, intermittent, or incorrect.

(09D20E)

QST30 (135ZV-2)

QSK19 (115ZV-2)

QSX15 (95ZV-2)

QSM11 (92ZV-2)

QSM11 (90ZV-2)

QSC8.3 (85ZV-2)

QSC8.3 (80ZV-2)

DESCRIPTION

QSB6.7 (70ZV-2) (70TMV-2)

FAULT CODE/ LAMP

QSB4.5 (60ZV-2)

80ZV-2 EU 62-33 62 Function & Structure Electrical Group ECM (Engine Controller)

80ZV-2 EU 62-34 62 Function & Structure Electrical Group ECM (Engine Controller)

Accelerator pedal

Pedal A-Black-APS signal B-White-APS ground C-Red-APS supply (5 V) D-Green-Throttle active E-Blue-Idle active F-Orange-IVS supply (5 V)

Throttle pedal Throttle opening sensor

BrW (733) R

YV (734)

B

BLg (735)

22 9 23

W IDLE S/W OFF IDLE

GyY (736) G GyW (737)

IDLE

L

35

E C M 1 11

O

Note APS-Acceleration Position Signal IVS-Idle Validation Switch

Circuit diagram

Connector (G) 6 (L) 5 (O) 4

1-Black-APS signal 2-White-APS ground 3-Red-APS supply (5 V) 4-Orange-IVS supply (5 V) 5-Blue-Idle active 6-Green-Throttle active

1 (B) 2 (W) 3 (R)

A View A

85V2E62003

Note To calibrate a new pedal to the ECM, do the following within about a 5 or 6 second time frame. - Turn "on" key switch - Stroke the pedal fully up and down 3 times. - Turn "off" the key switch Potentiometer voltage (V) Input

5

Up position

3.75~3.95

Down position

0.55~0.75

Pedal Test Typical pedal potentiometer resistance at 18ºC (65ºF). Wire colors are at the pedal harness with accelerator pedal unplugged. Wire colors

 at pedal up position

 at pedal down position

R-B

1,540~2,310

260~390

W-B

260~390

1,540~2,310

R-W

2,000~3,000

2,000~3,000

G-O

Open

0

L-O

0

Open

80ZV-2 EU 62-35 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.

A

Pedal stop

Stroke

Pedal angle K65V2U62004

17 Installation angle 45

Note Part “A” is added on S/N 9251 and thereafter and force on pedal is increased from 50 N (5.1 kgf) (11.2 lbf) to 77 N (7.9 kgf) (17.3 lbf).

28

Pedal Angle

Between terminal 9 (YV-B) and 23 (BLg-W) Refer to circuit diagram for details.

Potentiometer Voltages when plugged in, key "ON"

5V 4 3 2 1 0

17

0 Pedal Angle

85V2E62019

80ZV-2 EU 62-36 62 Function & Structure Electrical Group ECM (Engine Controller)

Accelerator pedal installation Throttle pedal sends electrical signal to the engine ECM*. When the throttle pedal or the ECM* is replaced or when the battery cable is disconnected the throttle pedal must be calibrated, or "initialized", with the ECM*. Failure to initialize the throttle pedal will result in a fault code warning light, and a possible power deration. When a new throttle pedal or ECM* is installed or when the battery cable is re-connected or a fault code (listed below) is indicated follow these steps within a time frame of about 5 or 6 seconds to initialize the throttle pedal with the ECM*. 1. Shut off the engine 2. Turn the key to "ON" 3. Fully depress and release the throttle pedal three times. 4. Turn the key to "OFF". The throttle pedal and ECM* have now been initialized or calibrated. The engine may be restarted and retested for proper performance. If the problem continues disconnect the wiring harness connector at the throttle pedal and inspect both sides. The pins and sockets should be clean, dry and straight. If there is a problem correct it, reconnect the connector, follow the steps above and retest. Using the Quantum fault code information section the following fault codes may indicate a non-initialized throttle pedal: - Fault Code 132 - Fault Code 134 - Fault Code 287 - Fault Code 431 - Fault Code 432 - Fault Code 443 If the problem is not corrected contact your Cummins Engine distributor for assistance. *Engine Control Module; Computer that controls engine functions, and monitors engine faults.

80ZV-2 EU 62-37 62 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit

Transmission Control Circuit and Monitor Circuit Machine control unit (MCU)

To S5

To S6

To S7

To S8

To S9

85V2E62041

80ZV-2 EU 62-38 62 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit

Connector

MCU

To S5

To S6

To S7

To S8

To S9

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

A1

A2

A3

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

A4

A5

A6

A7

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

A8

A9

A10

A11

A12

A13

A14

A15

A16

A17

A18

A19

A20

A21

A22

A23

A24

A25

A26

A27

A28

A29

A30

A31

To S5

A32

A33

A34

B1

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

B2

B3

B4

B5

B6

B7

B8

B9

B10

B11

B12

B13

B14

B15

B16

B17

B18

B19

B20

B21

B22

B23

B24

To S6

B25

B26

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

E1

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

E2

E3

E4

E5

E31.TT_SE E32.OT_SE E33.OUT_RSE E34.ET_M

E6

E7

E8

E9

E10

E11

E12

E13

E14

E15

E16

E17

E18

E19

E20

E21

E22

E23

E24

E25

E26

E27

E28

E29

E30

E31

E32

E33

To S7

E34

C1

C2

C3

C4

C5

C6

C7

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

C8

C9

C10

C11

C12

C13

C14

C15

C16

C17

C18

C19

C20

C21

C22

C23

C24

C25

C26

C27

C28

C29

C30

C31

To S8

C32

C33

C34

D1

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

D2

D3

D4

D5

D6

D7

D8

D9

D10

D11

D12

D13

D14

D15

D16

D17

D18

D19

D20

D21

D22

D23

D24

D25

D26

To S9

Connector details 85V2U62009

80ZV-2 EU 62-39 62 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit

Machine control unit (MCU) connection diagram (S/N 9001~9350)

(L) (005-b)

TO PARKING S/W

ACC’ (005) L2

F5

(L) (005-a)

30A F10

G (010) Lx4 (005-A~005-D) E

ACC’

E05 E06 E17 WL (707)

E24

E04 E12 E03 E11 B18 B12

LR (126) LBr (128)

B11

D04

B10

LgW (101) BrB (258) L (273)

NR

NEUTRAL RELAY

X

MCU FAILURE RELAY

KO

LIFT KICKOUT RELAY

BS

LOWER KICKOUT RELAY

SHIFT LEVER

F N R

D11

(SbP)(145)

1

23A

E A03

LW (120) LO (123) LG (122) LY (121)

D12 D05 D03

B13 B04

D10 A18

YO (232)

S/S SHIFT S/W F

YW (233)

S/S SHIFT S/W R

D19 D26

YGy (242)

SECONDARY STEERING MOTOR RELAY COIL

M

LR (146)

F SOLENOID VALVE

LBr (148)

R SOLENOID VALVE

(141) LY

1ST SPEED SOLENOID VALVE

(LY) A02

(142) LG

2ND SPEED SOLENOID VALVE

(LG) YV (231)

S/S SHIFT SELECTION S/W

D18

F5 LB (230)

ARMREST S/W

LG (122)

SHIFT UP S/W

LY (121)

SHIFT DOWN S/W

A05

D24

YSb (125)

SHIFT HOLD S/W

LP (168)

DECLUTCH SET-UP

(GW) (210)

SLIP CONTROL S/W

BrG (255)

LIFT KICKOUT SET-UP

BW (271)

LOWER KICKOUT SET-UP LOWER KICKOUT S/W

A08

REVERSAL FAN S/W

LgY (223)

AUTO FAN REVERSAL S/W

(Y) (105)

RECALL S/W

(R) (106)

RESET S/W

LLg (165) GO (164) GyW (200) GL (265) (GyW) (260)

F13

E (013) (Lg) YO (176)

EP

E/G OIL PRESS. S/W

BrY (181)

HYD. OIL LEVEL S/W

(LgY) (167)

DECLUTCH S/W ON

PARKING SOL (162) LgG

E

(163) (SbW)

OFF ON

LgL (182)

AIR CLEANER CLOGGING S/W

DECLUTCH

(005-b) (L)

OFF

Gy (750)

(144) LW

4TH SPEED SOLENOID VALVE

D06 (LW) D07 D14 B14 D17 A07

LP (149)

D SOLENOID VALVE

WR (170) LLg (140)

D15 A04

LgL (261)

RIDE CONTROL SOLENOID VALVE

D23 D22 C13

A01 B06

C31 Lg (222)

3RD SPEED SOLENOID VALVE

(LO)

A17 (YL) (124)

DOWNSHIFT S/W

(143) LO

Transmission clutch sol. valve

E01 C25 C34

B07

C30

E02

GB (267)

EFFICIENT LOADING SYSTEM SELECTION SOL. VALVE

LgL (225)

REVERSAL FAN SOL. VALVE (OPT)

(236) BR

S/S SOLENOID VALVE R

1A (237) BL (226) LgB

1A

S/S SOLENOID VALVE L (221) LgB

1A C12 D21 D01 C23 C22 C33 C16

A21 A29 A14 A28 A19 A15

C11 C06

A16 A27 A12

(LgR) (130) (GR) (135) (GyB) (103) (LgY) (173) (Gy) (749) (GyG) (753) (GyL) (190) (LgW) (192) (O) (241)

FAN SPEED CONTROL SOL.VALVE F13 (013) (Lg)

AUTO SHIFT INDICATOR LAMP NEUTRAL INDICATOR LAMP CENTRAL WARNING LAMP BRAKE OIL PRESS. WARNING LAMP E/G OIL PRESS. WARNING LAMP E/G COOLANT TEMP. WARNING LAMP T/M OIL TEMP. WARNING LAMP

Instrument panel indicator lamp

AIR CLEANER WARNING LAMP STEERING OIL PRESS. WARNING LAMP

F5

PARKING S/W

FUEL EFFICIENT MODE S/W

EFFICIENT LOADING SYSTEM S/W

RIDE CONTROL S/W X

MCU FAILURE FUEL LEVEL GAUGE

(LgW) (102)

(404) (YBr) (LgSb) (112)

WARNING BUZZER E

BZ

Note Refer to Section 92 for the detailed electrical connection diagram for the MCU including modification information. K85V2E62003

80ZV-2 EU 62-40 62 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit

A30 V (100)

S/S POTENTIOMETER

G (234)

BOOM ANGLE SENSOR

BrR (251)

DECLUTCH SENSOR

(LgR) (166)

BRAKE OIL PRESS. SENSOR 1

SbY (171)

BRAKE OIL PRESS. SENSOR 2

SbY (172)

SECONDARY STEERING OIL PRESS. SENSOR

SbR (240)

EFFICIENT LOADING SYSTEM OIL PRESS. SENSOR

GyB (266)

A32

E09(+5V)

A24

E/G COOLANT TEMP. SENSOR

GyL (180)

T/M OIL TEMP. SENSOR

(G) (415)

AIR TEMP. PROBE

GyO (220)

HYD. OIL TEMP. SENSOR

BY (114)

B09

E/G SPEED SENSOR

ECM (41)

W (161) Y (159)

E34 E21

PG (109) PB (110)

S/S INDICATOR LAMP BUZZER

BZ

(YB) (401)

E/G COOLANT TEMP. GAUGE

(BrW) (402)

T/M OIL TEMP. GAUGE

E30 B24

E22 C27

(WL) (400)

METER OUTPUT (SPEEDOMETER/TACHOMETER)

(420) OSb (+)

(-)

(421) OB (+)

(-)

TACHOGRAPH E/G SPEED

C01 E26

B25

TACHOGRAPH GROUND SPEED

E31 A06

E32

B08

E23

A09

E07

YSb (403) SbR (208) SbP (202)

A34 SbLg (204)

E15

(GW) (212)

A25

HOUR METER DRIVE AI

E/G IDLE SELECTION

TC

E/G TORQUE SELECTION

SbW (203)

E16

E/G DROOP SELECTION 1 E/G DROOP SELECTION 2

B19

C02

(LB) (138) (RG) (331)

SLIP CONTROL SELECTION

ECM (3)

E08 A10

P (107) PL (108)

LgBr (104)

E27

E

OPT OPT A/M SELECTION ODOMETER SELECTION TIRE DIA. SELECTION SPEED SENSOR SELECTION METER SELECTION

REVERSAL FAN INDICATOR LAMP

(LgB) (224)

C26

B15 Y (160)

GROUND SPEED SENSOR

SLIP CONTROL INDICATOR LAMP

(RL) (235)

E19

E10

GyG (754)

(OSb) (211)

E

TO BACK-UP LAMP TO BRAKE LAMP

C03 D02

(RIN1)B16

D16

(DOUT1)B22

GL (810) RS232C

GR (811)

D25 D08

(CANH0)E29

D09

(CANL0)E20

S2H S2L

CAN

S2S E

MAIN MCU

E

K85V2E62004

Note Refer to Section 92 for the detailed electrical connection diagram for the MCU including modification information.

80ZV-2 EU 62-41 62 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit

Machine control unit (MCU) connection diagram (S/N 9351~) *

"

- $ + %/

*

%.+ - ,$ %/ %.+ - %/

%/% %.+ % -+ %/ ) %- %/

%.+ - %/

%.+ - . %/

%

,- . % - ,$

$

% +$ - %/ + - + ,% - ,$ + ,% - ,$ % %/ ,- % %/ ,- . % -+ ) % -+

# #

#

#

,- . %/

$ + % #

%"

- + %- ,) $ - + %- ,) $ "

$ + %/

$

+ - %/ - # + %- ,) $ #%"

/ + $ %%0 %/ . 0 + %/ + + %/

#

(

$- ( , 2>;6 517!

,- ) , + , + - + ,- + ,-

% + %- %$ % + %- %$ $

%$ % + %$ $ %$ % + %$ $

% + , ,%

#

, ,%

#

+ - % +

+ + - + % %- ) % -+ % +

#

%

$- ( , 2>;6 517!

%/% % +

#

% +

%/% % +

#

- 123422451 67896: 257;154< = 7=;

-. %$ % + -. %$ $

$ '

# ' ! # ! ' ' ! ! ' # ' '

% %- + ) - + % +

)

! ! !

!

+ + - + % %- ) %/

&

#

, + + - ) %/

) , + , + ,((

'

$ $ $ $ ' $ '

%$ + + -+ % +- . %$ + + -+ % +- . ,- / , ,- % -+ /) % -+ . $ + - % -+ . $ + - % -+ ) - % -+ %$ % % % -+ ) - % -+

/ $ % -+ %"$ # & %

/ %/

$

%.+

#

%$ - % + ,- %.+ - + + - )$ ,- + + - )$ - + )$ + $ %%0 + )$ / + $ %%0 + )$ / - - )$0 + )$ -/) + - )$0 + )$ + + )$ %- + + $ %%0 + )$ ,- + + - )$ , ,% % +$ - + + - )$ % + + - )$ %/% + + - )$

/ - - )$0 ,

-/) + - )$0 ,

) - ,-$, %$ ) -

+129 83;19 > 1;7 41<46 95 7 3>

Note Refer to Section 92 for the detailed electrical connection diagram for the MCU including modification information.

? 2:5@2 $-0

80ZV-2 EU 62-42 62 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit

, ' # #$ ) #

)

! "#

'# % . " 0123 456

! # $ ' - , # # )'- & $ ' #$ #,) $ # )'- "# $! $ # )'- !- $ # )'-

)

(

, ' !

) " ' ) ( $#

&&$ $ # !$ # ) $ ' -

& ( # +! #+! )! !

$ ' - $ ' -

" ! ' !

' (

(

# ' " ! ' !

" ) # ! $ $ # !

&

)

, $! #$ , # /" #$ , ! ' #$ , ! ' #$ " " ! $' # #$

."' )'

"#*& ( "#* +! #+! "#*)!

"%%

# ' , ' !

&

%

$ ! "#

) $ ) "

7 08490 '#

Note Refer to Section 92 for the detailed electrical connection diagram for the MCU including modification information.

80ZV-2 EU 62-43 62 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit

Machine control unit (MCU) function Forward/reverse (F/R) shifting and speed change

From T/C pump F/R clutch solenoid valve

Shift lever

Clutch pressure regulator valve Surge suppression diode (incorporated in solenoid valve)

Speed clutch solenoid valve

To solenoid valve bank Clutch piston

Downshift button

MCU

Speed indicator lamp (instrument panel)

Drain

Clutch control solenoid valve energized de-energized

clutch engage clutch disengage

Speed sensor

AUTO indicator lamp ON when shift lever in A position

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 for input detection signal is sent from the MCU to the grounding circuit via shift lever contact F. The MCU, therefore, judges that the shift lever is set to the F (forward) position. There is no shift lever contact for the R (reverse) input circuit and electric current will not flow. For the speed change, the MCU 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, the machine will stay engage in the gear just before the shift lever stuck and still move with it’s gear selection. When the starter switch is at OFF position, if both the forward and reverse commands are input at the same time due to a problem, the engine does not start even if the starter switch is placed in the start position. This is because the neutral relay does not work.

80ZV-2 EU 62-44 62 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit Shift lever

2

1

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 (B)

3

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 downshift button 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 MCU will judge that the shift lever is at the neutral (N) position.

80ZV-2 EU 62-45 62 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit

Automatic shift

Operation of solenoid valve Clutch solenoid valve

Shift up

A

Shift down

10.8 N-m (1.1 kgf-m) (8 lb-ft)

Speed

4 3 + side

2

SKM6 G24D

K W E 6 K- 21/ N 19.0 16.5 10.0 7.5 (11.9) (10.3) (6.3) (4.7)

– side

Reverse

View from A

0

7.0 10.0 (4.4) (6.3)

16.0 18.5 (10.0) (11.6)

Speed km/h (mile/h)

Forward

Automatic shift map (Normal mode)

80V2U62082

35 N-m (3.6 kgf-m) (26 lb-ft) Shift up Shift down

80ZV62012

4 Solenoid valve (with built-in diode) Rated voltage

DC 24 V

Coil resistance value

Approx. 27 

3 2

When the input signal is transmitted, the output circuit of the corresponding solenoid valve is connected to the grounding circuit. As a result, power is supplied to the solenoid valve and the clutch is engaged. At the same time, the speed indicator lamp in the cab lights. Note that when the parking brake or declutch brake is applied, the forward or reverse (F or R) clutch solenoid valve is turned off and the transmission is set to neutral.

16.5 14.5 (10.3) (9.1)

Reverse

9.0 6.0 (5.6) (3.8)

0

5.5 9.0 (3.4) (5.6)

14.0 17.0 (8.8) (10.6)

Speed km/h (mile/h)

Automatic shift map (Fuel efficient mode)

Forward 80V2U62083

When the shift lever is set to A position, 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.

80ZV-2 EU 62-46 62 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit

Machine speed sensor

Clearance 0.15~1.4 mm (0.006~0.055 in) 70V2U62008

Speed sensor (proximity switch)

Transmission

K80V2U62001

Internal resistance *

2.3±0.2 k (25ºC) (77ºF)

* Internal resistance changes greatly with temperature. At lower temperature the resistance is lower. At operating temperature the resistance increases. If resistance is 0  or   the speed sensor is defective.

The detector is adjacent to the transmission output gear. The pulse voltage is transmitted to the MCU. Note To prevent electronic "noise" from other sources that may corrupt signal, "twist" the wire from sensor all the way to the MCU.

IMPORTANT Make sure to apply the correct torque value when replacing the sensor. Shims help to set clearance between sensor & gear but over-torque can change clearance.

80ZV-2 EU 62-47 62 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit

Switching from automatic to manual

Downshift button operation Downshift button

B

LgL SbY GR A502 A507 A701

A/M SELECTION B PG S902 1

SbLg A608

GR T103

SbL H718

SbP RG F701 H139

L BrB LgW LR SbR LgBr F102 G602 T001 T901 F901 H205 LBr H206

9

1

WL GyG A806 H136

WO SbW GL H117 H703 T104

LY Gy Gy LP LgB A708 A506 A807 A808 A604 H201 RL GyB GyG GyL LP 0 H128 A809 A505 A501 H207 A609 T801 GB LG YGy LgSb LO YSb LLg LW SbP H121 A709 E804 H122 A710 A901 H110 A711 F202 H204 H202 H203

LgL BL E502 E001

7

1

(BLACK) S4

S5

S6

85V2E62025

The machine has automatic shift cancellation function for troubleshooting. Connect the coupler (OPT) to S4 coupler to cancel the automatic shift function. The mode will be switched from automatic to manual. Position "A" of the shift lever, therefore, is fixed to the 4th speed.

80ZVE62017

The downshift button is attached to the boom control lever. In any operation mode, pressing the downshift button during 2nd speed operation shifts the 2nd speed to the 1st speed. After that, if the downshift button is pressed again, the speed is changed from the 1st to the 2nd, or to move the shift lever to neutral or to the opposite direction, the speed will be changed to the 2nd again. Note that when the speed is shifted, the transmission status monitor lamp on the instrument panel changes from the 2nd gear to the 1st gear or from the 1st gear to the 2nd gear. Downshift button

YL

BY

70ZV62031

Allowable value

Max. voltage

DC 24 V

Current

10 mA

The downshift button is of the momentary type. It is spring loaded to the "OFF" position.

80ZV-2 EU 62-48 62 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit

Adjustable declutch preset switch 200

Clutch OFF

Clutch ON

0

310

510

(kPa)

Declutch sensor

85V2E62028

Declutch preset switch ON

Declutch sensor

Transmission clutch

More than 510 (kPa)

Disengage

Less than 310 (kPa)

Engage

Adjustable declutch preset switch is used to change the angle of the left brake pedal (Declutch pedal) to disengage the transmission clutch. Declutch sensor

With the engine running, step on the left brake pedal (Declutch pedal) up to the desired angle and press the switch to set the brake pedal (Declutch pedal) angle. 85V2E62006

Switch 70V2U62015

80ZV-2 EU 62-49 62 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit

Back-up alarm

Back-up lights

F

N

R

Shift lever

Back-up alarm MCU

+24 V

1

2 3

A10

A

85V2E62027

When the shift lever is set to the reverse (R) position, the back-up lamp will light, and the buzzer will sound.

80ZV-2 EU 62-50 62 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit

Parking brake

5A F13

+ 24V

Monitor lamp

P

Parking (ON)

Parking brake Cylinder

Running (OFF) Parking switch ON OFF MCU

F

D01

P

R

30A F5 + 24V

85V2E62029

The parking brake solenoid valve activates the parking brake. Parking switch ON:

Parking switch OFF:

When the power of the solenoid valve is turned off, no oil will be fed to the oil cylinder. The spring inside the cylinder applies force to make the brake apply (drum type). If the transmission shift lever is set to the forward or reverse (F or R) position, the buzzer will sound and the clutch will not be engaged.

When the power of the solenoid valve is turned on, oil will be fed into the oil cylinder. The oil will depress the spring to release the brake.

Parking brake operation Parking switch

Monitor lamp

Buzzer

Parking brake solenoid valve

Parking *

"Parking" position (pulled up)

P

Sounds when shift lever is set to F or R

No electric power supply

Running

"Running" position (pushed in)

Off

No buzzer

Electric power supply

*When the parking switch is set to "parking", the forward or reverse clutch is disengaged and set to neutral.

80ZV-2 EU 62-51 62 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit Solenoid valve for parking brake Spring chamber (brake actuator) B

Reducing valve

Solenoid

Knob

P

T Seat face A

Manual release (counterclockwise rotation)

Spool

Seat face B Tank

115V2E62020

Solenoid specifications Rated voltage

B

P

DC 24 V

Rated current

0.92 A

Resistance

26.2 

T

Hydraulic circuit diagram

95ZV52045

Solenoid valve for parking brake

Rear chassis

Valve assembly

Front

Installation position 80V2E52006

80ZV-2 EU 62-52 62 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit

Machine control unit (MCU) failure warning Should the MCU stop working due to the following cause, a dash mounted monitor lamp lights up to give warning. MCU failure monitor lamp

4

3

MCU replacement If the monitor lamp lights up under the cause above, it is an indication that the MCU's program has malfunctioned and the MCU assembly must be replaced.

Electric circuit

LgW

2

B

1

L

The MCU has a self-diagnosis function incorporated in it, and if the computer program becomes abnormal due to abuse or defect, a dangerous condition may occur, the monitor lamp lights up and all the outputs from the MCU are turned OFF.

LgW

Body blue

If a warning is given as a result of self-diagnosis of the MCU

Chassis side coupler

When installing a new MCU on the machine, all specifications must be registered into the MCU through the MODM.

85V2E62030

Rating

DC 24 V

Operation voltage

16 V or less

Reset voltage

2.4 V or more

Coil resistance

320 

MCU fault relay (Normally closed)

80ZV-2 EU 62-53 62 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit

Secondary steering function

Secondary steering motor and pump

Magnetic switch

Pressure sensor

Hydraulic pump To battery relay

Steering valve

Hydraulic circuit Electrical circuit Check valve K80V2U42003

Speed sensor Pilot lamp

To steering valve

F13 MCU

To loading line Pressure sensor

Check valve

Check valve G1 G1/2

+24 V

Secondary steering motor and pump

M

G1 G1/2

10 cm3/rev

G3/8

11.7MPa (119.3 kgf/cm2) (1696 psi)

To brake and pilot line

M

80.2 32.2 25.3 cm3/rev cm3/rev cm3/rev G1/4 TS

Magnetic switch (on motor and pump) Steering pump

Hydraulic line Electrical circuit

80V2E42011

80ZV-2 EU 62-54 62 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit

In normal operation, the oil from the steering pump flows into the steering valve through the check valve. And the signal of the pressure sensor is always sent to the MCU. With some problems, as the steering hydraulic pressure goes down while the engine is running, the pressure sensor signal becomes less than the preset value at the MCU. In this condition, if the machine speed is more than 2 km/h, the MCU sends a signal to the magnetic switch. As a result, the secondary steering motor and pump are driven. Then it is ready to steer the machine. Pressure sensor preset value Steering hydraulic pressure ON: at 0.3 MPa (3 kgf/cm2) (44 psi) or lower OFF: at 0.4 MPa (4 kgf/cm2) (58 psi) or higher

The signal from MCU to magnetic switch

Machine speed signal

ON

Machine speed

OFF

1

2

(km/h)

85V2E42051

80ZV-2 EU 62-55 62 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit

Monitoring system If a problem of a unit is detected while the engine is running, a monitor lamp lights to inform the operator.

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).

For some problems, the buzzer sounds also, and the central alarm lamp flashes also.

Items to be monitored and operation condition Monitor lamp No.

1

Item to be monitored

Lighting color

Machine control unit (MCU)

Operation condition

Buzzer

Lamp test

Remarks

Symbol

Defective machine control unit (MCU)

—

(red) 2

3

4

(red)

Unloader valve accumulator port oil pressure is lower than 3.9±0.5 MPa (40±3 kgf/cm2) (569±71 psi)

(red)

While engine running 0.08±0.01 MPa (0.84±0.14 kgf/cm2) (12±2 psi) or less for more than 2 seconds

Brake oil pressure

Engine oil pressure

Engine water temperature (red)

5

6

Torque converter oil (transmission) temperature

(red)

Clogged air cleaner (red)

7

Charging condition

101±2ºC or more (214±4ºF or more) for more than 2 seconds

—

120±5ºC or more (248±9ºF or more) for more than 2 seconds

—

Filter resistance: 635±58 mmAq or more (25 inches H2O) for more than 2 seconds

—

Defective charge system

—

For items 1~6, 9

—

(red) 8

Central alarm

Flashing type

(red) 9

Steering oil pressure (option)

(red)

(red) 10

Hydraulic oil level

When operates steering pressure is less than 0.4 MPa (4 kgf/cm2) (57 psi) Machine speed is more than 2 km/h.

Hydraulic oil level is low when the engine is stopped.

(red) 11

—

Engine warning lamp (yellow)

12

Engine stop lamp

Any fault in engine detected by ECM (Engine controller)

(2 sec.) —

(red)

80ZV-2 EU 62-56 62 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit

Operation monitor lamps Monitor lamp No.

Monitor item

Lighting color

Lighting condition

Remarks

Symbol

1

Parking

Red

When parking brake switch is set to ON

2

Declutch

Green

When declutch selector switch is set to ON

3

Working light

Green

When working light (rear) switch is set to ON

4

Preheat

Yellow

When starter switch is in the PREHEAT position

5

Turn signal indicator (left)

Green

When turn signal lever (left) is actuated

6

Turn signal indicator (right)

Green

When turn signal lever (right) is actuated

7

High beam

Blue

When head lamp is set to high beam

8

Auto shift

Green

When transmission shift lever is set to automatic position

9

Neutral

Green

When transmission shift lever is set to neutral position

10

Transmission status

Yellow

When transmission shift lever is set to corresponding gear (1~4)

11

K-Lever indicator

Green

When K-Lever system is set to ON.

(OPT)

12

Reversal fan

Green

When the reversal fan switch is set to ON.

(OPT)

Caution on storage of individual instrument panel Gauge pointer

IMPORTANT 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.

Pointer axis Axis hole

Main body frame

Magnet

Meter

Damper oil

70ZV62087

80ZV-2 EU 62-57 62 Function & Structure Electrical Group Instrument Panel and Switch

Instrument Panel and Switch Instrument panel (S/N 9001~9350)

21

1

20

17

9 19 5 18

2

23

4

10

11(35)

12

29

26

28

27

32

13 14

33

34,37 15 16

STOP

6,36 31

30

24 25(35)

22 7 8

38

3 K85V2E62002

1. Speedometer 2. Engine coolant temperature gauge 3. Transmission oil temperature gauge 4. Fuel gauge 5. Parking brake indicator lamp 6. F/R switch indicator lamp (option) 7. Working light indicator lamp (rear) 8. Preheat indicator lamp 9. Central warning lamp 10. Machine control unit (MCU) warning lamp 11. Brake oil circuit warning lamp 12. Engine oil pressure warning lamp 13. Engine coolant temperature warning lamp 14. Transmission oil temperature warning lamp 15. Air cleaner clogging warning lamp 16. Charge warning lamp 17. Turn signal indicator lamp (left) 18. Turn signal indicator lamp (right) 19. High beam indicator lamp 20. Auto shift indicator lamp

21. Neutral indicator lamp 22. Transmission status monitor 23. Hour meter 24. Reversal fan pilot lamp (option) 25. Secondary steering warning lamp 26. Working light switch (front) 27. Working light switch (rear) 28. Fuel efficient mode switch 29. Four-way flasher switch (option) 30. Engine warning lamp 31. Engine stop lamp 32. Efficient loading system switch 33. Declutch selector switch (S/N 9001~9100) 34. Selection switch for shift lever or F/R switch (option) 35. Hydraulic oil level warning lamp 36. K-Lever indicator lamp (green) (option) 37. K-Lever switch (option) 38. Declutch selector indicator lamp

80ZV-2 EU 62-58 62 Function & Structure Electrical Group Instrument Panel and Switch (S/N 9351~)

1. Speedometer 2. Engine coolant temperature gauge 3. Transmission oil temperature gauge 4. Fuel gauge 5. Parking brake indicator lamp 6. F/R switch indicator lamp (option) 7. Working light indicator lamp (rear) 8. Preheat indicator lamp 9. Central warning lamp 10. Machine control unit (MCU) warning lamp 11. Brake oil circuit warning lamp 12. Engine oil pressure warning lamp 13. Engine coolant temperature warning lamp 14. Transmission oil temperature warning lamp 15. Air cleaner clogging warning lamp 16. Charge warning lamp 17. Turn signal indicator lamp (left) 18. Turn signal indicator lamp (right) 19. High beam indicator lamp 20. Auto shift indicator lamp

21. Neutral indicator lamp 22. Transmission status monitor 23. Hour meter 24. Reversal fan pilot lamp (option) 25. Secondary steering warning lamp 26. Working light switch (front) 27. Working light switch (rear) 28. Fuel efficient mode switch 29. Four-way flasher switch (option) 30. Engine warning lamp 31. Engine stop lamp 32. Efficient loading system switch (option) 33. Selection switch for shift lever or F/R switch (option) 34. Hydraulic oil level warning lamp 35. K-Lever indicator lamp (green) (option) 36. K-Lever switch (option) 37. Declutch selector indicator lamp

80ZV-2 EU 62-59 62 Function & Structure Electrical Group Instrument Panel and Switch

Instrument panel rear surface (S/N 9001~9350)

1

CN4 L11

4

8P

L1 L2

CN1

5

58 57

8

S

L4 E

L5 L6

Fuel gauge

V

E

L10

L10

L8

E

L9

V

T/M oil temp. sensor

V

E L10

L18

Speedometer

L19

S

L7

56 L10

S

L21

L17

Engine water temperature sensor

48

16P

35

L16

S V

12P L10

L15

L3

CN3

29

L20

L14

L10

Hour meter

L10

L13

L12

9

CN2

L22

18

L23

L24

L25

L26

L27

20P 19

28

Layout of connector pins (Instrument panel side) CN1(8P)

A5

1 2 3 4 5 6 7 8

A6

A7

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)

Pin No.

Signal

Lamp No.

Pin No.

1

—

L9

21

Signal

Fuel gauge (sensor)

CN3(12P/16P)

A8

A9 CN4(2P)

41 42 43 44 46 47 48 49 50 53 54 55 56

Lamp No.

Pin No.

—

41

58 57

Signal AUTO lamp

85V2E62052

Lamp No. L20

2

Charge lamp

L7

22

—

42

3

Air cleaner clogging alarm

L6

23

—

—

43

Converter (+)

—

L16

4

T/M oil temperature alarm

L5

24

—

—

44

Converter (–)

5

Engine water temperature alarm

L4

25

—

—

45

6

Engine oil pressure alarm

L3

26

—

—

46

Declutch lamp

L17

7

Brake alarm

L2

27

—

—

47

Preheating lamp

L19

8

MCU failure alarm

L1

28

GND (–)

—

48

Work lamp

L18

+24 V power supply

— — —

9

+24 V power supply

—

29

—

49

Central alarm lamp

L14

10

Secondary steering

L22

30

—

—

50

GND (–)

—

11

Reversal fan (optional)

L23

31

—

—

51

—

12

Engine warning lamp

L25

32

—

—

52

—

—

53

High-beam lamp

L12

L21

54

Turn signal (left) lamp

L13

Turn signal (right) lamp

L11

13

—

L24

33

14

Engine stop lamp

L26

34

Neutral

—

15

—

L27

35

GND (–)

—

55

16

E/G water temperature (sensor)

—

36

1st speed indication

—

56

17

T/M oil temperature (sensor)

—

37

2nd speed indication

—

57

Hour meter (–)

—

18

—

—

38

3rd speed indication

—

58

Hour meter (+)

—

19

Instrument panel illumination

L10

39

4th speed indication

—

20

—

L8

40

Parking brake lamp

L15

—

—

80ZV-2 EU 62-60 62 Function & Structure Electrical Group Instrument Panel and Switch (S/N 9351~)

E

18

19

CN2

E S

S

V

V

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

2

—

Lamp No.

Pin No.

CN2-Signal

25

1

Reversal fan (option)

—

2

3

—

—

3

4

—

—

4

5

13

1

E

1

24

S

V

36

Pin No.

1

E S

V

CN1 12

—

— F/R switch (option) —

Lamp No.

Pin No.

24

19

—

20

Fuel gauge

6

21

T/C (T/M) oil temperature gauge

—

22

80Z562010

CN2-Signal

Lamp No.

—

— 4

—

—

5

Preheat lamp

8

23

6

4th speed indication

22

6

Declutch lamp

37

24

Charge lamp

16

7

3rd speed indication

22

7

—

25

Air cleaner clogging alarm

15

—

—

3 — —

8

2nd speed indication

22

8

Central alarm lamp

9

26

T/C (T/M) oil temperature alarm

14

9

1st speed indication

22

9

Neutral indication

21

27

Engine water temperature alarm

13

10

GND (–)

—

10

Turn signal (left) lamp

17

28

Engine oil pressure alarm

12

11

Backup battery

—

11

AUTO lamp

20

29

12

+24 V power supply

—

12

—

—

30

13

Speed meter

1

13

Instrument panel illumination

—

31

14

Parking brake lamp

— Brake alarm

— 11

—

5

14

High-beam lamp

19

32

15

—

—

15

Work lamp

7

33

E/G stop lamp

16

—

—

16

Turn signal (right) lamp

18

34

E/G warning lamp

30

17

—

—

17

—

35

—

—

18

—

—

18

10

36

—

—

19 20

— Hour meter

— 23

21

—

—

22

—

—

23

—

—

24

Engine water temperature gauge

2

— Controller failure alarm

—

— — 31

80ZV-2 EU 62-61 62 Function & Structure Electrical Group Instrument Panel and Switch

Gauge circuit

Controller

Grounding

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.

Power supply 24V

S V

Sensors respectively detect the temperature and fuel level, and then convert them into electric signals. The signals are transmitted to the corresponding gauges that indicate the transmitted values.

15V (S/N ~9350) 13V (S/N 9351~)

Viewed from rear surface of instrument panel K90ZV62016

(S/N ~9350) Gauge

Engine water temperature 97ºC(206ºF)

T/C, T/M oil temperature 110ºC(230ºF)

100ºC(212ºF)

35ºC(95ºF)

103ºC(217ºF)

Fuel level

100ºC(212ºF)

120ºC(248ºF)

50ºC(122ºF)

125ºC(257ºF)

Indication

White

Red

Red

White

White

Resistance between S and E ()

120~125

75~80

115~120

Resistance between S and V ()

120~125

85~90

115~120

Resistance between E and V ()

170~190

130~150

165~170

Engine water temperature

T/C, T/M oil temperature

Fuel level

(S/N 9351~) Gauge

67C° (152.6°F) 50C° (122°F)

125C° (257°F)

56C° 102C° (132.8°F) (215.6°F)

White

Indication

White Red

White

Red

Resistance between S and E ()

80~95

80~95

130~150

Resistance between S and V ()

26~30

26~30

26~30

Resistance between E and V ()

106~126

106~126

160~180

80ZV-2 EU 62-62 62 Function & Structure Electrical Group Instrument Panel and Switch Temperature sensor (For engine water temperature (S/N 9001~9100), torque converter oil temperature and hydraulic oil temperature)

2

1

115V2E62023

Temperature of detection part (ºC)

80 [176ºF]

90 [194ºF]

100 [212ºF]

120 [248ºF]

Resistance (k)

6.2~6.9

4.7~5.2

3.6~3.9

2.1~2.4

80ZV-2 EU 62-63 62 Function & Structure Electrical Group Instrument Panel and Switch

Fuel level sensor (S/N 9001~9128) Float arm

Float

344

(13.54 in)

344

(13.54 in)

FULL

Highest position

77.5

(3.05 in)

195.5

(7.7 in)

1/2

(A)

1/4

Support

Lowest position

EMPTY

85ZV62014

Fuel gauge

The sending unit float arm in the fuel tank moves by the fuel level movement in the tank. The contact installed on the float arm axis back side (A) also moves by contacting the resistance wire. The contact position is fixed, based on the float position and the fuel level. When the fuel level becomes low, the resistance value rises accordingly. The position of the fuel gauge pointer is decided by this resistance value, and the fuel gauge shows the fuel amount left in the tank.

F13 5A

Fuel level sensor

E Fuel level circuit K90V2J62007

Float position

FULL

1/2

1/4

EMPTY

Resistance ()

10 +1.0 - 0.5

(32)

49.5±4

85 +100

Note Figure in ( ) is for the reference resistance, at 1/2 way position in sweep.

80ZV-2 EU 62-64 62 Function & Structure Electrical Group Instrument Panel and Switch

(S/N 9129~)

(S/N 9273~)

Fuel gauge

The sending unit float arm in the fuel tank moves by the fuel level movement in the tank. The contact installed on the float arm axis back side (A) also moves by contacting the resistance wire. The contact position is fixed, based on the float position and the fuel level. When the fuel level becomes low, the resistance value rises accordingly. The position of the fuel gauge pointer is decided by this resistance value, and the fuel gauge shows the fuel amount left in the tank.

F13 5A

Fuel level sensor

E Fuel level circuit K90V2J62007

Float position

FULL

1/2

1/4

EMPTY

Resistance ()

10 +1.0 -3

(32)

49.5±4

85 +100

Note Figure in ( ) is for the reference resistance, at 1/2 way position in sweep.

80ZV-2 EU 62-65 62 Function & Structure Electrical Group MODM

MODM Monitor Changeover

(Machine Operation Diagnostic Module)

[ ]button

Display window

[

]button

[ (step back)] [ (step forward)] button button

Replacement monitor

Fault log monitor

Information monitor

Input/Output monitor

Specification setting monitor

Parameter setting monitor

90ZV-262001

MODM function The MODM has the following functions:

Change over the monitor using the following procedure: When the starter switch is ON, the MODM software version displays for 3 seconds.

- Information monitor Displays outside air temperature, machine speed and engine speed, engine coolant temperature, transmission oil temperature, hydraulic oil temperature and miles driven etc.

80V2U62001

After this, machine information screen displays information relative to the machine function.

- Replacement monitor Allows check of the replacement time for the parts and oil periodically replaced, allows setting of the replacement interval, and displays the replacement pop-ups. - Fault log monitor Allows check of previous errors, and displays active errors. - Input/Output monitor - Parameter setting monitor Allows check and change of the parameter setting. - Specification setting monitor Allows check and change of the specification setting.

80V2U62002

80ZV-2 EU 62-66 62 Function & Structure Electrical Group MODM

Changing display from one function to next Press both the [ (step back)] button and [ (step forward)] button at the same time to change over the monitor mode in sequence "Information monitor  Replacement monitor  Fault log monitor  Input/Output monitor  Parameter setting monitor  Specification setting monitor Information monitor".

From Information monitor to Replacement monitor: Press both the [ (step back)] and [ ward)] buttons at the same time. Display should now appear as shown below.

However the monitor mode can not be changed in reverse such as "Information monitor  Specification setting monitor  Parameter setting monitor ....." The display will not be changed to the next monitor when you hold the buttons. For the display sequence, refer to "Outline of MODM (Machine Operation Diagnostic Module) Operation" page 92-53.

(step for-

90ZV-262034

By pressing the [ (step forward)] button or [ (step back)] button you may then continue to navigate through the items that should be replaced at given service intervals.

From Replacement monitor to Fault log monitor: Press both the [ (step back)] and [ ward)] buttons at the same time.

(step for-

70V2U62016

Display should appear as shown. (Example: Downshift button malfunction) This screen shows fault logs or inactive fault codes and provides a chronological date and time line of when they occurred. By pressing the [ (step forward)] button or [ (step back)] button you may then continue to navigate through inactive codes. Up to 100 are stored. In the upper left corner you will notice a numerical sequence of number between 01~00. This represents faults 1~100 as they have been logged.

80ZV-2 EU 62-67 62 Function & Structure Electrical Group MODM

From Fault log monitor to Input/Output monitor:

From Specification setting monitor to Information monitor:

Press both the [ (step back)] and [ ward)] buttons at the same time.

Press both the [ (step back)] and [ ward)] buttons at the same time.

(step for-

80V2U62004

With the shift lever in "Neutral" and "Automatic", the screen should appear as above. This screen shows the "Input and Output" signal data.

From Input/Output monitor to Parameter setting monitor: Press both the [ (step back)] and [ ward)] buttons at the same time.

(step for-

80V2U62005

Display should appear similar to above. This screen shows "Parameter settings" and may be used to make changes in an already validated parameter.

From Parameter setting monitor to Specification setting monitor: Press both the [ (step back)] and [ ward)] buttons at the same time.

(step for-

70V2U62017

Display should appear similar to above. This screen shows "Specification settings" and may be used to make changes in a MODM to validate or invalidate a given parameter; effectively turning ON or OFF the function of an option.

(step for-

80V2U62002

While in default temperature screen, the password input screen can be seen by simultaneously pressing the [ ] and [ ] buttons. When the password input is finished, fuel consumption can be seen. Pressing [ ] button toggles between metric and US values.

80ZV-2 EU 62-68 62 Function & Structure Electrical Group MODM

Information Monitor

1. Outside air temperature

(Refer to page 92-55)

Information monitor display 90ZV-262024

The following items are displayed: When the starter switch is ON, the software version displays for 3 seconds, then shows default screen.

The monitor displays the current outside air temperature when the starter switch is ON. Press the [ ] button to change over the display unit from "ºC" to "ºF". Press the [ ] button again to return the display unit from "ºF" to "ºC".

90ZV-262024

2. Machine speed and engine speed To toggle between metric standard values (ºC, MPa, km/h, etc.) and US standards (ºF, PSI, MPH, etc.), press the [ ] button.

Press the [

(step forward)] button and release.

To get fuel consumption data, press the [ ] and [ ] buttons simultaneously and release, as seen below.

90ZV-262025

You will now be at the screen shown above. 90ZV-262023

When the password input is finished, you will now be at the screen shown below.

This indicates the actual machine speed and engine revolutions. This is useful for determining items like shift mapping patterns in relationship to speed range selection. For speed to be accurate, the correct tire size must be entered into the main MCU via this MODM unit.

80V2U62007

To leave this screen, press the [ ] and [ ] buttons simultaneously again. Every time the [ (step forward)] button is pressed, the displayed contents are changed "Machine speed and engine speed  Engine coolant temperature  Transmission oil temperature  Hydraulic oil temperature" in sequence. Every time the [ (step back)] button is pressed, the displayed contents are changed over in sequence "Hour meter  Voltage  Boom cylinder oil pressure  Cycle". For the display sequence, refer to "Outline of MODM (Machine Operation Diagnostic Module) Operation" page 92-53 and 92-55.

Press the [ ] button to change the display unit from "km/h" to "mph" Press the [ ] button again to return the display unit from "mph" to "km/h".

80ZV-2 EU 62-69 62 Function & Structure Electrical Group MODM

3. Current engine coolant temperature and maximum engine coolant temperature recorded (which can be reset)

4. Current transmission oil temperature and maximum transmission oil temperature recorded (which can be reset)

Press the [

Press the [

(step forward)] button and release.

(step forward)] button and release.

90ZV-262026

90ZV-262027

You will now be at the screen shown above.

You will now be at the screen shown above.

The monitor displays the current engine coolant temperature in the "EG COOLANT" line and maximum engine coolant temperature for the day in the "MAX" line. This self resets daily at 24:00 (12:00 Midnight).

The monitor displays the current transmission oil temperature in the "TC OIL" line and maximum transmission oil temperature for the day in the "MAX" line. This self resets daily at 24:00 (12:00 Midnight).

Even if the engine is stopped once and then started again, if the time is before 24:00, the monitor displays the maximum engine coolant temperature recorded on the day.

Even if the engine is stopped once and then started again, if the time is before 24:00, the monitor displays the maximum transmission oil temperature recorded on the day.

The maximum engine coolant temperature is automatically reset everyday at 24:00, whether the engine starter switch is turned on or off.

The maximum transmission oil temperature is automatically reset everyday at 24:00, whether the engine starter switch is turned on or off.

Immediately after reset, the engine coolant temperature at the time of reset is displayed as the maximum engine coolant temperature. In other words, the current engine coolant temperature is equivalent to the maximum engine coolant temperature.

Immediately after reset, the transmission oil temperature at the time of reset is displayed as the maximum transmission oil temperature. In other words, the current transmission oil temperature is equivalent to the maximum transmission oil temperature.

To manually reset, press the [ ] button to reset the maximum engine coolant temperature. Immediately after reset, the engine coolant temperature at the time of reset is displayed as the maximum engine coolant temperature.

To manually reset, press the [ ] button to reset the maximum transmission oil temperature. Immediately after reset, the transmission oil temperature at the time of reset is displayed as the maximum transmission oil temperature.

Press the [ ] button to change over the display unit from "ºC" to "ºF". Press the [ ] button again to return the display unit from "ºF" to "ºC".

Press the [ ] button to change over the display unit from "ºC" to "ºF". Press the [ ] button again to return the display unit from "ºF" to "ºC".

80ZV-2 EU 62-70 62 Function & Structure Electrical Group MODM

5. Current hydraulic oil temperature and maximum hydraulic oil temperature recorded (which can be reset)

6. Odometer (total miles driven) and trip meter (which can be reset) Press the [

Press the [

(step forward)] button and release.

(step forward)] button and release.

90ZV-262029 90ZV-262028

You will now be at the screen shown above. You will now be at the screen shown above. The monitor displays the current hydraulic oil temperature in the "HYD OIL" line and maximum hydraulic oil temperature for the day in the "MAX" line. This self resets daily at 24:00 (12:00 Midnight). Even if the engine is stopped once and then started again, if the time is before 24:00, the monitor displays the maximum hydraulic oil temperature recorded on the day. The maximum hydraulic oil temperature is automatically reset everyday at 24:00, whether the engine starter switch is turned on or off. Immediately after reset, the hydraulic oil temperature at the time of reset is displayed as the maximum hydraulic oil temperature. In other words, the current hydraulic oil temperature is equivalent to the maximum hydraulic oil temperature. To manually reset, press the [ ] button to reset the maximum hydraulic oil temperature. Immediately after reset, the hydraulic oil temperature at the time of reset is displayed as the maximum hydraulic oil temperature. Press the [ ] button to change over the display unit from "ºC" to "ºF". Press the [ ] button again to return the display unit from "ºF" to "ºC".

The monitor displays the total number of miles that machine is operated in top line and miles for operator selected time frame the trip meter in lower line. This logs miles in forward and reverse. Press the [ ] button to reset the trip meter displayed in lower line. Press the [ ] button to change over the display unit from "km" to "mile". Press the [ ] button again to return the display unit from "mile" to "km".

7. Number of cycles and cycle time Press the [

(step forward)] button and release.

90ZV-262030

You will now be at the screen shown above. The monitor displays the number of cycles in the upper line and the time required for one cycle (moving forward and backward twice) in the lower line. This can be used to determine comparative production data between operators and between working sites. Press the [ ] button to reset both the number of cycles and the cycle time. After reset, the monitor displays newly the number of cycles in the upper line and the time required for one cycle in the lower line.

80ZV-2 EU 62-71 62 Function & Structure Electrical Group MODM

8. Hydraulic system oil pressure

Unit conversion and language selection

Press the [

Select the unit and language using the [ ] button.

(step forward)] button and release.

Unit conversion (for traveling distance, temperature and pressure) 80V2U62008

Press the [ ] button once to change the display unit. Press the [ ] button again to return to the previous display unit.

You will now be at the screen shown above. The monitor displays the unloader pressure of the efficient loading system (ELS). Press the [ ] button to change over the display unit from "MPa" to "psi". Press the [ ] button again to return the display unit from "psi" to "MPa".

Language selection Press and hold the [ ] button for 3 seconds or longer to get language selection screen.

9. Voltage Press the [

80V2U62009

(step forward)] button and release. You will now be at the screen shown above. English is selected as the initial setting. 90ZV-262032

You will now be at the screen shown above.

Japanese, French, German, Italian, Spanish, Turkish, Dutch and English can also be selected.

Shows complete electrical system voltage as is seen at the battery level.

Press the [ (step forward)] button or [ back)] button to view the language selections.

Note If voltage drops below 27 V DC, the hibernate mode (lowers RPM’s to conserve fuel) will not work.

For returning to the information monitor after selecting the desired language, press and hold the [ ] button for 2 seconds or longer.

10. Hour meter (total operating hours) and trip meter (which can be reset) Press the [

(step forward)] button and release.

90ZV-262033

You will now be at the screen shown above. The monitor displays total operating hours in upper line, and trip meter hours in lower line. Press the [ ] button to reset the trip meter displayed in the lower line.

(step

For returning to the information monitor without selecting another language, press the [ ] button. Refer to "Main Menu" page 92-54.

80ZV-2 EU 62-72 62 Function & Structure Electrical Group MODM

Replacement Monitor

2. Fuel filter

(Refer to page 92-56)

Press the [

(step forward)] button and release.

Replacement time check 1. Engine oil filter

80V2U62010

Press both the [ (step forward)] and [ (step back)] buttons simultaneously to change over the screen from the information monitor to the replacement monitor.

90ZV-262034

You will now be at the screen shown above.

You will now be at the screen shown above. The display window displays remaining time until next replacement of fuel filter cartridge. Note If an exclamation mark shows before the numbers that indicate hours, this shows how many hours overdue the filter is. Ex. "!12 h" indicates that it is 12 hours overdue.

The display window first displays the remaining time until next replacement of the engine oil filter cartridge. This interval is based on using low sulfur fuel and when engine oil sulfur content is less than 0.5 %. If engine oil sulfur content exceeds 0.5 %, this interval must be cut in half. Note If an exclamation mark shows before the numbers that indicate hours, this shows how many hours overdue the filter is. Ex. "!12 h" indicates that it is 12 hours overdue.

80V2U62079

Note Make sure to set the replacement interval (timer reset) whenever the engine oil filter is replaced.

70V2U62018

Note Make sure to set the replacement interval (timer reset) whenever the fuel filter is replaced. It may be necessary to change this filter more frequently, depending on fuel cleanness.

80ZV-2 EU 62-73 62 Function & Structure Electrical Group MODM

3. Coolant filter (80ZV-2 ~ 135ZV-2 only)

4. Torque converter and transmission filter

Press the [

Press the [

(step forward)] button and release.

(step forward)] button and release.

80V2U62011

80V2U62012

You will now be at the screen shown above.

You will now be at the screen shown above.

The display window displays remaining time until next replacement of the engine coolant filter cartridge.

The display window displays remaining time until next replacement of the torque converter and transmission filter cartridge.

Note If an exclamation mark shows before the numbers that indicate hours, this shows how many hours overdue the filter is.

Note If an exclamation mark shows before the numbers that indicate hours, this shows how many hours overdue the filter is.

Ex. "!12 h" indicates that it is 12 hours overdue. Ex. "!12 h" indicates that it is 12 hours overdue.

70V2U62019 70V2U62020

Note Make sure to set the replacement interval (timer reset) whenever the coolant filter is replaced. It may be necessary to change this filter more frequently, depending on engine coolant condition.

Note Make sure to set the replacement interval (timer reset) whenever the torque converter and transmission filter is replaced. It may be necessary to change this filter more frequently, depending on transmission oil cleanness.

80ZV-2 EU 62-74 62 Function & Structure Electrical Group MODM

5. Hydraulic return filter

6. Engine oil

Press the [

Press the [

(step forward)] button and release.

(step forward)] button and release.

80V2U62013

80V2U62014

You will now be at the screen shown above.

You will now be at the screen shown above.

The display window displays remaining time until next replacement of hydraulic return filter.

The display window displays remaining time until next replacement of engine oil.

Note If an exclamation mark shows before the numbers that indicate hours, this shows how many hours overdue the hydraulic return filter change is.

Note If an exclamation mark shows before the numbers that indicate hours, this shows how many hours overdue the oil change is.

Ex. "!12 h" indicates that it is 12 hours overdue.

Ex. "!12 h" indicates that it is 12 hours overdue.

70V2U62021

Note Make sure to set the replacement interval (timer reset) whenever the hydraulic return filter is replaced.

70V2U62022

Note Make sure to set the replacement interval (timer reset) whenever engine oil is replaced. It may be necessary to change this oil more frequently, depending on work site conditions, oil sampling results and oil cleanness.

80ZV-2 EU 62-75 62 Function & Structure Electrical Group MODM

7. Torque converter and transmission oil

8. Axle oil

Press the [

Press the [

(step forward)] button and release.

(step forward)] button and release.

80V2U62015

80V2U62016

You will now be at the screen shown above.

You will now be at the screen shown above.

The display window displays remaining time until next replacement of torque converter and transmission oil.

The display window displays remaining time until next replacement of both front and rear axle and planetary unit oils.

Note If an exclamation mark shows before the numbers that indicate hours, this shows how many hours overdue the oil change is.

Note If an exclamation mark shows before the numbers that indicate hours, this shows how many hours overdue the oil change is.

Ex. "!12 h" indicates that it is 12 hours overdue. Ex. "!12 h" indicates that it is 12 hours overdue.

70V2U62023 70V2U62024

Note Make sure to set the replacement interval (timer reset) whenever torque converter and transmission oil is replaced.

Note Make sure to set the replacement interval (timer reset) whenever axle oil is replaced.

It may be necessary to change this oil more frequently, depending on work site conditions, oil sampling results and oil cleanness.

It may be necessary to change this oil more frequently, depending on work site conditions, oil sampling results and oil cleanness.

80ZV-2 EU 62-76 62 Function & Structure Electrical Group MODM

9. Hydraulic oil

Replacement interval set (timer reset)

Press the [

When the machine is shipped, the standard replacement interval is set as the initial setting.

(step forward)] button and release.

80V2U62017

You will now be at the screen shown above. The display window displays remaining time until next replacement of hydraulic oil. Note If an exclamation mark shows before the numbers that indicate hours, this shows how many hours overdue the oil change is. Ex. "!12 h" indicates that it is 12 hours overdue.

70V2U62025

Note Make sure to set the replacement interval (timer reset) whenever hydraulic oil is replaced. It may be necessary to change this oil more frequently, depending on work site conditions, oil sampling results and oil cleanness.

Press and hold the [ ] button for 2 seconds or more on the replacement monitor screen to display the timer reset screen. The timer reset screen displays the standard replacement interval. For setting the standard replacement interval, press the [ ] button. Then, the standard replacement interval is set, and it returns to the replacement monitor screen again.

80ZV-2 EU 62-77 62 Function & Structure Electrical Group MODM

Replacement interval pop-up

Example: Engine oil

90ZV-262037

When the remaining time until the next replacement interval reaches " 0 " (or 0 hours), the replacement popup appears and flashes in the display window.

For setting the replacement interval other than the standard replacement interval, follow the procedure below: 90ZV-262038

 50  100 (2 seconds or more)  50  100 (2 seconds or more) Press the [ (step forward)] button once to add "50" hours. Press the [ (step forward)] button twice to add "100" hours. Press the [ (step forward)] button three times to add "150" hours. "50" hours is added every time the [ (step forward)] button is pressed. Every time the [ (step back)] button is pressed, "50" hours is subtracted. When the [ (step forward)] button is pressed and held for 2 seconds or more, "100" hours is added continuously. It means that "100", "200", "300" hours ..... is added in 100 hour increments. 90ZV-262039

When the [ (step back)] button is pressed and held for 2 seconds or more, "100" hours is subtracted continuously in the same manner. After setting the replacement interval, press and hold the [ ] button for 2 seconds or more. The replacement interval is reset, and the display returns to the replacement monitor screen again.

When two or more replacement pop-ups occur at the same time, the corresponding items flash in turn. After the remaining time for the next replacement reaches " 0 ", the corresponding pop-up appears up to three times when the starter switch is ON. (The MODM software version is displayed for 3 seconds, and then the replacement pop-up flashes.) When the [ (step forward)] button, [ (step back)] button, [ ] button or [ ] button is pressed, it returns to the previous screen again. After replacing the corresponding filter or oil, return to the timer reset screen and set the replacement interval. Refer to the replacement interval set (timer reset) procedure above.

80ZV-2 EU 62-78 62 Function & Structure Electrical Group MODM

Display language The same language selected in the information monitor is used as the display language for the replacement monitor. For selecting the display language, it is necessary to return to the information monitor. The display language can be selected only on the information monitor screen.

Fault Log Monitor (Refer to page 92-57) Start from key ON. Press the [ (step back)] button and [ (step forward)] button together twice to get to this point.

Fault log history check 1. Active faults

For returning from the replacement monitor to the information monitor, change the monitor in turn as described in the sequence "Replacement monitor [ ][ ] (pressing them at the same time)  Fault log monitor [ ][ ] (pressing them at the same time)  Input/ Output monitor [ ][ ] (pressing them at the same time)  Parameter setting monitor [ ][ ] (pressing them at the same time)  Specification setting monitor [ ][ ] (pressing them at the same time)  Information monitor". For the display sequence, refer to "Outline of MODM (Machine Operation Diagnostic Module) Operation" page 92-53.

Up to 100 machine faults and 100 engine faults can be recorded in fault log (200 total). Failure codes that begin with CN are machine faults. (CN=Chassis fault #) Failure codes that begin with EN are engine faults. (EN=Engine fault #) What is shown The following list of items are shown. Fault descriptor, fault code number, date of occurrence and hour-minutesecond of occurrence. Examples shown below. This shows fault CN321. This is caused by an engine coolant temperature fault (open circuit). Note descriptions.

Fault descriptor

Date July 20, 2006

Fault code

Time in 24:00 hour scale 3:27:32 PM 80V2U62018

This shows fault EG146. This is caused by an engine coolant temperature fault (overheat condition).

80V2U62019

Fault codes are split into input and output signals.

80ZV-2 EU 62-79 62 Function & Structure Electrical Group MODM

2. Inactive faults (Checking history )

Selection of machine fault log and engine fault log

Again, up to 100 machine faults and 100 engine faults can be recorded in the fault log (200 faults total). Failure codes that begin with CN are machine faults.

You can toggle between viewing the engine faults or machine faults.

Failure codes that begin with EN are engine faults.

Machine fault

What is shown The following list of items are shown. Order of occurrences, fault code number, date, hour-minute-second, and frequency of occurrence. Examples shown below.

When the machine fault log screen is displayed, press and hold the [ (step forward)] button for 2 seconds or more to display the engine fault log screen which shows the latest engine fault code.

This shows fault CN321. This is caused by an engine coolant temperature fault (open circuit). Note descriptions.

Order of occurrences 100 total 01~00 Fault code number

A=Active fault 002 is qty of occurrences

80V2U62022

Engine fault When the engine fault log screen is displayed, press and hold the [ (step back)] button for 2 seconds or more to display the machine fault log screen which shows the latest machine fault code.

Date July 20, 2006

Time in 24:00 hour scale 3:27:32

80V2U62023 80V2U62020

This shows fault EG146. This is caused by an engine coolant temperature fault (overheat condition). Note descriptions.

Order of occurrences 100 total 01~00 Fault code number

Date July 25, 2006

A=Active fault 016 is qty of occurrences

Time in 24:00 hour scale 1:31:38 80V2U62021

..... If still active, shows "A" before fault number.

The machine fault log screen and engine fault log screen can be distinguished as follows: Displayed fault code: CN ..... Machine fault log screen EG ..... Engine fault log screen

80ZV-2 EU 62-80 62 Function & Structure Electrical Group MODM

Machine fault log navigation When two or more fault codes are recorded, press the [ (step forward)] button to display the next latest fault code. Press the [ (step back)] button to display the fault code in chronological order.

Engine fault log navigation When two or more fault codes are recorded, press the [ (step forward)] button to display the next latest fault code. Press the [ (step back)] button to display the fault code in chronological order.

Clear fault log Clear inactive fault log Fault codes can be cleared by pressing the [ ] button and holding it for more than 2 seconds while in the engine fault mode, or in the machine fault mode screens. Note When pressing the [ ] button to clear a fault code, password entry is required on the 80ZV-2 S/N 9201 and thereafter. The password must be acquired from the Kawasaki Service Representative and is not for general public use as it can cause troubles if the necessary troubleshooting information is deleted. If you have the password, write it in the value entry blanks provided below. ———— DO NOT GIVE THIS PASSWORD OUT TO CUSTOMERS OR END USERS! Press and hold the [ ] button for 2 seconds or more to clear the entire fault log. When there are two or more fault codes recorded, all fault codes recorded are cleared by performing the clear fault log operation once. Press the [ ] button not to clear the fault log and to return to the machine fault log screen again. Note To clear engine fault codes, you must be in the engine fault screen. To clear machine fault codes, you must be in the machine fault screen. Individual faults cannot be cleared only one at a time. All engine or machine faults are cleared at once. Note any fault codes prior to erasing them from memory, in case you need that information later. After engine fault codes (EGXXX) or machine fault codes (CNXXX) have been cleared, the buzzer will sound to alert that the code has been erased from memory. If you do not hear the buzzer, the fault codes have not been erased from memory history.

80ZV-2 EU 62-81 62 Function & Structure Electrical Group MODM

Clear active fault log (error pop up) (S/N 9001~9101, 9103, 9104 only) When a fault occurs, the corresponding fault code is forcibly displayed on the screen. When two or more active faults occur, up to 5 fault codes each are displayed repeatedly. (Up to total 10 fault codes for CN and EG errors together) For deleting the displayed fault codes, press one of the [ (step forward)] button, [ (step back)] button, [ ] button or [ ] button.

80V2U62024

Then, the screen displayed before the active fault codes appears again. Active fault codes are displayed repeatedly when the starter switch is ON and will continue to display until the cause of each fault code is eliminated. If there is a fault that has been erased, and the cause is not repaired, the fault will quickly reappear in the screen due to being active. It will continue to reappear until the underlying cause of the fault is eliminated.

80ZV-2 EU 62-82 62 Function & Structure Electrical Group MODM

Failure code (Input side) Code

Failure

Detection condition (In case of)

CN121

Shift lever F & R switch malfunction

Shift lever F & R contact ON at the same time Failure continues for more than 3 seconds

CN122

Shift lever 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 (30 seconds from program ver. 100915)

CN123

Shift lever 1•2•3•A switch malfunction (2)

All 1•2•3•A signal OFF continues for more than 3 seconds (30 seconds from program ver. 100915)

CN141

Shift-up switch malfunction

Switch is ON for more than 10 seconds

CN142

Shift-down switch malfunction

Switch is ON for more than 10 seconds

CN143

Shift-up switch & shift-down switch malfunction

Shift-up switch & shift-down switch contact ON at the same time Failure continues for more than 3 seconds

CN145

Kick-down switch malfunction

Switch is ON for more than 10 seconds

CN146

Shift hold switch malfunction

Switch is ON for more than 10 seconds

CN151

T/M oil pressure switch malfunction (This applies to the model 115ZV-2/135ZV-2 only)

Signal OFF continues for more than 10 seconds during engine running

CN152

T/M oil pressure sensor malfunction (This applies to the model 95ZV-2 only)

T/M pressure below 294 kPa (3.0 kgf/cm2) (43 psi) continues for more than 10 seconds during engine running

CN161

Machine speed sensor malfunction (1)

Input circuit is disconnected for more than 3 seconds

CN162

Machine speed sensor malfunction (2)

Input value is over 70 km/h (44 mile/h) for more than 3 seconds

CN163

E/G speed sensor 1 (ECM output) malfunction (1)

No E/G speed sensor input for more than 3 seconds when E/G speed sensor selection is OFF (Input circuit is disconnected)

CN164

E/G speed sensor 1 (ECM output) malfunction (2)

Input value is more than 3,000 min-1 for more than 3 seconds when E/G speed sensor selection is OFF

CN165

E/G speed sensor 2 (Sensor output) malfunction (1)

No E/G speed sensor input for more than 3 seconds when E/G speed sensor selection is ON (Input circuit is disconnected)

CN167

E/G speed sensor 2 (Sensor output) malfunction (2)

Input value is more than 3,000 min-1 for more than 3 seconds when E/G speed sensor selection is ON

CN213

Inching sensor malfunction (1)

Voltage is lower than 0.2 V for more than 3 seconds

CN214

Inching sensor malfunction (2)

Voltage is larger than 4.6 V for more than 3 seconds

CN232

S/S potentiometer malfunction (1)

Voltage is lower than 0.1 V for more than 3 seconds

CN234

S/S potentiometer malfunction (2)

Voltage is larger than 4.9 V for more than 3 seconds

CN236

S/S shift switch (F & R contact) malfunction

Failure continues for more than 3 seconds

CN251

Secondary steering oil pressure sensor malfunction (1)

Voltage is lower than 0.2 V for more than 3 seconds

CN252

Secondary steering oil pressure sensor malfunction (2)

Voltage is larger than 4.6 V for more than 3 seconds

CN254

Low secondary steering oil pressure

Oil pressure sensor detects secondary steering oil pressure below 306 kPa (3.1 kgf/cm2) (44 psi) for more than 3 seconds during engine running

CN262

Kickout potentiometer malfunction (1)

Voltage is lower than 0.2 V for more than 3 seconds

CN263

Kickout potentiometer malfunction (2)

Voltage is larger than 4.6 V for more than 3 seconds

CN271

Efficient loading system hydraulic oil pressure senVoltage is lower than 0.2 V for more than 3 seconds sor malfunction (1)

CN272

Efficient loading system hydraulic oil pressure senVoltage is larger than 4.6 V for more than 3 seconds sor malfunction (2)

CN312

Brake oil pressure sensor 1 malfunction (1)

Voltage is lower than 0.2 V for more than 3 seconds

CN313

Brake oil pressure sensor 1 malfunction (2)

Voltage is larger than 4.6 V for more than 3 seconds

CN315

Brake oil pressure sensor 2 malfunction (1)

Voltage is lower than 0.2 V for more than 3 seconds

CN316

Brake oil pressure sensor 2 malfunction (2)

Voltage is larger than 4.6 V for more than 3 seconds

CN321

E/G coolant temperature sensor malfunction (1)

Input voltage is larger than 3.56 V for more than 3 seconds

CN323

E/G coolant temperature sensor malfunction (2)

Input voltage is lower than 0.263 V for more than 3 seconds

CN341

T/M oil temperature sensor malfunction (1)

Input voltage is larger than 3.56 V for more than 3 seconds

CN342

T/M oil temperature sensor malfunction (2)

Input voltage is lower than 0.263 V for more than 3 seconds

80ZV-2 EU 62-83 62 Function & Structure Electrical Group MODM

Code

Failure

Detection condition (In case of)

CN351

Hydraulic oil temperature sensor malfunction (1)

Input voltage is larger than 3.56 V for more than 3 seconds

CN352

Hydraulic oil temperature sensor malfunction (2)

Input voltage is lower than 0.263 V for more than 3 seconds

CN381

Fuel level sensor malfunction

Input signal corresponds to "any other pattern" in fuel level indication table

CN391

Air temperature probe malfunction (1)

Input voltage is larger than 4.35 V for more than 3 seconds

CN392

Air temperature probe malfunction (2)

Input voltage is lower than 0.13 V for more than 3 seconds

CN412

Abnormal brake oil pressure (1)

Brake oil pressure sensor 1 detects pressure below 4,081 kPa (41.6 kgf/ cm2) (592 psi) for more than 1 second during engine running

CN413

Abnormal brake oil pressure (2)

Brake oil pressure sensor 2 detects pressure below 4,081 kPa for (41.6 kgf/cm2) (592 psi) more than 1 second during engine running

CN414

Abnormal brake oil pressure difference

Brake oil pressure difference switch is in abnormal condition for more than 1 second

CN415

Abnormal brake oil amount

Brake oil amount switch is in abnormal condition for more than 1 second

CN421

Abnormal engine oil pressure

Engine oil pressure switch is OFF for more than 2 seconds during engine running

CN431

Abnormal engine coolant temperature (1)

Engine coolant temperature switch is ON for more than 2 seconds

CN432

Abnormal engine coolant temperature (2)

Engine coolant temperature sensor is in 101 deg. C (214 deg. F) condition for more than 2 seconds

CN451

Abnormal T/M oil temperature (1)

T/M oil temperature switch is ON for more than 2 seconds

CN452

Abnormal T/M oil temperature (2)

T/M oil temperature sensor is in 122 deg. C (252 deg. F) condition for more than 2 seconds

CN461

Abnormal hydraulic oil temperature

Hydraulic oil temperature sensor is in 100 deg. C (212 deg. F) condition for more than 2 seconds

CN471

Clogged T/M oil filter

30 minutes after starter switch is ON, T/M oil filter switch is ON for more than 2 seconds when T/M oil temperature sensor detects oil temperature more than 60 deg. C (140 deg. F)

CN481

Clogged air cleaner element

Air cleaner switch is ON for more than 2 seconds

CN491

Abnormal cooling water level in radiator

Radiator cooling water level switch is OFF for more than 2 seconds when the engine is off.

CN496

Abnormal hydraulic oil level

Hydraulic oil level switch is in abnormal condition for more than 30 seconds

CN497

Abnormal brake disc oil temperature (This applies to the model 135ZV-2 only)

Brake disc oil temperature switch is ON for more than 1 second

CN498

Abnormal disc wear (This applies to the model 135ZV-2 only)

Brake disc wear switch is ON for more than 1 second

CN801

CAN disconnect

CAN line is disconnected

CN802

Abnormal engine coolant temperature (CAN)

No engine coolant temperature data received for more than 3 seconds

CN912

Abnormal MCU voltage (1)

Voltage is larger than 32±1 V

CN913

Abnormal MCU voltage (2)

Voltage is lower than 22±0.5 V for more than 10 seconds during engine running

(CN_In 14F05)

Fuel level display table Input 1/8

1/4

x

Note This table applies to the 95/115/135ZV-2 units.

Output

1/2

3/4

x

x

x

x

x

x

x

x

x

x

x

—

x

x

—

—

x

—

—

—

—

—

—

—

—

—

—

—

Other than above : No input signal given x : Input signal given

F

E

: Lamp on — : Lamp off

1/4

1/2

3/4

F

—

—

—

—

—

—

—

—

—

—

—

—

— —

: Lamp flashing

—

80ZV-2 EU 62-84 62 Function & Structure Electrical Group MODM

Failure code (Output side) Code

Failure

Detection condition

CN512

F solenoid valve malfunction

F solenoid valve is short-circuited or disconnected

CN514

R solenoid valve malfunction

R solenoid valve is short-circuited or disconnected

CN516

1st solenoid valve malfunction

1st solenoid valve is short-circuited or disconnected

CN518

2nd solenoid valve malfunction

2nd solenoid valve is short-circuited or disconnected

CN521

3rd solenoid valve malfunction

3rd solenoid valve is short-circuited or disconnected

CN524

4th solenoid valve malfunction

4th solenoid valve is short-circuited or disconnected

CN526

D solenoid valve malfunction

D solenoid valve is short-circuited or disconnected

CN528

H solenoid valve malfunction

H solenoid valve is short-circuited or disconnected

CN531

LU solenoid valve malfunction

LU solenoid valve is short-circuited or disconnected

CN534

Auto brake solenoid valve malfunction

Auto brake solenoid valve is short-circuited or disconnected

CN536

Speed change control solenoid valve malfunction (1)

Speed change control solenoid valve is short-circuited

CN537

Speed change control solenoid valve malfunction (2)

Speed change control solenoid valve is disconnected

CN621

S/S solenoid valve R malfunction (1)

S/S solenoid valve R is short-circuited

CN622

S/S solenoid valve R malfunction (2)

S/S solenoid valve R is disconnected

CN623

S/S solenoid valve L malfunction (1)

S/S solenoid valve L is short-circuited

CN624

S/S solenoid valve L malfunction (2)

S/S solenoid valve L is disconnected

CN631

Pressure increase solenoid valve malfunction

Pressure increase solenoid valve is short-circuited or disconnected

CN641

Ride control solenoid valve malfunction

Ride control solenoid valve is short-circuited or disconnected

CN681

Efficient loading system selection solenoid valve malfunction

Efficient loading system selection solenoid valve is short-circuited or disconnected

CN712

Cooling fan solenoid valve malfunction (1)

Cooling fan solenoid valve is short-circuited

CN713

Cooling fan solenoid valve malfunction (2)

Cooling fan solenoid valve is disconnected

CN721

Hour meter drive malfunction

Hour meter drive is short-circuited

(CN_Out 14F05)

Failure code (Engine) Refer to "Quantum fault code information" page 62-28.

80ZV-2 EU 62-85 62 Function & Structure Electrical Group MODM

Input/Output Monitor

By pressing the [ (step forward)] button, you will arrive at a window as shown below.

(Refer to page 92-58)

Input/Output monitor display 80V2U62026

1. Input signal monitor From a position of turning on the key switch, press both the [ (step back)] and [ (step forward)] buttons simultaneously 3 times, you will arrive at the screen shown below.

80V2U62025

This is because in window 2, it shows the parking brake as being released and the corresponding slot would have a 1 in that place. In other words, the parking brake coil has been energized and the slot has a 1 in it indicating that it is energized and the parking brake is released. Now press the [ (step forward)] button once. You will arrive at the screen shown below.

This is the beginning of the section for input and output signal display. 80V2U62027

Input signal monitor (D1~D7) This monitor displays the ON/OFF status of the shift lever, setting switches, pressure switches, etc. There are seven input groups from INPUT 1 to INPUT 7.

Nothing in this case is activated, so all of the slots are occupied with the number 0. Now press the [ (step forward)] button once. You will arrive at the screen shown below.

Each group has eight items from item 0 to 7. When input signal is ON, "1" is displayed under corresponding item number.

80V2U62028

When input signal is OFF, "0" is displayed under corresponding item number.

The screen indicates that ride control and ELS are activated, or the switch for each one is energized.

Refer to "MODM: Input/Output Monitor - Input/Output Signal Correspondence Table" page 92-62.

Now press the [ (step forward)] button once. You will arrive at the screen shown below.

As shown in table of section "MODM: Input/Output Monitor - Input/Output Signal Correspondence Table" that follows, the selection below reflects that forward and automatic have been selected by the shift lever.

80V2U62029

This indicates that the engine is running as the place for alternate neutral voltage under slot 3 is occupied by a 1. 80V2U62025

80ZV-2 EU 62-86 62 Function & Structure Electrical Group MODM Now press the [ (step forward)] button once. You will arrive at the screen shown below.

2. Current output monitor Every time the [ (step forward)] button is pressed and held for 2 seconds, the displayed contents are changed. First item seen is as shown below.

80V2U62030

This indicates that there are no inputs happening in this situation.

Note The [ (step back)] or [ (step forward)] button must be held for 2 seconds or more with each change. If not, it will not move to next item.

Now press the [ (step forward)] button once. You will arrive at the screen shown below.

If the feature is set to "Invalid" in specification setting, the following items will be skipped. - STEERING PRESS - SP7 (Secondary steering)

80V2U62031

- BOOM ANGLE - SP15 (Lift kickout)

This indicates that there are inputs for a full fuel tank, the machine is equipped with an optional reversing fan, and the switch for the fan is in the "ON" or energized position. Now press the [ (step forward)] button once. You will arrive back the screen shown below.

90ZV-262019

This area is called the "Current Output Monitor". As seen, it first shows actual front brake circuit pressure. Next, by pressing the [ (step forward)] button, the following screen is seen if equipped with secondary steering.

80V2U62025

You have completely reviewed all of the input signals. 80V2U62032

Again, in review, note the following: - This monitor displays the ON/OFF status of the shift lever, setting switches, pressure switches, etc.

Next, by pressing the [ following screen is seen.

(step forward)] button, the

- There are seven input groups from INPUT 1 to INPUT 7. 80V2U62033

- Each group has eight items from item 0 to the item 7. - When input signal is ON, "1" is displayed under corresponding item number.

Next, by pressing the [ following screen is seen.

(step forward)] button, the

- When input signal is OFF, "0" is displayed under corresponding item number. 80V2U62034

For more clarification, refer to "MODM: Input/Output Monitor - Input/Output Signal Correspondence Table".

80ZV-2 EU 62-87 62 Function & Structure Electrical Group MODM Next, by pressing the [ following screen is seen.

(step forward)] button, the

80V2U62035

Note Brake main pressure 1 is accumulator oil pressure for rear accumulator which serves only the rear brake circuit. Brake main pressure 2 is accumulator oil pressure for front accumulator which serves the front brake circuit and all pilot derived pressures; these are pilot oil pressure for the pilot control valves, auto brake, park brake release, etc. The actual real-time pressures are shown in these fields. Next, by pressing the [ following screen is seen.

(step forward)] button, the

3. Output signal monitor (D1~D6) This monitor displays the ON/OFF status of the transmission forward/backward solenoid valves, speed range solenoid valves, indicator lamps and warning lamps on the instrument panel, etc. There are six output groups from OUTPUT 1 to OUTPUT 6. Each group has eight items from item 0 to 7. When output signal is ON, "1" is displayed under corresponding item number. When output signal is OFF, "0" is displayed under corresponding item number. Refer to "MODM: Input/Output Monitor - Input/Output Signal Correspondence Table" page 92-62. Next, by pressing the [ (step forward)] button for 2 seconds or longer will show the following screen.

90ZV-262019

You have now navigated through the entire "Current Output Monitor" part of the "Input and Output Monitor" section. All of the aforementioned screens can be seen in reverse order by using the [ (step back)] button. Holding this button in for longer than 2 seconds will take you to the input signal monitor screen section.

80V2U62036

This shows the 2nd speed solenoid coil and the forward coil outputs have been applied, as the transmission is in forward and automatic. 1st, 3rd, 4th, reverse, high, and autobrake solenoid coils are not energized and show no application signal. Next press the [ following screen.

(step forward)] button to show the

80V2U62037

Again, note that all values except the last are 0, and only the brake lamp output is in the "ON" position.

80ZV-2 EU 62-88 62 Function & Structure Electrical Group MODM Next press the [ following screen.

(step forward)] button to show the

4. Electric current output monitor This indicates the milliamps (mA) of electric current that are being sent to the fan solenoid valve from the MCU.

80V2U62038

Press the [ (step forward)] button for 2 seconds or longer to show the following screen.

All values are at 0 as there are no outputs needed in this scenario. Next press the [ following screen.

(step forward)] button to show the

80V2U62039

Note that the place under slot 5 is occupied by a 1, as MCU failure relay should be energized by MCU if MCU passes software logic test at MCU boot-up that occurs with the key in the "ON" position. Next press the [ following screen.

(step forward)] button to show the

80V2U62040

Note that the place under slot 1 is occupied by a 1, as the unit is in automatic shift mode and the dash lamp should be illuminated to indicate this. Also the place under slot 7 is occupied by a 1, as the unit is full of fuel. Next press the [ following screen.

(step forward)] button to show the

80V2U62041

Note that this shows no input signal at this time.

80V2U62042

This current output will vary as demands for fan revolutions change, according to amount of heat that is being generated. This heat must be discharged to cool the system that is heating back down. When the machine systems are cold and the machine is in warm up mode, the mA level will be higher than when the machine has worked for a time and has become heat saturated. Note Disconnecting the fan solenoid wire will increase the fan’s revolutions to full speed, and will set a CN713 fault code. This will reside in the system fault code memory until it is cleared. If you disconnect the solenoid coil, you must remember to clear this fault code when finished with work. Refer to fault code table for the chassis side for more detail.

80ZV-2 EU 62-89 62 Function & Structure Electrical Group MODM

Parameter Setting Monitor

1. Shift inhibitor

(Refer to page 92-59)

From turning on key switch which would default to screen shown below.

Parameter setting monitor display This monitor allows check of parameters that are currently set.

80V2U62002

Value levels to set parameter for items like ride control, tire ratios, date/time clock (used to log faults), declutch pressures, secondary steering, detent values sensor, etc. Note If the feature is set to "Invalid" in specification setting view, the following items will be skipped in the parameter setting monitor view. - RIDE CONTROL - SP5 (Ride control) - SECONDARY STEERING - SP7 (Secondary steering) - K-LEVER - SP8 (K-Lever) - TRACTION CONTROL - SP11 (Traction control) - 2 STAGE - SP13 (Efficient loading system)

Pressing both the [ (step forward)] and [ (step back)] buttons simultaneously, 4 times once after another, arrive at the screen shown below.

80V2U62005

The transmission changes the speed range automatically according to the machine speed. If the machine speed sensor is disconnected when the machine is running high, the machine speed is suddenly reduced because of that the transmission is automatically shifted to the low range. As a result, the operator becomes very unstable condition by rapid deceleration. This device prevents the above. By pressing the [ (step forward)] button, you will arrive at a window as shown below.

- BOOM SOFT LAND - SP14 (Lower kickout) - KICK OUT - SP15 (Lift kickout) 80V2U62043

80ZV-2 EU 62-90 62 Function & Structure Electrical Group MODM

2. Ride control

Press the [ (step forward)] button to add "1" to a numerical value.

Now press the [ (step forward)] button once. You will arrive at the screen shown below.

80V2U62044

Note Value for "ON" must be 1 km/hr or more greater than "OFF". The numerical value will increase as you press the [ (step forward)] button as follows;

The screen should appear similar to what is shown. This shows the speed at which ride control turns on and permits the base end oil to work against the accumulator piston.

0  1  2 ..... 9  0  1  2 .....

Now press the [ (step forward)] button once. You will arrive at the screen shown below.

The number then decreases as follows;

80V2U62045

The screen should appear similar to what is shown. This shows the speed at which ride control turns off and does not permit the base end oil to work against the accumulator piston. Changing ride control on/off speed values: These values can be changed for machines that are equipped with this option by doing the following. Press and hold the [ ] button for 2 seconds or more on the parameter setting screen to display the parameter change screen. The cursor flashes in a 1-second cycle (flashes on for 0.5 second and flashes off for 0.5 second). Press the [ ] button to move the cursor. The cursor moves to the right. When the cursor reaches the right end in the upper line, pressing [ ] button will move it to the left end in the lower line. When the cursor reaches the right end in the line, pressing [ ] button moves it to the left end in the line. The cursor skips digits which can not be changed. Cursor movement: Moving to the right  Right end in the upper line  Left end in the lower line  Right end in the lower line  Left end in the upper line.

Press the [ (step back)] button to subtract "1" from a numerical value.

9  8  7 ..... 0  9  8  7 ..... After changing parameter values, press and hold the [ ] button for 2 second or more to finalize the input values and return to the parameter setting screen. Press the [ ] button to return to the parameter setting screen without changing parameter values.

80ZV-2 EU 62-91 62 Function & Structure Electrical Group MODM

3. Meter division ratio Next, by pressing the [ following screen is seen.

4. Tachograph (step forward)] button, the

Next, by pressing the [ following screen is seen.

80V2U62046

The screen should appear similar to what is shown. This is the speed division ratio for the smaller tire. This permits the speed reading to be accurate when equipped with smaller tires. Next, by pressing the [ following screen is seen.

(step forward)] button, the

80V2U62048

Next, by pressing the [ following screen is seen.

(step forward)] button, the

(step forward)] button, the 80V2U62049

5. Secondary steering 80V2U62047

Next, by pressing the [ following screen is seen.

The screen should appear similar to what is shown. This is the speed division ratio for the larger tire. This permits the speed reading to be accurate when equipped with larger tires. Note Model

(step forward)] button, the

80V2U62050

The screen should appear similar to what is shown and indicates the engagement speed.

Tire size Small size (B)

Large size (A)

65ZV-2

17.5

20.5

70ZV-2

20.5

23.5

80ZV-2

20.5

23.5

85ZV-2

23.5

26.5

90ZV-2

23.5

26.5

92ZV-2

26.5

26.5

95ZV-2

26.5

29.5

115ZV-2

29.5

35/65

When this option is on the machine, this screen will permit the technician to see the engagement speeds. This will engage when the machine loses power to the engine, or if the steering pump were to fail and hydraulic system pressure falls below 0.4 MPa (4 kgf/cm2) (57 psi) as long as the machine speed is above 2 km/h, and it disengages when the speed falls below 1 km/h. Next, by pressing the [ following screen is seen.

(step forward)] button, the

Note that the 1/12 ratio is the small size (B), and the 1/ 11 ratio is the large size (A). 80V2U62051

80ZV-2 EU 62-92 62 Function & Structure Electrical Group MODM

6. K-Lever (stick steering) Next, by pressing the [ following screen is seen.

(step forward)] button, the

Review the following screens that are able to be seen by pressing the [ (step forward)] button. (A setting shown.)

80V2U62055 80V2U62052

The screen should appear similar to what is shown and indicates the K-Lever voltage.

80V2U62056

Note The default setting for K-Lever is to the "A" type. The voltage settings are displayed in the MODM monitor display.

80V2U62057

i=Signal intensity (or mA) Review the following screens that are able to be seen by pressing the [ (step forward)] button. (A setting shown.)

A Type

Solenoid valve LH side

Solenoid valve RH side

Current (mA)

imax i2

80V2U62053

80V2U62054

i1

V=Voltage The screen should appear similar to what is shown and indicates the K-Lever mA signal strength or intensity.

Potentiometer (V)

0

V1 V2 Vmax

2.5 V1

5 V2 Vmax

Note The default setting for K-Lever is to the "A" type. The voltage settings are displayed in the MODM monitor display.

80V2U62077

Initial set values K-LEVER V1

0.25 V

K-LEVER V2

2.0 V

K-LEVER Vmax

2.4 V

K-LEVER i1

290 mA

K-LEVER i2

450 mA

K-LEVER imax

470 mA

80ZV-2 EU 62-93 62 Function & Structure Electrical Group MODM

7. Traction control

B Type

Solenoid valve LH side

Next, by pressing the [ following screen is seen.

Solenoid valve RH side

Current (mA)

imax

(step forward)] button, the

i3

i2 80V2U62058

i1 Potentiometer (V)

0

V1 V2 V3

2.5 V1

5 V2

This indicates parameter of 1.0 second when in forward and 1st (F1) gear before traction control will engage. If time of engagement for F1 is less than 1 second, it is looked at as not permanent; software will not respond to signal as it is considered to be inconsequential. This helps avoid erratic machine function.

V3

Vmax

Vmax 80V2U62078

Next, by pressing the [ following screen is seen.

(step forward)] button, the

Initial set values K-LEVER V1

0.25 V

K-LEVER V2

1.0 V

K-LEVER V3

2.0 V

K-LEVER i1

290 mA

K-LEVER i2

400 mA

K-LEVER i3

450 mA

K-LEVER imax

470 mA

Note Type A and B are switched on the specification setting monitor. (Refer to page 62-99)

80V2U62059

This stands for Dual Stage for slip control. This parameter is not used in USA production and should be disregarded. (It would have set a given hydraulic system pressure value to indicate that machine was excavating and MCU logic for traction control would take into account this additional parameter.) Next, by pressing the [ following screen is seen.

(step forward)] button, the

In case of type A, screen changes as follows. 80V2U62060

V1  V2  Vmax  i1  i2  imax In case of type B, screen changes as follows. V1  V2  V3  i1  i2  i3  imax

This stands for Inching slip control feature and is not used. This parameter is not used in USA production and should be disregarded. (If it were used, declutch (or inching circuit) sensor would signal MCU to know brake circuit pressure & deactivate traction control if the brake circuit pressure was over a given value for a given time frame (See "ti" below; ti is also not used).)

80ZV-2 EU 62-94 62 Function & Structure Electrical Group MODM Next, by pressing the [ following screen is seen.

(step forward)] button, the

Next, by pressing the [ following screen is seen.

80V2U62061

This is time inching. This is time frame in lsc above. Next, by pressing the [ following screen is seen.

(step forward)] button, the

(step forward)] button, the

80V2U62065

This stands for Slip Control time; data is provided in seconds of time. When the set time for starting slippage begins, traction control engages and makes adjustments accordingly.

8. Declutch 80V2U62062

Next, by pressing the [ following screen is seen.

(step forward)] button, the

This stands for Slip Control velocity, or ground speed regulation for traction control "ON"; speed has to be at or below this setting to activate traction control. 80V2U62066

Next, by pressing the [ following screen is seen.

(step forward)] button, the This is brake circuit pressure; at this pressure, the declutch circuit will put the transmission to neutral position, and delete the forward or reverse clutch output. IS stands for Inching Sensor. 80V2U62063

This stands for Slip Control engine, or engine speed regulation for traction control "ON"; rpm speed has to be at or above this setting to activate traction control. Next, by pressing the [ following screen is seen.

(step forward)] button, the

80V2U62064

This stands for Slip Control intensity; indicates accelerated slipping velocity of traction control. The value is indicated in km/h per 0.1 second. Each 1/10th of a second the velocity is cut back by engine rpm reduction so slippage will not occur, and this provides reduced tire slippage.

80ZV-2 EU 62-95 62 Function & Structure Electrical Group MODM

9. Efficient loading system (ELS)

10. Engine power control

Next, by pressing the [ following screen is seen.

Temperature

(step forward)] button, the

Next, by pressing the [ following screen is seen.

(step forward)] button, the

80V2U62067

This is the voltage at the rotary sensor wire that returns signal to MCU. This signal from the rotary sensor determines the boom height position. If the boom is high, the unloader valve solenoid coil at the ELS control valve will not be energized, and the ELS will not operate to unload the loading pump.

80V2U62070

The screen should appear similar to what is shown. This is the temperature at which hibernate mode will engage.

DS=Dual Stage (or ELS)

TWni=Temperature Water normal idle.

on="on". (Thus the term "DSon".)

Voltage

This indicates that the dual stage system is on when it senses 2.5 V or less.

Next, by pressing the [ following screen is seen.

(step forward)] button, the

Typical voltage for the rotary sensor is as shown in graphic below (approximate values). 65V2E62024

Approximate voltage values Boom fully up=4.8 V

The screen should appear similar to what is shown. This is the voltage at which hibernate mode is changed to normal operation mode forcibly. Vni=Voltage normal idle. If the voltage is less than 26.7 V DC, hibernate low idle will not engage. This is so battery will stay charged.

80V2U62068

Bucket can be in any orientation

Boom fully down=0.40 V Carry level

80V2U62069

80ZV-2 EU 62-96 62 Function & Structure Electrical Group MODM

11. Lower kickout (for return to dig)

13. Calendar (Date and time)

Next, by pressing the [ following screen is seen.

Next, by pressing the [ following screen is seen.

(step forward)] button, the

80V2U62072

The screen should appear similar to what is shown; voltage will vary. When lowering, position can be set to make the detent system stop bucket prior to hitting the ground. The MCU will recognize this only when value is 2.50 V or less. If it is greater than 2.50 V, MCU ignores the signal.

12. Lift kickout (for boom raise) Next, by pressing the [ following screen is seen.

(step forward)] button, the

80V2U62073

The screen should appear similar to what is shown; voltage will vary. Ks=Kickout set point When raising boom, position can be set to make the detent system stop the boom prior to the piston hitting the cylinder head. The MCU will recognize this only when value is 4.20 V or more. If it is less than 4.20 V, MCU ignores the signal. This feature protects boom cylinders from inertial damage caused by the mass of the boom, bucket, and linkage moving up rapidly with the boom cylinders extending and causing the pistons to hit the boom cylinder heads.

(step forward)] button, the

90ZV-262022

The screen should appear similar to what is shown.

80ZV-2 EU 62-97 62 Function & Structure Electrical Group MODM

Parameter change The parameter values can be changed when the both conditions below are satisfied: The engine is stopped (starter switch is ON). The parking switch is ON.

Press the [ (step forward)] button to add "1" to a numerical value. The numerical value will increase as you press the [ (step forward)] button as follows. 0  1  2 ..... 9  0 Press the [ (step back)] button to subtract "1" from a numerical value. The number decreases as follows.

A parameter value can be changed, however, only when the corresponding item is set to "VALID" in the specification setting monitor. (Refer to page 92-59) Ride control setting 1

9  8  7..... 0  9 After changing parameter values, press and hold the [ ] button for 2 second or more to finalize the input values and return to the parameter setting screen. Press the [ ] button to return to the parameter setting screen without changing parameter values.

When the corresponding item is set to "INVALID", the parameter screen is not displayed. (It is skipped to the next screen.) Calendar

The date & time sequence reads as shown. DATE TIME

YY / MM / DD hh : mm : ss

Y=year M=month D=day 90ZV-262022

Changing date and clock values:

h=hour m=minute s=second

These values can be changed by doing the following.

Example:

Press and hold the [ ] button for 2 seconds or more on the parameter setting screen to display the parameter change screen.

DATE TIME

The cursor flashes in a 1-second cycle (flashes on for 0.5 second). Press the [ ] button to move the cursor. The cursor moves to the right. When the cursor reaches the right end in the upper line, pressing [ ] button will move it to the left end in the lower line. When the cursor reaches the right end in the lower line, pressing [ ] button will move it to the left end in the upper line. The cursor skips digits which cannot be changed. Cursor movement: Moving to the right  Right end in the upper line  Left end in the lower line  Right end in the lower line  Left end in the upper line

06 / 07 / 12 = July 12, 2006 20 : 15 : 11 = 8:15:11 pm

Note Failure to enter the values correctly will make the clock give the wrong time, and the date to read incorrectly in all of the dependent functions, such as fault code messages, etc.

80ZV-2 EU 62-98 62 Function & Structure Electrical Group MODM

Specification Setting Monitor

1. Specification setting display

(Refer to page 92-60 and 92-61)

This monitor allows check of the specifications currently set.

Specification setting monitor display From turning on key switch which would default to screen shown below.

When attaching an optional unit, change the specification setting to make the corresponding function valid. It is necessary to log with the correct password for changing the specification setting.

80V2U62002

Pressing both the [ (step forward)] and [ (step back)] buttons simultaneously, 5 times once after another, arrive at the screen shown below.

If no password is entered, only the initial specification setting monitor can be seen, and is shown the program number that is designed for that particular machine model.

80V2U62074

80V2U62074

When you are at this point, press the [ (step forward)] button for over 2 seconds will take you to the following screen.

90ZV-262023

The asterisk symbol will have a flashing _ underscore below it, indicating that it is ready to have a password entered into it to permit login access to change variable parameters. The login access code must be acquired from the Kawasaki Service Representative and is not for general public use as it can cause machine troubles if the wrong parameters are inserted. If you have the password, write it in the place value entry blanks provided below. _ _ _ _ DO NOT GIVE THIS PASSWORD OUT TO CUSTOMERS OR END USERS ! IT IS FOR TRAINED KAWASAKI SERVICE PERSONNEL ONLY ! SERIOUS DAMAGE TO MACHINE MAY RESULT BY USING INAPPROPRIATE ENTRY VALUES.

80ZV-2 EU 62-99 62 Function & Structure Electrical Group MODM

2. Password entry and changing settings Note To make changes to entry settings, engine must be "OFF", and key switch in "ON" position with parking brake applied. Otherwise changes will not happen.

90ZV-262023

Every time the [ (step back)] button is pressed, the displayed content is changed "FR switch  Wheel type  Kickout  ..." in sequence. The following items can now be selected as "VALID" or "INVALID" by pressing and holding the [ ] button for 2 seconds or longer, and then selecting the [ (step forward)] or the [ (step back)] button to choose "VALID" or "INVALID" as required. When finished, press and hold the [ ] button for 2 seconds or longer to accept the change.

The password is a numerical password. Press the [ (step forward)] button to add "1" to a numerical value.

If you need to return without making a selection, press the [ ] button, and you will return to the previous screen without making a change of selection.

The numerical value will increase as you press the [ (step forward)] button as follows;

- Selection switch shift (shift lever or F/R switch) Valid/Invalid

0  1  2  3  4  5 ..... 9  0  1  2  3  4  5 ..... etc.

- Shift hold Valid/Invalid

Press the [ ] button to change the cursor position to continue password entry. When finished, press the [ ] button for longer than 2 seconds to get to the following screen.

- Ride control Valid/Invalid - Secondary steering Valid/Invalid - K-Lever (Stick steering) A Type/B Type/Invalid

80V2U62075

Every time the [ (step forward)] button is pressed and held for 2 seconds, the displayed contents are changed over "All setting reset  Specification group 1  Specification group 2  All setting reset" in sequence. Every time the [ (step back)] button is pressed and held for 2 seconds, the displayed contents are changed over "All setting reset  Specification group 2  Specification group 1  All setting reset" in sequence. For the display sequence, refer to "Outline of MODM (Machine Operation Diagnostic Module) Operation" page 92-53. Specification group 1 Every time the [ (step forward)] button is pressed, the displayed content is changed "FR switch  Shift hold  Ride control  ..." in sequence.

- Hydraulic pressure increase Valid/Invalid - Traction control Valid/Invalid - Tachograph Valid/Invalid - Efficient loading system (ELS) Valid/Invalid - Lower kickout Valid/Invalid - Lift kickout (variable) Valid/Invalid - Wheel type A type (Big wheel)/B type (Small wheel)

80ZV-2 EU 62-100 62 Function & Structure Electrical Group MODM Specification group 2 Every time the [ (step forward)] button is pressed, the displayed content is changed "Downshift button  Auto brake  Engine speed  ..." in sequence. Every time the [ (step back)] button is pressed, the displayed content is changed "Downshift button  Brake oil level  Brake oil differential sw  ..." in sequence.

- Engine oil pressure sensor (for communication and monitor control) Valid/Invalid - Brake pressure differential switch Valid/Invalid - Brake oil level Valid/Invalid Use the table on page 62-103 to do this.

The following items can now be selected as "VALID" or "INVALID" by pressing and holding the [ ] button for 2 seconds or longer, and then selecting the [ (step forward)] or the [ (step back)] button to choose "VALID" or "INVALID" as required. When finished, press and hold the [ ] button for 2 seconds or longer to accept the change. If you need to return without making a selection, press the [ ] button, and you will return to the previous screen without making a change of selection. - Kick-down (downshift button) Valid/Invalid - Auto brake Valid/Invalid - Engine speed Communication/Sensor - E/G curve selection Communication/Output/Invalid - Cooling fan Valid/A type/B type - Transmission oil temperature switch (for monitor control) Valid/Invalid - Engine coolant temperature switch (for monitor control) Valid/Invalid - Engine coolant temperature sensor (for monitor control) Net/Sensor - Engine oil pressure switch (for monitor control) Valid/Invalid

You may exit back to the default screen when finished by pressing the [ (step forward)] and [ (step back)] buttons simultaneously.

WARNING Changing the systems parameters to non factory settings will render the monitor ineffective. This can lead to warranty claims that will not be covered by the factory warranty. DO NOT VALIDATE OPTIONS OR SETTINGS THAT DO NOT APPLY !

80ZV-2 EU 62-101 62 Function & Structure Electrical Group MODM

All setting reset Item

Allows batch deletion or batch reset of information monitor, replacement monitor or fault log monitor. Specified Parameter

Comment

Kick down (downshift button)

SP1

Always valid

Selection switch shift (shift lever or F/R switch)

SP2

Optional (EU valid)

Information monitor When this is performed, the following items will be reset.

Shift hold

SP3

Always lnvalid

Autobrake

SP4

Valid 92~135ZV-2

Ride control

SP5

Option

Engine speed

SP6

Sensor

Secondary steering

SP7

Option (EU always valid)

- Maximum hydraulic oil temperature

K-Lever

SP8

Option

- Number of cycles

Engine curve

SP9

Output

Hydraulic pressure increase (power up)

SP10

Option

- Cycle time - Trip meter (for hour meter)

Traction control

SP11

Valid 92~135ZV-2

Tachograph

SP12

Always invalid

Efficient loading system (ELS) SP13

Valid (Option on 65/70ZV-2)

Lower kickout

SP14

Always valid

Lift kickout

SP15

Always valid

Cooling fan

SP16

A type

Torque converter oil temperature switch

SP17

Invalid

Engine coolant temperature switch

SP18

Invalid

Engine coolant temperature sensor

SP19

Net or Sensor

Engine oil pressure switch

SP20

Always valid

Engine oil pressure sensor

SP21

Invalid

Brake pressure differential switch

SP22

50/60ZV-2 only

Brake oil level

SP23

50/60ZV-2 only

Wheel type

SP24

A or B type

- Maximum engine coolant temperature - Maximum transmission oil temperature

Replacement monitor - Engine oil filter timer - Fuel filter timer - Coolant filter timer - Torque converter line filter timer - Hydraulic oil return filter timer - Engine oil timer - Torque converter and transmission oil timer - Axle gear oil timer - Hydraulic oil timer After timers are reset, each of them is automatically set to the standard initial set value.

Fault log monitor - The machine fault log is deleted. - The engine fault log is deleted. Note This can be reset with engine running. It will retain reset results.

80ZV-2 EU 62-102 62 Function & Structure Electrical Group MODM

All setting reset procedure (Start at screen shown)

80V2U62075

Press and hold the [ ] button for 2 seconds or more to display the all setting reset execution screen. See example below.

80V2U62076

When executing the all setting reset function, press and hold the [ ] button for 2 seconds or more. Then, the all setting reset function is executed, and the specification setting screen appears again. Press the [ ] button to return to the specification setting screen without executing the all setting reset function.

80ZV-2 EU 62-103 62 Function & Structure Electrical Group MODM

Default position of specification setting monitor (EU) ITEM

OPTION EITHER VALID OR INVALID

65ZV-2 65TMV-2

70ZV-2 70TMV-2

80ZV-2

85ZV-2

90ZV-2

92ZV-2

95ZV-2

115ZV-2

x

x

x

Kick down (downshift button)

Valid/Invalid

Selection switch shift (shift lever or F/R switch)

Valid/Invalid

Shift hold

Valid/Invalid

x

x

x

x

x

Autobrake

Valid/Invalid

x

x

x

x

x

Ride control

Valid/Invalid

x

x

x

x

x

x

x

x

Engine speed

Net/Sensor

Sensor

Sensor

Sensor

Sensor

Sensor

Sensor

Sensor

Sensor

Secondary steering

Valid/Invalid

K-Lever

Valid/Invalid

Engine curve

Output/Net/Invalid

Hydraulic pressure increase (power up)

x

x

x

x

x

x

x

x

Output

Output

Output

Output

Output

Output

Output

Output

Valid/Invalid

x

x

x

x

x

x

x

x

Traction control

Valid/Invalid

x

x

x

x

x

x

x

Tachograph

Valid/Invalid

x

x

x

x

x

x

x

x

Efficient loading system (ELS)

Valid/Invalid

x

x

Lower kickout

Valid/Invalid

Lift kickout

Valid/Invalid

Cooling fan

A type/B type/Invalid

A type

A type

A type

A type

A type

A type

A type

A type

Torque converter oil temperature switch

Valid/Invalid

x

x

x

x

x

x

x

x

Engine coolant temperature switch

Valid/Invalid

x

x

x

x

x

x

x

x

Engine coolant temperature sensor

Net/Sensor***

Net

Net/ Sensor

Net/ Sensor

Net/ Sensor

Net/ Sensor

Net

Net/ Sensor

Net/ Sensor

Engine oil pressure switch

Valid/Invalid

Engine oil pressure sensor

Valid/Invalid

x

x

x

x

x

x

x

x

Brake pressure differential switch

Invalid/Nc/No

x

x

x

x

x

x

x

x

Brake oil level

Invalid/Nc/No

x

x

x

x

x

x

x

x

Wheel type

A or B type

A type

B type

A type

B type

A type

A type

A type

A type

=Valid x=Invalid  Auto brake is always valid on 92/95/115ZV-2 units.

 Pilot operated hydraulics for K-Lever on 115/135ZV-2.

Items that are not shaded in table are available options.

Note*** Concerning engine coolant temperature sensor, “Net” must be selected for the listed S/N machines in the following table, and “Sensor” must be selected for the machines prior to them. (The sensor wes no longer installed but temperature data was derived from the engine ECM on and after the listed S/N.)

Model

Serial number to use “Net”

65TMV-2/65ZV-2

Always “Net” (all S/N)

70TMV-2

Always “Net” (all S/N)

70ZV-2

70C5-9101~

80ZV-2

80C5-9101~

85ZV-2

85C5-9101~

90ZV-2

90C5-9201~

92ZV-2

Always “Net” (all S/N)

95ZV-2

97C5-9151~

115ZV-2

11C5-9051~

80ZV-2 EU 62-104 62 Function & Structure Electrical Group Electrical Detent Circuit

Electrical Detent Circuit Bucket leveler After dumping, if the control lever is set to the "rollback" position, the control lever will be held at that position until the bucket is tilted to the set angle. This is because the detent solenoid in the pilot valve is energized so that the fixing disc connected to the push rod is held by the magnetic force. When the bucket is positioned at the set angle, the rod will retract from the proximity switch. The proximity switch is turned off and the detent solenoid in the pilot valve is de-energized and demagnetized. The control lever is automatically returned to the neutral position by the spring. As a result, the bucket is set to the selected digging angle automatically.

Detent (Pilot valve)

Multiple control valve Bucket leveler Adjusting rod (detected object)

Proximity switch

Connector Bucket cylinder

85V2E62007

Proximity switch Adjusting the clearance Proximity switch Switch main circuit

LED

+24V

Br 1

Coil for detent inside pilot valve

B 2 L 3 +24V

Detection part Operation indicator lamp (LED) Detected object

1(Br)

View Z 3(L)

5±2 mm (0.197±0.079 in)

Adjust the clearance between the sensor and the adjusting plate to 5±2 mm (0.197±0.079 in). In this condition, the operation indicator lamp (LED) is on, and the circuit between the switches (2) – (3) is on.

2(B) 85ZV62015

80ZV-2 EU 62-105 62 Function & Structure Electrical Group Electrical Detent Circuit

Detent solenoid

Push rod

Detent solenoid Fixing disc

85V2E62035

Three detent solenoids are installed in the pilot valve. One detent solenoid, for the bucket leveler, is installed in the pilot valve bucket side. Two detent solenoids, for the boom kickout and float, are installed in the pilot valve boom side. Voltage

DC 24 V

Coil resistance

62±3 

80ZV-2 EU 62-106 62 Function & Structure Electrical Group Electrical Detent Circuit

Lift kickout & lower kickout Location

2

4 A 5

3

1 Detail A

6

85V2E62008

1. Rotary sensor assy 2. Rod 3. Link 4. Cover 5. Cover 6. Boom

Lift kickout When the boom control lever is placed at "Raise" position and the boom reaches at the preset height, the lift kickout automatically releases the detent and returns the boom control lever to "Hold" position. The detent function and the units are the same way as those of the bucket leveler.

80ZV-2 EU 62-107 62 Function & Structure Electrical Group Electrical Detent Circuit

Lower kickout When the boom control lever is placed at "Float" position and the boom reaches at the preset height, the lower kickout automatically releases the detent and returns the boom control lever to "Hold" position. The detent function and the units are the same way as those of the bucket leveler.

80ZV-2 EU 62-108 62 Function & Structure Electrical Group Electrical Detent Circuit

Sensor assy 4

4

2

2

3 3

5 A-A

Detail of grease applying

1

1

A

A 30 Position sensor detail

85V2E62009

1. Position sensor 2. Link 3. Plate 4. Shaft 5. Ball bearing

80ZV-2 EU 62-109 62 Function & Structure Electrical Group Electrical Detent Circuit

A B C

View A

A Position sensor detail

CCW

70T2U62008

70T2U62009

Resistance

5 k ± 1 k

Electrical rotation

128º (Theoretical)

Mechanical rotation

180º

Clockwise stop

90º from elect. center

Spring return

To clockwise end of rotation

80ZV-2 EU 62-110 62 Function & Structure Electrical Group Electrical Detent Circuit

Detent solenoid

Lever position: Lower kickout side

Preset height adjustment

Lever position: Lift kickout side

Push rod

Push rod

Detent solenoid (for lift) Fixing disc

Detent solenoid (for lower) Fixing disc

Switch K70V2J62003

(Upper)

(Lower)

Hold

Hold

Reset

Reset

85V2E62017 65V2E62018

Two detent solenoids are installed in the pilot valve boom side. One is for the lift kickout and another is for the lower kickout. Voltage

DC 24 V

Coil resistance

62±3 

1. Lift kickout preset height Raise the boom to the desired position and press the left side of the kickout control switch located on the console box to set the boom height for the lift kickout. 2. Lower kickout preset height Lower the boom to the desired position and press the right side of the kickout control switch located on the console box to set the boom height for the lower kickout.

80ZV-2 EU 62-111 62 Function & Structure Electrical Group Diode

Diode Open circuit, failed in open position.

Symbols

+24V Switch

+

Solenoid

[Anode]

[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

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.

Switch

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.

Solenoid

Diode

Current flows while the diode is normal (The solenoid is energized.)

70ZV62052

Short-circuit, failed in closed position.

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.

80ZV-2 EU 62-112 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

12V

Diode check mode

12V

30A

Battery (1)

ECM F15

R1 BR B AC R2 C

WR

(2) (3)

5A

WP

(2)(3): Diode unit

5A

5A

F13

F14

F12

15A

Suppression diode Charge circuit

B

R1

From alternator R terminal

Neutral relay 70V2U62005

Normal

Abnormal

Forward check

Continuity is detected in the status shown in the figure. Continuity is not detected when tester terminals are connected in opposite way. Continuity is not detected in either way Disconnection Continuity is detected in either way

Short-circuit

Note When the circuit tester is the digital (number indication) type, exchange the positions of the terminals of the tester during the check. Some solenoid coils contain diodes inside the solenoid coil pack. Backward check 85V2E62036

Forward check

Backward check

Continuity (voltage value)

Over level

Judgement Normal

Over level

Over level

Open circuit

0 volt

0 volt

Short-circuit

80ZV-2 EU 62-113 62 Function & Structure Electrical Group Diode

Resistance check mode Analog type tester

R1>0

R2=

0

0

Forward check

Backward check Digital type tester

R1>0

R2=

R1

Forward check

Backward check

Forward check

Backward check

Judgement

R  (0<R<)



Normal





Open circuit

0

0

Short-circuit

80ZV-2 EU 62-114 62 Function & Structure Electrical Group Diode

Surge voltage and surge suppression diodes

Fig. 3

Fig. 1

Surge suppression diode

Coil

Current Switch or transistor Time [sec]

Load 115ZVE62032

Some electrical parts such as solenoid valves are equipped with a coil. When a coil is energized, an electromagnetic field is formed. See fig. 1. Fig. 2

Battery

Coil

When the switch opens, the field collapses across the coil windings. Voltage

Voltage [V] Current [A]

K70V2J62006

When the surge voltage was generated, it causes to increase wear on the switch points. During the coil is being activated by the transistor, when the excruciating high voltage is loaded on the transistor, the transistor may be broken. In order to absorb this surge voltage, connect the diode parallel to the coil in the reverse direction against the power supply. When the switch is off, the same amount of electric current, that was flown till now, flows through the diode. This electric current is attenuated gradually and finally it reaches zero. That means no surge voltage is generated in the circuit.

Current

Load

Coil

Voltage

Voltage [V] Current [A]

Current direction

Battery

Electromagnetic field forms when switch closes.

This diode is called as flywheel diode.

ON OFF Time [sec]

Surge voltage 115ZVE62033

When the solenoid coil is de-energized, the field collapses across the coil. The collapse of this electromagnetic field across the solenoid coil generates an unregulated voltage surge. See fig. 2. This can damage transistors, contacts, and other electronic parts. (See connection diagram.)

80ZV-2 EU 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

80ZV-2 EU 72-2 72 Function & Structure Operator Station Group Cabin

Cabin B A

A 3

7 5 6

1

2

B

A-A 4

B-B 85V2E72001

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

80ZV-2 EU 72-3 72 Function & Structure Operator Station Group Cabin

Glass

3

2

1

2

70V2E72001

1. Front glass 2. Front side glass 3. Rear glass

80ZV-2 EU 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)

Green glass (Inside)

T=3.0

T=3.0

A-A

A-A

(mm) 327.5 (mm) R3

953

0

R2

A

A

96

R3

299.5 52.5

0 R3

R3

4-

R53

A

1149

1195

A

699

646.5

70V2E72002

Note This glass must comply with ECE REG43.

70V2E72003

Note This glass must comply with ECE REG43.

80ZV-2 EU 72-5 72 Function & Structure Operator Station Group Cabin

3. Part number 32011-21500

(mm) 1262.5

R2

4

R2

848

4

T=6.0

0 R3

R3

0

1325.5

70V2E72004

Note This glass must comply with ECE REG43.

80ZV-2 EU 72-6 72 Function & Structure Operator Station Group Cabin

Wiper mount Front wiper

714 (Along surface)

5

ng surf ace)

Wipin g ang le 56º

2

R750(A lo

1 4

2 3

1 4

97ZV72004

1. Wiper motor 2. Wiper arm 3. Wiper blade

4. Intermittent wiper relay 5. Washer jet nozzle

Rear wiper

4

2

106

450

R5

50

3

1

97ZV72005

1. Wiper motor 2. Wiper arm

3. Wiper blade 4. Washer jet nozzle

80ZV-2 EU 72-7 72 Function & Structure Operator Station Group Cabin

Wiper motor Front Cabin

(Automatic stop position) 12 159200 589 24V

100

3

e) ol rh ø5 the a re

(B

115

80 70

5

6

R8

5.6

±0

(3º 10')

.2

60

4

Wipin

g angl e 56º

22

Ro

tati ng

dire cti

on

(-1) AVS0.85 W

(-2) AVS0.85 L

(+) AVS0.85 R

(S) AVS0.85 Y

(+) AVS0.85 R

( L1~L3=3.7µH C1~C3=0.2µF )

MOTOR

1

Circuit breaker

M L3

L1

L2

C3 C2 R

Washer motor

R

Y

B

C1 L

W

24 V OFF LOW HIGH

SWITCH

Circuit diagram

2

7

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

80ZV-2 EU 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 (+)

1

AVS0.85 WB ( )

MOTOR (Circuit breaker)

AVS0.85 Y (S)

WB

M 2 LB

Y

+1

S

3

4

Cabin

L +

5

6

Pantagraph arm

Tightening torque: 6.4~9.3 N-m (0.6~0.9 kgf-m)

OFF ON

24V

SWITCH Circuit diagram (motor stop position)

K97V2J72001

1. 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

80ZV-2 EU 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.

6

Note The seat is designed so that it is unnecessary to make any adjustment for the driver weight. 4

95ZV OM EU SEAT

5

Up-stop height adjustment control (europe specification) 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 handwheel (6) clockwise to raise the seat unseated, rotate it counterclockwise to lower the seat unseated.

80ZV-2 EU 72-10 72 Function & Structure Operator Station Group Steering and Transmission Shift Lever

Steering and Transmission Shift Lever Tilt quantity 56

56

1

3

2

4

5 4 6

Operator stand

7

8

1. Steering wheel 2. Transmission shift lever 3. Turn signal indicator and head lamp high/low selector lever 4. Handle tilt adjustment lever 5. Gas spring 6. Column shaft assembly 7. Lower column shaft 8. Orbitrol® Tilt case (1~6) can select the optimal position in the following range:

95ZVE72009

Handle tilt 56 mm in each direction from the center Handle slide 85 mm upward and downward Note - Install gas spring (5) with its rod side facing downward as shown in the figure above. - Install lower column shaft (7), together with the Orbitrol®, from the underside of the operator stand.

80ZV-2 EU 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

2 5 4 Operator stand

Slide quantity 85

Lock position

270 (355 when slid)

9 Operator stand

10

3

3

97ZV72017

1. Column shaft assembly 2. Bracket 3. Bracket 4. Handle tilt adjustment lever 5. Bolt 6. Nut (double-start thread, tapered in lever mounting area) 7. Nut 8. Nut 9. Bushing 10. Nut

: (6): 21.5 N-m (2.2 kgf-m) : (7): 49 N-m (5.0 kgf-m) : (8): 54 N-m (5.5 kgf-m) : (10) (inside): 31.9 N-m (3.3 kgf-m) : (10) (outside): 89.1 N-m (9.1 kgf-m)

80ZV-2 EU 72-12 72 Function & Structure Operator Station Group Steering and Transmission Shift Lever

Column shaft Grease charged

4

3

Adhesive applied

1 8 10

2

11

8

9

7

6

5 Waterproof seal

13 11 11

8

12

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".

80ZV-2 EU 72-13 72 Function & Structure Operator Station Group Air Conditioner

Air Conditioner Denso air conditioner components

4 1-1

3 1-2

5

1 7 9

12

10

2

11

14

6 13

8

97ZV72020

1. Air conditioner assembly 1-1 Cooling unit assembly 1-2 Blower assembly 2. Air distributor assembly 3. Recirculating air filter 4. Control panel 5. Condenser assembly 6. Compressor assembly 7. Receiver drier 8. Receiver drier bracket 9. Joint 10. Drain hoses 11. Relay 12. Thermistor* (inside air sensor) 13. Thermistor* (outside air sensor) 14. Solar sensor (insolation sensor) * or thermal resistor

Air conditioner specifications (system performance) Cooling system performance Cooling capacity

4.65 kw (15,881 BTU) ± 10%

Air quantity

550 m3/h (720 yd3/h) ± 10%

Rated voltage

DC 24 V

Power consumption

345 W (14.4 amps) ± 10%

Heating system performance Heat radiation quantity

5.2 kw (17,759 BTU) ± 10%

Air quantity

380 m3/h (500 yd3/h) ± 10%

Rated voltage

DC 24 V

Power consumption

170 W (7.1 amps) ± 10%

(Difference in temperature: 65ºC, water flow rate: 6 L/min)

80ZV-2 EU 72-14 72 Function & Structure Operator Station Group Air Conditioner

Denso air conditioner structure Cooling unit 37

14 57

51

38 13 25

2

50 49 24 1

9 24

23 6

11

8

5 15 4

17

3 16 12

97ZV72021

80ZV-2 EU 72-15 72 Function & Structure Operator Station Group Air Conditioner

1. Cooling unit case (rear) 2. Cooling unit case (front) 3. — 4. Evaporator core 5. Heater core 6. Expansion valve 7. — 8. Tube 9. De-icing sensor (thermal resistor) 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 integrated circuit 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)

80ZV-2 EU 72-16 72 Function & Structure Operator Station Group Air Conditioner

Heater and accessories

Air distributor (hood & defroster selection box) 13 3 6

6

9

4

7 2

7 2 5 1 1 97ZV72024

11 17

10

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 actuator (AY, inside/outside air)

80ZV-2 EU 72-17 72 Function & Structure Operator Station Group Air Conditioner

Air compressor (with magnetic clutch)

2-1 2

2-2

2-3

2-6

2-8 5~7 2-7 1 85V2U72001

3. — 4. — 5. Plate washer 6. Plate washer 7. Plate washer

1. Compressor 2. Magnetic clutch assembly 2-1 Magnetic stator coil 2-2 Magnetic clutch pulley 2-3 Clutch hub 2-6 Plate washer 2-7 Snap ring 2-8 Snap ring

Condenser unit 3 1

4 2

3

12

7

4

10

1. Condenser core 2. Blower assembly 3. Condenser bracket 4. Condenser bracket 5. — 6. —

7. Cover 8. — 9. — 10. Wire harness 11. — 12. Resistor

95V2U72001

80ZV-2 EU 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

80ZV-2 EU 72-19 72 Function & Structure Operator Station Group Air Conditioner

Function of cooling mechanism Principle of cooling

Indoor

Evaporator

Expansion valve

Expansion Evaporation Condensation

Deprives heat of the adjacent area.

Condenser Releases heat to the outside.

Compression Refrigerant

Compressor Basic cooling cycle

contain some minor gas fractions, it is routed into the receiver drier. There it dries the refrigerant by use of a material we term a "desiccant", which means drying agent. A down tube in the receiver drier is submerged into the heavier liquid that is now at the bottom of the receiver drier. This tube will permit passage of only the heavier liquid that is at the bottom of the receiver drier. Then the high-pressure liquid passes through the thermal expansion valve that provides a restriction or throttles the flow of refrigerant. This restriction reduces the pressure of the liquid refrigerant thus reducing its boiling point. The expansion valve also meters the amount of refrigerant to the evaporator, by modulating the valve from wide open to closed, which varies with the heat load. The expansion valve separates the high-pressure side from the low-pressure side.

97ZV72029

Function and operation of air conditioning system Very often, things are much simpler than they may appear. This is also the case with an air conditioning system. Gas when compressed often heats as a result of molecular compression, and when decompressed it cools. Some gases are more prone to heat or cool to a greater degree when undergoing these changes than are others. We use these natural laws to make an air conditioning system work. Another factor to take into consideration is that we enhance the natural effects of hot and cold in these refrigerants by manipulating the gas temperature while it is undergoing the heating or cooling process. Note HFC 134A is a very effective "vehicle" to carry away heat. Explanation of function of air conditioning unit. As an example of manipulating refrigerant temperatures, imagine that you can very quickly make the refrigerant intensely hot. This is done by use of a compressor, as we just mentioned in paragraph one. If you course the heated refrigerant that just came from the compressor through a condenser that will cool it while it is very hot and in a compressed gaseous state, you will make it shed some of its heat that it gained in the compression process. This refrigerant then is converted into a liquid at this point, while still in the condenser. This is why it is called the condenser, as it has condensed the gas into a liquid. As a liquid that may still

The refrigerant is now at the evaporator. Temperatures in the evaporator are cold enough to cause the ambient air to cool when blown through it. This causes condensation to happen. The fan-charged air that rushes through the evaporator is now going to shed its humidity. This humidity, or condensed water, is routed through some tubing to be discharged to the outside of the cab as waste water that falls to the ground. The refrigerant is now on its way back to the compressor. It is still under pressure when compared to the atmospheric air pressure. However, because it is drawn along by the refrigerant compressor suction, we now say that is in the suction side (low-pressure side) of the circuit.

80ZV-2 EU 72-20 72 Function & Structure Operator Station Group Air Conditioner

Refrigerant A liquid object which circulates inside cooling circuit and transmits heat is called "refrigerant". The refrigerant changes repeatedly its state, from "liquid --> gas --> liquid --> gas ...", and carries heat from the low temperature side (inside the cab) to the high temperature side (outside the cab) while changing its status. There are many types of refrigerants. This air conditioner adopts refrigerant R134a which does not contain chlorine and does not destroy the ozone layer.

IMPORTANT Make sure to use the specified refrigerant (R134a). If any other refrigerant is used, following problems may occur: - The air does not become cool enough. - The equipment may be damaged. And never mix R134a with any other refrigerant. Chemical formula Molecular weight

CH2FCF3 102.03

Boiling point

-26.19ºC (-15ºF)

Critical temperature

101.14ºC (214ºF)

Critical pressure

4.1 MPa (41.45 kgf/cm2) (595 psi)

Critical density

511 kg/m3 (0.073 lbs)

Density of saturated liquid (at 25ºC/77ºF)

1,206 kg/m3 (595 psi)

Specific volume of saturated vapor (at 25ºC or 77ºF) Latent heat of evaporation (at 0ºC/32ºF) Combustibility Ozone decomposition modulus

0.0310 m3/kg 197.54 KJ/kg (186 BTU) (47.19 kcal/kg) Noncombustible 0

80ZV-2 EU 72-21 72 Function & Structure Operator Station Group Air Conditioner

Refrigerant characteristics

Generally, fluid (which is the generic name for compressed / condensed non-gas liquid) has following properties.

Refrigerant temperature (ºC) (ºF)

100 (212)

1. When the temperature of gas at a certain pressure decreases, the gas starts to condense and change into liquid at a certain temperature. For each substance (liquid), this temperature is fixed at a given pressure. This temperature determined by a given pressure is called the "saturated temperature".

80 (176) 60 (140) 40 (104) 35 (95) 20 (68) 15 (59) 0

(

20 4)

(

30 22) 0

3.6 5 8 10 353 490 785 981 51 71 114 142

15 1,471 213

20 1,961 284

25 2,452 355

30 2,942 426

35 3,432 497

Gauge pressure (kgf/cm2G) Relationship between saturated pressure and saturated temperature of R134a

2

40 (kgf/cm ) 3,923 (kPa) 568 (psi)

85V2U72002

2. On the contrary when the temperature is determined, the pressure at which liquefication starts is fixed. This pressure is called the "saturated pressure". The figure on the left shows the relationship between the saturated temperature and the saturated pressure of refrigerant R134a. At the temperature and the pressure below at the lower right side of the curve, the refrigerant is liquid. At the temperature and the pressure above at the upper left side of the curve, the refrigerant is gas. Suppose that the air conditioner is used in mid summer. When evaporated, the refrigerant absorbs the heat of evaporation from the air inside the cab. Accordingly, in order to cool down the air inside the cab to approximately 25ºC (77ºF), the refrigerant should change (be evaporated) from liquid into gas at a temperature lower than 25ºC (77ºF). From the figure, it can be seen that the refrigerant R134a can sufficiently cool down the air inside the cab at a pressure above the atmospheric pressure. (If used refrigerant requires a pressure below the atmospheric pressure to cool down the air to the necessary temperature, air enters into the circuit and the ability of the cooler is diminished.) In the process at which the vaporized refrigerant is condensed to liquid, the refrigerant is cooled down by outside air of about 35ºC (95ºF) so that it can condense. Accordingly, as is seen from the figure, the refrigerant can be liquefied at the pressure of 785 kPa (8.0 kgf/ cm2G) (114 psi) or more.

80ZV-2 EU 72-22 72 Function & Structure Operator Station Group Air Conditioner

Cooling circuit

The figure on the left shows the cooling circuit of the air conditioner.

Inside cab

Pressure bulb

Expansion valve

Evaporator Blower

Inside engine room

Compressor

Cooling fan Pressure switch

Receiver dryer Condenser

In this circuit diagram, the area which cools down the air inside the cab is the evaporator. The cooling circuit utilizes the fact that the refrigerant absorbs heat (latent heat of evaporation) from the adjacent area when evaporated, and cools down the air inside the cab. The area where the refrigerant is evaporated is the evaporator. The "cooling" effect can be obtained only when the air to be cooled down is continuously fed to the area around the evaporator by the blower fan and the liquid refrigerant (wet evaporation refrigerant with low degree of dryness) is supplied into the evaporator. For example, in order to cool down the air to 15ºC (59ºF), the refrigerant can absorb the latent heat of evaporation from the air only when it is evaporated at a temperature lower than 15ºC (59ºF). It can be seen from the figure in the previous page that the pressure of the refrigerant inside the evaporator should be 353 kPa (3.6 kgf/cm2G) (51 psi) or less to realize it. And in order to keep sufficient cooling effect, the supplied refrigerant quantity should be adjusted so that the refrigerant supplied to the evaporator is completely evaporated inside the evaporator into dry vapor or gas.

Structure of cooling circuit 85V2U72003

Accordingly, the cooling circuit should be constructed to reduce the pressure inside the evaporator and supply proper quantity of refrigerant into the evaporator so that the evaporator can cool down the air sufficiently. The supplied refrigerant quantity is adjusted by the expansion valve. The pressure inside the evaporator is kept at a low value by the closing action of the expansion valve and the suction action of the compressor. The compressor works as a pump which circulates the refrigerant. The refrigerant in the dry vapor status returns into liquid by the compression action of the compressor and heat change (heat radiation) of the condenser, which acts to change the state of the gas to liquid.

80ZV-2 EU 72-23 72 Function & Structure Operator Station Group Air Conditioner

Electrical circuit Control schematic drawing

Outside air sensor

Input signals

Input signals

Set temperature, room temperature, water temperature, air temperature after evaporator

Insolation sensor Outside air sensor

e = Inside air temperature - Set temperature

Insolation sensor

Set temperature correction

Freeze sensor

Water temperature sensor

55

BLC Temperature control servo HOT Blower motor Temperature control servo

Blow-off servo

25

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 FLOOR Y value

Blow-off servo Compressor ON-OFF ON 3

4

Freeze sensor temperature (ºC)

95ZVE72018

80ZV-2 EU 72-24 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 OFF switch (1) is pressed, the set temperature and the air blow quantity displayed on LCD unit (7) as well as the indicator lamps above AUTO switch (5) and air conditioner ON/OFF switch (8) turned "off", and operation is stopped.

(4) Vent mode selector switch

Indicator lamps

(5) AUTO switch

(8) Air conditioner ON/OFF switch

97ZV72036

- (2) Blower switches These switches change over the air flow quantity in six steps. The air flow quantity is displayed on the LCD unit. When the switch is pressed, the air flow quantity increases. When the switch is pressed, the air flow quantity decreases. In the automatic mode, the air flow quantity is automatically changed over. Display on the LCD unit and the air blow quantity Display on LCD unit

Air blow quantity Air quantity "low" Air quantity "medium 1" Air quantity "medium 2" Air quantity "medium 3" Air quantity "medium 4" Air quantity "high"

80ZV-2 EU 72-25 72 Function & Structure Operator Station Group Air Conditioner - (3) Temperature setting switches These switches set the temperature inside the cab in the range from 18.0ºC (65ºF) to 32.0ºC (90ºF). When the switch is pressed, the set temperature increases. When the switch is pressed, the set temperature decreases. Usually, set the temperature to 23~25.0ºC (72~77ºF). Display on the LCD unit and the function Display on LCD unit

Set temperature

18.0ºC (65ºF)

Maximum cooling

18.5~31.5ºC (65~95ºF)

Temperature inside cab is controlled so that set temperature is realized.

32.0ºC (90ºF)

Maximum heating

- (4) Vent mode selector switch This switch changes over the vent mode. When vent mode selector switch (4) is pressed, the vent mode displayed on LCD unit (7) is changed over, and air is blown from the displayed vent positions. In the automatic mode, the vent mode is automatically changed over. Display on LCD unit

Vent mode

Vent positions (A)

(B)

Face (blow-off to upper portion of body mainly during cooling)

○

○

Face & foot

○

○

Foot (blow-off to feet mainly during heating)

(C)

(D)

Remarks

○

○

Foot & defroster

○

Defroster

○

○

○

This mode is not selected in automatic mode.

○

This mode is not selected in automatic mode.

- (5) AUTO switch This switch automatically changes over the air blow quantity, the vent mode and the inside/outside air in accordance with the set temperature. When AUTO switch (5) is pressed, the indicator lamp above it lights. Usually, press this switch, set the temperature by using temperature setting switches (3), and use the air conditioner in the automatic mode.

When the automatic mode is changed over to the manual mode, the indicator lamp above AUTO switch (5) is extinguished. In the manual mode, the air blow quantity, the vent mode and the inside/outside air can be changed over by manipulating each switch.

80ZV-2 EU 72-26 72 Function & Structure Operator Station Group Air Conditioner - (6) Inside/outside air selector switches These switches change over inside air circulation and outside air entry. When an either switch is pressed, the indicator lamp above it lights to indicate the selected air flow status. In the automatic mode, outside air introduction and inside air circulation are automatically changed over. Inside air recirculation

Outside air entry

The outside air is shut down, and the air inside the cab is circulated. Press this switch to rapidly cool or heat the air inside the cab or when the outside air is dirty. The outside air enters the cab. Press this switch to introduce clean air into the cab or defog the windows.

- (7) Liquid crystal display (LCD) unit This LCD unit indicates the set temperature, the air flow quantity and the vent mode during operation. When 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.)

80ZV-2 EU 72-27 72 Function & Structure Operator Station Group Air Conditioner

Operating method

2. Stopping the automatic operation

Normal use 1. Automatic operation

Set temperature

(1) OFF switch

(3) Temperature setting switches

(5) AUTO switch

97ZV72041

Air flow quantity

(8) Air conditioner ON/OFF switch 97ZV72040

(a) Set AUTO switch (5) to ON. Confirm that the set temperature and the air flow quantity are displayed on the LCD unit, and that the indicator lamps above AUTO switch (5) and the air conditioner ON/OFF switch (8) are lit. (b) Adjust temperature setting switches (3), and set arbitrary temperature. The air conditioner automatically changes over the air flow quantity, the vent mode and the inside/outside air to realize the set temperature. Note When the vent mode is set to or in the automatic operation, if the engine water temperature is low, the air flow quantity is restricted to prevent blow-off of cold air.

Press OFF switch (1). Then, the set temperature and the air flow quantity displayed on the LCD unit are extinguished, the indicator lamps above AUTO switch (5) and air conditioner ON/OFF switch (8) are extinguished, and the operation is stopped.

80ZV-2 EU 72-28 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 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.

Press OFF switch (1). Then, the set temperature and the air flow quantity displayed on the LCD unit are extinguished, the indicator lamps above AUTO switch (5) and air conditioner ON/OFF switch (8) are extinguished, and the operation is stopped.

(b) Set to ON air conditioner ON/OFF switch (8). Confirm that the indicator lamp above the switch lights. (c) Adjust temperature setting switches (3), and set arbitrary temperature. (d) Press vent mode selector switch (4), and select arbitrary vent mode. (e) Press an either inside/outside air selector switch (6) to select inside air circulation or outside air entry.

80ZV-2 EU 72-29 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 blower switches (2), and adjust the air flow quantity. Confirm that the set temperature and the air flow quantity are displayed on the LCD unit. (b) Press vent mode selector switch (4), and display the vent mode on the LCD unit. (c) Set to ON air conditioner ON/OFF switch (8). Confirm that the indicator lamp above the switch lights.

(3) Temperature setting switches 97ZV72045

(a) Press blower switches (2), and adjust the air flow quantity. Confirm that the set temperature and the air flow quantity are displayed on the LCD unit. (b) Press vent mode selector switch (4), and display the vent mode or on the LCD unit. (c) Set outside air introduction selector switch (6). (d) Press temperature setting switches (3), and display the set temperature "32.0" (maximum heating status) on the LCD unit.

(d) Arbitrarily set blower switches (2), temperature setting switches (3) and 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 cab in rainy season, set air conditioner ON/ OFF switch (8) to ON.

80ZV-2 EU 72-30 72 Function & Structure Operator Station Group Air Conditioner

Other functions

3. Failure code deletion

Self-diagnosis function Each sensor and equipment used in the air conditioner can be diagnosed for failure.

(1) OFF switch

After completing the inspection and/or the repair, delete the failure codes memorized in the computer. If not removed, the failure codes memorized in the computer continue to display on the LCD whenever diagnosing. To delete the failure codes, press and hold both air intake control switches (6) for 3 seconds or more. <Display on the LCD unit and the failure mode> Display

(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 both temperature setting switches " " and " " (3) are pressed and held together for 3 seconds or more, the failure mode is displayed on the LCD unit. (a) If two or more failure are detected, the displayed contents can be scrolled through by pressing either one of temperature levels (3) " " or " ". (b) Press 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 both temperature setting switches (3) " " and " " together for 5 seconds or more to change over the unit of the displayed value between Celsius and Fahrenheit. However, the unit type (C or F) itself is not displayed. Only the set value is displayed. Value displayed on LCD unit Celsius (ºC)

18.0~32.0

Fahrenheit (ºF)

65~90

80ZV-2 EU 72-31 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 coil Evaporator coil

Cold air Co ld

air

Air mixing damper B (completely closed) [In the case of maximum heating] Air mixing damper A (completely closed)

Ho ta ir

Blower motor Inside/outside air selection damper Air mixing damper A

ld

a ir

Inside air

Outside air

Fan

Blower motor Heater radiator

Co

Evaporator Air mixing damper B

80ZVE72001

The air conditioner unit has the cooling, heating and air blowing functions to perform conditioning of the air inside the cab, and consists of an evaporator which cools down the air, a heater radiator which warms the air and a blower motor which blows the air. The temperature in the vent position is adjusted when the opening/closing position of the air mixing damper is so controlled that the cooled air while passing through the evaporator and the warmed air while passing through the heater radiator are mixed. The air mixing damper is controlled by the servo motor for air mixing assembled in the unit.

Air mixing damper B (completely opened)

80ZVE72002

During maximum cooling, the air mixing damper B is completely closed, and the air mixing damper A is completely opened. As a result, the air cooled by the evaporator does not go through the heater radiator but is blown off. During maximum heating, the air mixing damper A is completely closed, and the air mixing damper B is completely opened. As a result, all the air which has gone through the evaporator goes through the heater radiator, then the warmed air is blown off.

80ZV-2 EU 72-32 72 Function & Structure Operator Station Group Air Conditioner

Evaporator

(7)

(5)

Evaporator

The evaporator is an important heat exchanger which evaporates liquid refrigerant set to low temperature and low pressure by an expansion valve, utilizes its latent heat, and absorbs heat from air (target) inside the cab. Accordingly, heat should be smoothly transmitted between the target and the refrigerant in the evaporator.

(4)

For this purpose, fins are provided on the air side of the evaporator to extend the heat transmission area on the air side so that heat can be smoothly transmitted between the refrigerant and the air.

(2)

By cooling, the moisture contained in the air condenses, changes into water drops, and adheres to the outside of the evaporator. If these water drops are frozen, the cooling effect deteriorates. To prevent this, attention should be paid also to proper drainage of condensed water.

(8) (1)

(6)

The refrigerant quantity supplied to the evaporator is adjusted by the expansion valve described next. In order to ensure that the refrigerant quantity is accurately adjusted, pressure drop of the refrigerant inside the evaporator should be minimal.

(3)

Refrigerant flow inside evaporator ( From expansion valve(1) to (8) Compressor

)

Accordingly, reduction of pressure drop is an element to enhance the performance of the evaporator. 97ZV72048

Troubleshooting the evaporator Item

Symptom

Cause

Gas leak

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

- 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

Air quantity is small, and low pressure is low.

- Blockage in filter (Evaporator is not preforming inadequately.)

- Cleaning/replacement

Freezing

Action

80ZV-2 EU 72-33 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, and transfers the detected temperature to the refrigerant gas 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 cab (cooling load) and fluctuation of the rotation speed of the compressor. The expansion valve consists of a needle valve, a diaphragm and a temperature sensing rod. The temperature sensing rod detects the temperature of the refrigerant which has gone through the evaporator, and transfers the detected temperature to the refrigerant gas chamber located in the upper portion of the diaphragm chamber.

The gas pressure changes in accordance with the detected temperature, the temperature sensing rod directly connected to the diaphragm is moved, then the needle valve opening is adjusted. - When the temperature at the exit of the evaporator is low or when cooling load is small, following occurs. The gas pressure inside the diaphragm chamber becomes low, the volume decreases, the temperature sensing rod moves to the right, and the needle valve is closed. - When the temperature at the exit of the evaporator is high or when cooling load is great, following occurs. The gas pressure inside the diaphragm chamber becomes high, the volume increases, the temperature sensing rod moves to the left, the needle valve is opened, and more quantity of refrigerant is supplied to the evaporator.

80ZV-2 EU 72-34 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.

80ZV-2 EU 72-35 72 Function & Structure Operator Station Group Air Conditioner

Heater radiator coil

Fin

Heater core

97ZV72051

The heater radiator utilizes the engine cooling water as the heat source. When going through the heater radiator, the air receives heat from the heater radiator fins and is warmed. The hot water inside the heater radiator is forcedly circulated by the engine water pump. Troubleshooting the heater radiator Item Water leak

Symptom Water leaks from heater core.

Cause - Joint portion of supply area - Cracks in heater core main body

Action - Repair/replacement

Blockage in circuit

Air inside cab does not become warm.

- Blockage inside heater radiator

- Replacement

Blockage in fins

Air quantity is small.

- Blockage in fins

- Cleaning

80ZV-2 EU 72-36 72 Function & Structure Operator Station Group Air Conditioner

5 4

3 2 1

Servo motor

1

6

2 3

M

5

7

4 6 7

97ZV72052

When a switch on the control panel is pressed, the power is applied from the control panel on terminal (6) or (7) of the servomotor. (The rotating direction is 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

80ZV-2 EU 72-37 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 (9.4 amps) ± 10%

Fan outer diameter

ø150 (5.9")

Note This unit can be bench tested with 24 V DC by using normal test methods. Determine if excessive amperage is required to turn it. It is controlled by the speed control (BLC) below. Air Air 97ZV72053

The blower motor assembly consists of a DC motor and a fan, and blows air. Troubleshooting the blower motor Item Blower motor operation is defective.

Symptom Air is not blown at all.

Cause - Blower motor - Control unit

Action - Repair/replacement

BLC (blower linear control)

85V2U72004

97ZV72054

This resistor changes over the air quantity of the blower motor. Troubleshooting the blower linear control Item

Symptom

Cause

Action

Wire in BLC is broken.

Air quantity does not change.

- BLC - Control unit

- Replacement

Blower motor operation is defective.

Air is not blown at all.

- Blower motor - Control unit

- Repair/replacement

80ZV-2 EU 72-38 72 Function & Structure Operator Station Group Air Conditioner

De-icing sensor (Thermistor (or thermal resistor))

Evaporator

Appearance of thermistor 8,000 7,000

Resistance ()

6,000

Thermistor

5,000

Heater radiator

4,000

97ZV72056

3,000 2,000 1,000 0

10 (14)

5 (23)

0 (32)

5 (41)

10 (50)

15 (59)

20 (68)

25 (77)

30 (86)

Temperature (ºC) (ºF) Characteristics curve between temperature 85V2U72005 and resistance of thermistor

The thermistor, a kind of semi-conductor, offers the characteristics as shown in the curve on the above. When the temperature becomes high, its resistance becomes small. When the temperature becomes low, its resistance becomes large.

The thermistor mounted on the blowoff port side of the evaporator detects the temperature of the air cooled by the evaporator, and transmits it as a signal to the control amplifier. If the air at the vent is 3ºC (37ºF) or less, the control amplifier turns off the compressor clutch relay. If the air at the blowoff port becomes 4ºC (39ºF) or more, the control amplifier turns on the compressor clutch relay again to restart cooling. Because the air temperature at the vent is detected and the compressor clutch relay is turned on and off accordingly, freezing of the evaporator is prevented.

Troubleshooting the thermistor Item

Symptom

Cable in thermistor is broken.

Compressor clutch does not work.

Thermistor is short-circuited.

Air not blowing.

*Note For temperature reference between ºC and ºF please see references below. Temp ºC

Temp ºF

-10ºC 0ºC 10ºC 20ºC 25ºC 30ºC

14ºF 32ºF 50ºF 68ºF 77ºF 86ºF

Cause - Thermistor

Action - Replacement

80ZV-2 EU 72-39 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 (-22ºF)

91.4 k

25ºC (77ºF)

5 k

100ºC (212ºF)

0.321 

Inside air temperature sensor

97ZV72058

This sensor detects the air temperature inside the cab, and feeds it back to the control panel. This sensor is installed in the inside are suction port, and can be taken out when the clamp is removed. Temperature

Resistance value

0ºC (32ºF)

16.45 k

25ºC (77ºF)

5 k

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.

80ZV-2 EU 72-40 72 Function & Structure Operator Station Group Air Conditioner

Compressor and magnetic clutch

Compressor specifications

Compressor Piston

Discharge valve

1

6

Discharge valve

74

3 10 5

Suction valve Diagonal plate

8

Suction valve

Suction/compression action

2

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 draws in and compresses the gaseous refrigerant at low temperature and low pressure which deprived heat of the air inside the cab in the evaporator and was vaporized to make the gaseous refrigerant be at high temperature and high pressure, then feeds it to the circuit on the high pressure side again. Five pairs of pistons (with ten cylinders) reciprocate in the same direction with the shaft in accordance with rotations of the shaft. Accordingly, when one piston of a pair is in the compression stroke, the other one is in the vacuum stroke. The compressor is lubricated by the compressor oil contained in the gaseous refrigerant and the oil splashed by the diagonal plate. Accordingly, if the refrigerant quantity decreases, the compressor will seize from oil starvation. To prevent seizure, a pressure switch is provided in the circuit so that the power supplied to the magnetic clutch is shut down and the compressor is protected when the refrigerant quantity decreases.

97ZV72061

Model

10S150

Cylinder diameter

ø32 (1.26")

Stroke

20.8 mm (0.82")

Number of cylinders

10

Cylinder capacity

167.3 cm3 (10.21"3)

Maximum allowable number of rotations

6,000 min-1

Lubricating oil

ND-OIL8

Lubricating oil quantity

180 cm3 (11"3) [6 oz]

80ZV-2 EU 72-41 72 Function & Structure Operator Station Group Air Conditioner

Magnetic clutch

Magnet clutch specifications Model S

Pulled 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 cab reaches or exceeds the temperature set by the temperature setting switches, the magnetic clutch stops or drives the compressor.

Suction face

Pulley Stator coil

Hub

Rotor

Stator Ball bearing

Magnet clutch 97ZV72063

The hub of the magnetic clutch is fitted onto the shaft of the compressor. While the compressor is not driven, the hub is separated from the rotor and only the pulley is rotating. When the air conditioner switch is set to ON, the current flows in the stator coil, the stator works as a magnet and engages the hub, then the compressor rotates together with the pulley. When the current applied on the stator coil is set to OFF, the hub is not immediately separated but rotates together with the pulley because the pulley has residual magnetism. Accordingly, clearance is provided between the hub and pulley so that they are not in close contact with each other during disengagement. This clearance is called air gap.

L50T

Voltage

DC 24 V

Power consumption

40 W (1.67 amps)

Drive belt

V-ribbed belt (six ribs)

Air gap

0.5±0.15 mm (0.020" ± 0.006")

80ZV-2 EU 72-42 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

- Suction or exhaust valve

Action

- Repair/replacement

- Abnormal sounds are made while clutch is turned on. Clutch draw voltage is low.

- Stator coil

- Replacement

Power is not supplied to stator coil.

- Wiring on main body - Control amplifier - Pressure switch

- Repair - Replacement - Replacement

- Magnetic clutch

- Replacement

Compressor main body is defective (seized, etc.).

- Shaft, piston

- Repair/replacement

Clutch bearing is damaged.

- Clutch bearing

- Replacement

- Magnetic clutch

- Replacement

V belt is slack.

- V belt

- Adjustment/replacement

Compressor main body is defective.

- Internal compressor trouble

- Repair/replacement

- V belt

- Adjustment/replacement

Gap between hub and rotor is large.

Contact or slippage caused by too small gap between hub and rotor.

V belt is slack.

- Compressor does not rotate. (Air in cab does not become cool enough.)

- Abnormal sounds are made while clutch is turned off.

- Abnormal sounds are made while clutch is turned on.

* This can be the result of "liquid charging". Do not liquid charge as a compressor cannot compress liquid; this will damage it.

80ZV-2 EU 72-43 72 Function & Structure Operator Station Group Air Conditioner

Condenser unit

Condenser fan motor The condenser fan motor used to cool down the condenser is mounted on the condenser together with a fan shroud.

Condenser Blower assembly Resistor Cover

Fan motor 95V2U72002

Each condenser unit consists of a condenser, a condenser fan motor and a resistor. Two condenser units are arranged in series with the piping. The condenser units cool down the gaseous refrigerant at high temperature and high pressure sent from the compressor, and change it into liquid refrigerant.

Condenser The condenser consisting of tubes and fins cools down the gaseous refrigerant at high temperature and high pressure (70ºC, 1,618 kPa (16.5 kgf/cm2)) (158ºF (235 psi)) sent from the compressor, and change it into liquid refrigerant during passing tubes.

Condenser specifications Voltage

DC 24 V

Power consumption

80 W (3.4 amps) x 10%

Air quantity

1,750±10 m3/Hr (61,800"3/Hr)

Number of rotations of motor

2,200 min-1 (rpm)

80ZV-2 EU 72-44 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 Rotation of condenser fan cool enough. motor is defective.

Cause

Action

- Blockage or crushed fins

- Clean or replace condenser

- Fan motor

- Repair or replace motor

Blockage / condenser airflow

High pressure is abnormally high, low pressure is abnormally low, and air does not become cool enough. Air bubbles can be seen through sight glass.

- Internal to condenser fins

- Clean or replace condenser

Gas leak

Both high pressure and low pressure are abnormally low, and air bubbles can be seen through sight glass.

- Leaks at joints - Cracks in main body

- Tightening - Repair or replacement

* It is important to check the fan blades also as these can become bent or packed with dirt, making them ineffective.

80ZV-2 EU 72-45 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 parts within the circuit may corrode, or moisture may be frozen inside expansion valve which may clog the circuit. To prevent such failure, synthetic zeolite (drying agent) is positioned inside the air conditioner and acts as a desiccant suitable to the circuit so that it absorbs moisture entering the circuit during installation or refrigerant charging. When the expansion valve is often frozen by moisture (icing), the desiccating agent does not have enough absorption ability. When this happens, the receiver must be replaced.

Strainer

Desiccant specifications

Receiver tube

Receiver tank

97ZV72065

The receiver dryer consists of a receiver tank, desiccant, strainers, and a receiver tube.

Receiver tank In the air conditioner, the number of rotations of the compressor changes and the proper refrigerant quantity in the cooling circuit fluctuates in accordance with fluctuation of the number of revolution of the engine. The receiver tank receives such fluctuation. When the cooling circuit does not require much refrigerant, the receiver stores temporarily excess refrigerant. When the cooling circuit requires much refrigerant, the receiver tank supplies refrigerant from its receiver tube to the circuit. In addition, the receiver tank stores a reserve of refrigerant in order to take balance of charging of the refrigerant and respond to any minute leaks of the refrigerant caused by permeation through rubber hoses.

Capacity

550 cm3

Desiccating agent

Synthetic zeolite

Desiccating agent capacity

290 g

IMPORTANT If parts of the cooling circuit are removed and left for a long time for repair or another reason, the desiccant absorbs moisture contained in the air and loses its absorption performance, and the receiver dryer should be replaced. To prevent this, after parts are removed, all openings should be plugged.

80ZV-2 EU 72-46 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. Strainers are provided to prevent dusts from flowing with in the refrigerant. The strainers cannot be cleaned. When they are considerably clogged (in this case, the high pressure increases and the low pressure decreases), the entire receiver dryer should be replaced. Troubleshooting the receiver tank Item

Symptom

Cause

Action

Icing

- At first, air in cab will cool down, but after a short time no longer will cool properly.

- Desiccating agent in receiver

- Replacement of receiver dryer

Blockage in strainers

- High pressure is excessively high, low pressure is excessively low, and air does not become cool enough*.

- Blockage in strainers

- Replacement of receiver dryer

*A means to test this is to check the temperature between the inlet and outlet of receiver dryer. If it drops more than it should the dryer is plugging and should be replaced.

80ZV-2 EU 72-47 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.

WARNING Possible freezing of eye tissue. Always wear protective eyewear when doing a visual inspection.

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.

80ZV-2 EU 72-48 72 Function & Structure Operator Station Group Air Conditioner

Switch

Switching pressure kPa (kgf/cm2) (psi)

Function

Switch operation confirmation method

Causes of abnormal pressure

Pressure switch coupler

High pressure switch

When pressure between compressor and expansion valve becomes abnormally high, this switch shuts down power supplied to compressor magnetic clutch to protect circuit.

2,550 (26) (370)

A

3,136 (32) (455)

C

ON

D B

OFF

Heat radiation of condenser is insufficient due to clogging in condenser or defective rotation of condenser fan*. *A damaged fan blade would produce a similar symptom.

Check conductivity between A and B.

Medium pressure switch

When detecting fluctuation of pressure between compressor and expansion valve, this switch gives a signal to control amplifier about whether to rotate condenser fan motor at low speed or high speed. While this switch is ON, fan motor rotates at high speed. While this switch is OFF, fan motor rotates at low speed.

Low pressure switch

When pressure between compressor and expansion valve becomes abnormally low due to refrigerant leak, this switch shuts down power supplied to compressor magnetic clutch to prevent seizure of compressor caused by insufficient compressor oil which decreased together with refrigerant.

1,519 (15.5) (220) ON

Check conductivity between C and D in pressure switch coupler shown above.

OFF 1,225 (12.5) (178)

226 (2.3) (33) ON

Check conductivity between A and B Refrigerant leak from a part in pressure switch coupler shown of circuit. above.

OFF 196 (2.0) (28)

Troubleshooting the pressure switch Item Insufficient cooling

Gas leak

Symptom

Cause

Action

- Condenser fan motor does not change its speed (to high speed).

- Medium pressure switch

- Replacement

- Even when abnormal high pressure (3,136 kPa (32 kgf/cm2) (455 psi)) occurs, compressor does not turn off. - Even when gas (refrigerant) has run short, compressor does not turn off.

- High or low pressure switch*

- Replacement

*If abnormally high pressure occurs while the high pressure switch is non-functioning, the equipment in the cooling circuit may be damaged. The pressure relief valve releases the refrigerant to the atmosphere in order to prevent equipment or personnel damage.

80ZV-2 EU 72-49 72 Function & Structure Operator Station Group Air Conditioner

Pressure relief valve

Flow rate (L/min) 113

Gas discharge route while valve is operating 97ZV72071

This valve mounted on the high pressure side of the compressor service valve releases the refrigerant to the atmosphere when abnormal high pressure occurs.

0

Pressure 28.1 2,756 400

35.0 3,430 500

42.4 4,158 600

(kgf/cm2 ) (kPa) (psi)

Characteristics drawing of relief valve operation 97ZV72069a

Pressure relief valve 97ZV72070

IMPORTANT When the refrigerant quantity inside the cooling circuit is correct, the pressure switch always remains ON even if the compressor is stopped because the refrigerant pressure is approximately 588 kPa (6.0 kgf/cm2) (85 psi) as far as the outside air temperature is around 25ºC (77ºF). When the outside air temperature becomes 0ºC (32ºF) or less, the pressure switch for low pressure detection turns off even if the refrigerant quantity is proper because the refrigerant pressure becomes 196 kPa (2.0 kgf/cm2) (28 psi) or less. As a result, the compressor does not work. It means that the pressure switch for low pressure detection functions also as a thermostat which detects the outside air temperature.

80ZV-2 EU 72-50 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

80ZV-2 EU 72-51 72 Function & Structure Operator Station Group Air Conditioner

Refrigerant hose

WARNING Burst hazard These hoses operate at high pressure for HVAC systems and must not be replaced with substandard hoses.

Outer layer Reinforcing layer

Use only OEM replacement hoses or hoses of the same rating as OEM replacement hoses. Mouth ring Inner layer Intermediate layer 97ZV72073

White line and "R134a" indication

97ZV72074

As shown in the figure on the above, the refrigerant hose consists of the outer layer, the reinforcing layer, the intermediate layer and the inner layer, and the mouth ring is crimped. Region

Material

Outer layer

Ethylene propylene rubber

Reinforcing layer

Polyester

Intermediate layer

Chlorinated butyl rubber

Inner layer

Nylon

The mouth ring of this hose is changed and the symbol "R134a" is indicated on this hose as shown in the figure on the right.

IMPORTANT Never use any other hose or any other refrigerant. Otherwise, refrigerant may leak.

80ZV-2 EU 72-52 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 (-22ºF)). 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 (104ºF) or less. Make sure to keep the can away from hot objects or fire. - During storage, make sure to avoid direct sunlight, and store the can in a dark and cool place. - Inside the closed cab (including trunk), the air temperature may rise considerably due to solar heat, etc., and may become dangerously temperature even in winter if the closed cab is exposed to direct sunlight. Never put the can inside the cab. - If the service can suffer from flaws, dents and deformations, its strength deteriorates. Never hit or drop it. And never throw or drop a package of cans while loading or unloading it. - Keep the can away from the reach of children.

IMPORTANT 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 (104ºF) 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.

80ZV-2 EU 72-53 72 Function & Structure Operator Station Group Air Conditioner

Work procedure

Charging procedure

The refrigerant charging process is mainly divided into "refrigerant evacuation procedure" and "gas charging procedure" as shown below.

1. Charge the system with the required amount of gas by weight, and check for leaks by letting the HVAC system sit static and permit pressure to equalize. 2. Check the system pressure in comparison to the ambient temperature. If acceptable, go to next step (3). 3. Turn on the engine, run at 1,200~1,500 rpm. 4. Turn on the HVAC air condition system, making sure that the heat is off and A/C is set with fan on high. 5. Let the HVAC system run on coldest setting until all parts are cold saturated; this should take about 30 minutes or more. 6. Check the temperature that is coming from the vents of the HVAC system inside the cab. Check the performance in the operating pressure and temperature chart. 7. Either remove or install more refrigerant depending upon the findings.

Refrigerant evacuation procedure The "refrigerant evacuation process"* eliminates moisture present inside the cooling circuit. If the moisture remains inside the circuit, it may cause varied problems even if its quantity is extremely small: The moisture may freeze inside the expansion valve during operation, and may block the circuit or generate oxidation. To prevent such problems, the refrigerant containing air inside the cooling circuit should be evacuated, and the moisture inside the circuit should be boiled and evaporated so that all moisture is eliminated before pure refrigerant is recharged into the circuit. *May be referred to as "air evacuation procedure" since it contains air which also contains water that can cause system damage as noted.

Gas charging procedure The "gas charging procedure" charges the refrigerant as gas into the circuit while in a vacuum state. The gas charging process not only affects the cooling ability of the air conditioner but also affects the system component life.* If the refrigerant is charged too quickly or in a liquid state, pressure inside the circuit may become extremely high and the cooling ability may deteriorate. If the refrigerant charging volume is too low, the lubricating oil for the compressor may not circulate smoothly and compressor pistons may seize and lock up the compressor. Because the gas charging process involves high pressure gas, it is extremely dangerous if it is not done correctly. Observe the work procedure shown below and the cautions, and charge the refrigerant correctly. *Note Liquid charging destroys a compressor. Never permit entry of liquid refrigerant.

Observe the work procedure and cautions shown below, and charge the refrigerant correctly. The system should operate within about 5% of the parameters. Be sure that the condenser is clear, evaporator is clean and the fans are all working as they should with good airflow in the system. Note If the inside of the cab become cold during the charging process, the compressor magnetic clutch turns off and system charging is disabled. When charging, completely open the cab doors. This will keep the system from turning off and on.

80ZV-2 EU 72-54 72 Function & Structure Operator Station Group Air Conditioner

Charging procedure chart

Start evacuation. 20~30 min Refrigerant evacuation process

Stop evacuation.

-750 mmHg (-30" Hg) or less If too little vacuum, repair leaking connection*

Leave system untouched for 5 min. Check pressure.

*It is possible that system may need pressurized and tested for leaks.

Stop when gage indicates excessive pressure (air entry)

When gage indicates a normal value Charge refrigerant gas.

Check for gas leak. Gas charging process

Charge gaseous refrigerant until gauge pressure reaches 98 kPa (1 kgf/cm2) (14 psi). Check for leaks.

Note A full charge should be about 2±0.1 lbs (900±50 g) of refrigerant.

Charge refrigerant.

Check for gas leak.

As a general guideline, with engine off and HVAC system static, the pressure in the system should be about 85 psi (588 kPa) (6.0 kgf/cm2) with the pressure has equalized between the low and high pressure side.

Performance test 95ZVE72042

80ZV-2 EU 72-55 72 Function & Structure Operator Station Group Air Conditioner

Refrigerant charging tools

Charging hose and quick connectors

Recovery and recycling unit

Gauge manifold*

Low pressure charging hose (blue) 95ZV72024

It is against Federal Regulations* in the United States to release refrigerant to atmosphere. A recovery and recycling unit must be used to capture the refrigerant so as not to release it into the atmosphere. *Refer to section 609 of the clean air act at www.epa.gov.

It is used for the following; 1. Recover the refrigerant. 2. Filter the refrigerant. 3. Measure the refrigerant weight. 4. Remove trapped non compressible gases (air). 5. Measure the refrigerant to install in system by weight. 6. Measure the pressure of the refrigerant in system. 7. Measure ambient temperature. 8. View bubbles in system if there are any. Read and understand the Operation Manual for the recovery and recycling machine.

IMPORTANT Only use a vacuum pump if the system is already open to atmosphere and refrigerant has completely left the system.

High pressure charging hose (red)

Quick connector (Lo)

Center charging hose (green or yellow) Quick connector (Hi)

97ZV72077

These different colored hoses are used to evacuate the air and charge the gas. (The colors may be different depending on the manufacturer.) Red hose Connects the high pressure valve of the gauge manifold and the high pressure charging valve (with "H" mark on its cap) of compressor outlet hose. Blue hose Connects the low pressure valve of the gauge manifold and the low pressure charging valve (with "L" mark on its cap) of the compressor inlet hose. Green or yellow hose Connects the center valve of the gauge manifold and the vacuum pump (or the service can valve). *Gauge manifold may be used with vacuum pump or recovery unit.

80ZV-2 EU 72-56 72 Function & Structure Operator Station Group Air Conditioner

Gauge manifold

Leak detector

Many recovery and recycling units are equipped with a gauge manifold, which is very similar to the gauge manifolds that were used for earlier application refrigerant handling systems. Typically, the low pressure side hose color is blue, the charging hose color is yellow (may be light green), and the high pressure side hose color is red. These are generally integrated into the recovery and recycling unit. 85V2U72007

Low pressure gauge

High pressure gauge

A leak detector find areas where refrigerant traces are leaking and sounds an alarm to alert the technician of areas of leakage. Gauge manifold

Low pressure valve Low pressure charging hose Center valve mounting nipple Center charging hose mounting nipple

High pressure valve High pressure charging hose mounting nipple 97ZV72078

It is used to evacuate the air and charge the gas, and equipped with a high pressure gauge, a low pressure gage, plus valves and hose mounting nipples as shown in the figure on the above. Some gauge manifolds are equipped with sight glasses. These are used to check for bubbles in the refrigerant. Excessive flow of bubbles may indicate: 1. Low pressure. 2. Leak to atmosphere (air ingestion) when in vacuum. 3. Boiling action, perhaps due to pressure changes.

80ZV-2 EU 72-57 72 Function & Structure Operator Station Group Air Conditioner

Cautions on handling of quick connector and charging valve When discharging the refrigerant, use a quick connector.

Precautions

Quick connector

1. Connecting the quick connector.

Screwdriver, etc. Sleeve

"Click" sound (OK) Valve pin

(A) Spring

Charging valve

Charging valve

97ZV72082

97ZV72080

IMPORTANT Slide the sleeve upward, push the quick connector against the charging valve, press and hold securely part (A) until a click is heard, then slide the sleeve downward.

IMPORTANT - Push quick connector against charging valve vertically. - If refrigerant remains inside the charging hose, the quick connector may not be easily connected. 2. Disconnecting the quick connector

Sleeve

"Click" sound (OK)

(A)

(B)

97ZV72081

While pressing and holding the part (A) of the quick connector, slide sleeve upward to disconnect quick connector.

If you push the valve pin with a considerable force [294 kPa (3 kgf/cm2) (43 psi)] with a screwdriver, etc., the spring may come off and the refrigerant may leak. Never do this.

80ZV-2 EU 72-58 72 Function & Structure Operator Station Group Air Conditioner

Refrigerant charging procedure

Valve setting

Air evacuation work

Lo Hi Closed Closed High pressure valve

WARNING If hoses are connected incorrectly, serious accidents may occur. Observe the following. - Never confuse connection of hose to the high pressure side and the low pressure side of the gauge manifold.

Low pressure valve

(red) (blue) (green)

(Hi)

Recovery and recycling unit (Lo)

Charging valve on high pressure side (located on receiver dryer) Vacuum pump shown Compressor (stopped) A refrigerant recycle and recovery unit may be used. 95ZVE72045

95ZV72024

With system "OFF"; (a) Close both the high pressure (Hi) valve and the low pressure (Lo) valve of the gauge manifold. (b) Connect the charging hose.

It is against Federal Regulations* in the United States to release refrigerant to atmosphere. A recovery and recycling unit must be used to capture the refrigerant so as not to release it into the atmosphere.

Red hose To be connected between the high pressure (Hi) valve of the gauge manifold and the high pressure charging valve.

*Refer to section 609 of the clean air act at www.epa.gov.

1. Connecting the gauge manifold

CAUTION Close both low and high pressure valve, as seen in "a" below.

Blue hose To be connected between the low pressure (Lo) valve of the gauge manifold and the low pressure charging valve of the compressor. Yellow or green hose To be connected between center valve of gauge manifold and recovery unit (equipped with vacuum pump).

IMPORTANT Connect quick connectors to both the high pressure and low pressure sides before starting air evacuation. The check valve of a quick connector cannot hold vacuum status. If a side of quick connector is not connected, a vacuum condition cannot take place.

80ZV-2 EU 72-59 72 Function & Structure Operator Station Group Air Conditioner 2b. Evacuating the system with a recycling and recovery unit.

2a. Evacuating the system with a vacuum pump When pulling a vacuum with a vacuum pump on a system that has been open due to replacing major components.

Valve setting

After air evacuation Valve setting Lo Hi Lo Hi for 30 minutes OpenedOpened Closed Closed High pressure valve

Low pressure valve 95ZV72024

(red) (blue) (green)

(Hi) (Lo) Charging valve on high pressure side Vacuum pump (operating) Compressor (stopped)

(stopped) 95ZVE72046

(a) Open both the high pressure (High) valve and the low pressure (Low) valve of the gauge manifold. (b) Turn on the switch of the vacuum pump, and evacuate until the degree of vacuum becomes -750 mm Hg (-30" Hg) for about 20~30 minutes. (c) After finishing evacuation, close both the high pressure valve and the low pressure valve of the gauge manifold. Then, turn off the switch of the vacuum pump.

IMPORTANT If you stop the vacuum pump before closing each valve of the gauge manifold, refrigerant from vacuum unit and tank is released to the atmosphere. It is important to first close both high and low side valves.

Each manufacture of recycling and recovery units provide operating instructions for their units. Read, understand and closely follow operating instructions as provided.

80ZV-2 EU 72-60 72 Function & Structure Operator Station Group Air Conditioner 3. Checking for leaks after vacuum has been drawn Valve setting

Leave for 10 minutes or more as per EPA regulations Lo Hi Pointer of low Closed Closed pressure gauge moves toward "0". Low pressure gauge 0

0

Moves toward "0".

Tighten connection areas of piping. 97ZV72085

After a vacuum has been pulled on system;

Refrigerant charging process This section describes a static charging procedure with the engine in "OFF" and compressor not turning. Do not run engine until high and low pressures are equal so that no damage is done to the compressor. The illustrations below show use of a gauge manifold assembly. This is not the preferred method in the USA due to EPA regulations against purging refrigerant to atmosphere. Use of a recovery and recycle unit is best. Carefully follow instructions with recovery unit. Valve setting Lo Hi Closed Closed

Leave the circuit for 5 minutes or more with H and L valves of gauge manifold closed. Then, make sure that the needle of each gauge does not move. If the needle of the gauge moves toward "0", a leak has occurred somewhere in the circuit. Tighten the connection areas of the piping, evacuate the system again, then make sure that there is no leaks.

Open the service canister valve. Blue (low)

Red (high) Service Charging hose R134a canister (green or yellow)

97ZV72086

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".

IMPORTANT Never purge or vent refrigerant to atmosphere. (EPA)

80ZV-2 EU 72-61 72 Function & Structure Operator Station Group Air Conditioner

Valve setting Lo Hi OpenedOpened

1. Charging the refrigerant from the high pressure side with the engine in the "OFF“ position.

Valve setting

After 1~1.5 service cans are charged

Lo Hi Closed Closed

High pressure valve

(a) After evacuation, disconnect the charging hose (green or yellow) of gauge manifold from vacuum pump, and connect it to the service canister. (b) Purging air from lines

Low pressure valve (red)

(blue)

(green)

(Hi)

Open the service canister valve very slightly with low and high pressure manifold valves closed. Open both high and low side valves so that lines are charged. Connect lines to HVAC system. A small amount of trapped air will escape from the lines, as air is discharged by the refrigerant pressure. EPA says that release of this tiny bit of air that is very small is ok.

(Lo) Charging valve on high pressure side

Compressor (stopped) R134a

Service can valve (opened charge closed) 95ZVE72052

WARNING If the refrigerant were changed from the high pressure side, the refrigerant would flow in reverse direction and the can and the hose may be burst if you start the engine and operate the compressor. Never start the engine in this condition.

IMPORTANT If you charge refrigerant with refrigerant canister placed upside down liquid will exit canister, refrigerant is sucked into the compressor in a liquid state. This will damage the compressor. Charge only with refrigerant gas.

(c) WITH ENGINE "OFF"; Open tank canister valve and charge the gaseous refrigerant until gauge pressure read 98 kPa (1 kgf/cm2) (14 psi). (This should take about one to one and half one lb service cans. If using scale, add one to one and a half lbs.) (d) After charging, close the low and high pressure valves of the gauge manifold and the service can valve. 2. Check for gas leak with a leak detector Check for gas leak in the circuit using a leak tester, etc. If a leak is detected, repair leak as required. If located at connections, tighten the connection area.

IMPORTANT Make sure to tighten the connection areas of the piping at a specified tightening torque. For the tightening torque, refer to the volume "Maintenance Standard". Do not overtighten or it will worsen.

80ZV-2 EU 72-62 72 Function & Structure Operator Station Group Air Conditioner 3. Charging the refrigerant - low pressure side - e/g "ON". Valve setting Lo Hi Opened Closed

Charge the refrigerant until air bubbles seen through the sight glass disappear.

(c) Start the engine, and increase the number of rotations to approximately 1,500 min-1(rpm). (d) On the control panel, set the fan speed to high and set the air flow volume to maximum cold, and set the vent port temperature switches to the coldest status.

Valve setting Lo Hi Closed Closed

High pressure valve

Low pressure valve

(e) Open the low pressure valve of the gauge manifold and service canister valve to charge the refrigerant. When air bubbles seen through the sight glass of the receiver dryer disappear, charge the refrigerant further more by 150~250 g.

(red)

(blue)

(green)

IMPORTANT (Hi)

(Lo) Charging valve on high pressure side

Compressor (On-load) R134a

Service can valve (opened charge closed) 95ZVE72052

When replacing service canister while charging refrigerant, connect the line as described earlier so as to not have air in the line. (f)

After charging, close the low pressure valve of the gage manifold and the service can valve. Then, stop the engine. Refrigerant quantity to be charged (guideline) 900±50 g (2.0±0.1 lb)

Refrigerant quantity

Proper

Gas bubbles are few. (When the number of rpm’s of the engine is gradually increased from the idle status to 1,500 min-1, gas bubbles disappear.)

Too much

Gas bubbles are not seen in the flow at all. System is over-pressurized. (In this case, both the high pressure and the low pressure are high, and the cooling ability is deteriorated.)

Insufficient

Many gas bubbles are seen in the flow. (Gas bubbles visibly seen constantly.)

Sight glass

Receiver joint

Receiver dryer

97ZV72066

(a) Make sure that the high and low pressure valves of the gauge manifold and service canister valve are closed. (b) If the inside of the cab becomes cold during the charging process, the compressor magnetic clutch turns off and system charging is disabled. When charging, completely open the cab doors. This will keep the system from turning off and on.

Sight glass situation

80ZV-2 EU 72-63 72 Function & Structure Operator Station Group Air Conditioner 4. Guidelines to determine quantities of refrigerant charge

5. Disconnecting the gauge manifold

Use the following table to determine the refrigerant charge quantity. Sleeve Item

Criteria

Doors

Completely open

Temperature control switches

Maximum cooling

Blower speed

High

Inside/outside air selection

Inside air

Number of rotations of engine

1,500 min-1

Air conditioner switch

ON

Pressure on high pressure side

1,862 kPa (19 kgf/cm2) (270 psi) or less

IMPORTANT - If outside air temperature is high (40ºC/104ºF or more) or if the pressure on the high pressure side is 1,862 kPa (19 kgf/cm2) (270 psi) or more when the judgement condition above is set, perform the following so that the pressure becomes 1,862 kPa (19 kgf/cm2) (270 psi) or less, then check the refrigerant quantity. - Close the doors completely, and set the blower fan to the low speed (by pressing the Lo switch). - Use a shaded area or a place indoors away from sunlight. - If you turn on the air conditioner while the refrigerant quantity is extremely low, lubricant in the compressor may be insufficient and a failure such as seizure of the compressor may occur. Never do this. - If the refrigerant quantity is over charged, cooling may be insufficient or the pressure inside the circuit may become abnormally high (which is dangerous). Never do this.

"Click" sound (OK)

(A)

(B)

97ZV72081

After inspecting the refrigerant charge, disconnect the charging hose from the high and low pressure charging valves using the following procedure. (a) While pressing and holding part (A) of the quick connector, slide sleeve upward and disconnect the quick connector. (b) Attach a cap to each of the high and low pressure charging valves.

80ZV-2 EU 72-64 72 Function & Structure Operator Station Group

Troubleshooting using the gauge manifold Normal status

<Low pressure side> 215~275 kPa (2.2~2.8 kgf/cm2) (31~40 psi)

Condition After warming up the engine, check the pressure under the following condition. - Doors Completely open

<High pressure side> 1,470~1,765 kPa (15~18 kgf/cm2) (213~255 psi)

- Inside/outside air selection Inside air - Number of rotations of engine 1,500 min-1 - Temperature at suction port of air conditioner 30~35ºC (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 (68~77ºF) 25~30ºC (77~86ºF) 30~35ºC (86~95ºF) 35~40ºC (95~104ºF)

Pressure

Pressure value by gauge

High pressure side

1,000~1,215 kPa

Low pressure side

127~167 kPa

High pressure side

1,215~1,470 kPa

Low pressure side

167~215 kPa

High pressure side

1,470~1,784 kPa

Low pressure side

215~275 kPa

High pressure side

1,784~2,146 kPa

Low pressure side

275~353 kPa

(10.2~12.4 kgf/cm2) (145~176 psi) (1.3~1.7 kgf/cm2)

(18~24 psi)

(12.4~15.0 kgf/cm2) (176~213 psi) (1.7~2.2 kgf/cm2)

(24~31 psi)

(15.0~18.2 kgf/cm2) (213~258 psi) (2.2~2.8 kgf/cm2)

(31~40 psi)

(18.2~21.9 kgf/cm2) (258~310 psi) (2.8~3.6 kgf/cm2)

(40~51 psi)

80ZV-2 EU 72-65 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) (7~14 psi)

<High pressure side> 686~981 kPa (7~10 kgf/cm2) (100~144 psi)

When the refrigerant does not circulate (due to clogging in the cooling circuit) <Low pressure side> Negative value

<High pressure side> 490~588 kPa (5~6 kgf/cm2) (71~85 psi)

97ZV72092

Symptom

Cause

- Pressure is low on both low and high pressure sides.

- Refrigerant quantity is insufficient.

- Gas bubbles go through sight glass continuously.

- Gas is leaking.

- Temperature of blown air is not cold.

Inspection/action point - Find and repair leaks. - Repair leak. Add refrigerant. - If pressure indicated by gage is around "0", detect and repair leaks, vacuum system and recharge.

97ZV72093

Symptom

Cause

Inspection/action point

- If cooling circuit is completely blocked, needle on low pressure side indicates a vacuum immediately.

Clogging in cooling circuit

- Inspect receiver dryer, expansion valve, etc. (Temperature is different between IN and OUT of failing part.)

- If cooling circuit is partially blocked, needle on low pressure side slowly indicates a vacuum.

- After finishing work, evacuate system and recharge.

80ZV-2 EU 72-66 72 Function & Structure Operator Station Group Air Conditioner

When the moisture has entered into the cooling circuit. <Low pressure side> Abnormal status Vacuum

<Low pressure side> 392~588 kPa (4~6 kgf/cm2) (57~85 psi)

<High pressure side> 686~981 kPa (7~10 kgf/cm2) (100~144 psi)

Normal status 215~275 kPa (2.2~2.8 kgf/cm2) (31~40 psi)

When the compression in compressor is defective. <High pressure side> 686~981 kPa (7~10 kgf/cm2) (100~144 psi)

1,470~1,765 kPa (15~18 kgf/cm2) (213~255 psi)

97ZV72095

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.

80ZV-2 EU 72-67 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) (35~50 psi)

When air has entered into the cooling circuit

<Low pressure side> 245~294 kPa (2.5~3.0 kgf/cm2) (35~43 psi)

<High pressure side> 1,961~2,452 kPa (20~25 kgf/cm2) (284~355 psi)

<High pressure side> 1,961~2,452 kPa (20~25 kgf/cm2) (284~355 psi)

97ZV72097

97ZV72096

Symptom

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.

80ZV-2 EU 72-68 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) (43~57 psi)

<High pressure side> 1,961~2,452 kPa (20~25 kgf/cm2) (284~355 psi)

97ZV72098

Symptom

Cause

Inspection/action point

- Pressure is high on both low pressure side and high pressure side.

Expansion valve is defective.

- Temperature sensing rod may be sticking. - Inspect expansion valve. Check temp in and out of valve to determine if it is operating correctly.

- Condensation forms on low pressure side pipes.

Thermal expansion valve

To and from evaporator

Diaphragm

Spring

Temperature sensing rod Needle valve Compressor return From receiver dryer

97ZV72049

80ZV-2 EU 72-69 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

80ZV-2 EU 72-70 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

<Trouble shooting charts>

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

80ZV-2 EU 72-71 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

80ZV-2 EU 72-72 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

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

80ZV-2 EU 72-73 72 Function & Structure Operator Station Group Air Conditioner

80V2E01015

D-2

D-1

2

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

80ZV-2 EU 72-74 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"

80ZV-2 EU 72-75 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

80ZV-2 EU 72-76 72 Function & Structure Operator Station Group Air Conditioner

80V2E01018

80ZV-2 EU 73-1 73 Check & Adjustment Operator Station Group

73 Check & Adjustment Operator Station Group Air Conditioner ........................................................ 73-2

80ZV-2 EU 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 refrigerant to atmosphere when removing components from air conditioner system. It not illegal to do so.

IMPORTANT

Fig. 1 97ZV73002

- When replacing components of the air conditioner, if the lubricant oil quantity is too small, the compressor may seize. And if the lubricating oil quantity is too much, the cooling ability may lessen. Use the correct amount of compressor lube oil. - When connecting a joint, apply compressor oil (ND-OIL 8) on the O ring before tightening (Fig. 1). - If the compressor oil (ND-OIL 18) is applied to paint, paint may peel or otherwise be damaged. If it gets on a painted surface, quickly wipe it off. - Tighten the piping, etc. at the recommended torque. Tightening torque table Connection area

Nut type (Fig. 2) Fig. 2 97ZV73003

Block joint (Fig. 3)

Fig. 3

97ZV73004

Pipe size or bolt size

Tightening torque N-m (kgf-cm) (lb-ft)

ø8 pipe

14.7 (150) (7)

1/2 pipe

24.5 (250) (18)

5/8 pipe

34.3 (350) (25)

M6 bolt in receiver (4T)

6.9 (70) (5)

Any M6 bolt other than above (6T)

11.8 (120) (9)

80ZV-2 EU 73-3 73 Check & Adjustment Operator Station Group Air Conditioner

When the compressor is replaced

New compressor

Torque values

Old compressor to be replaced

Compressor mounting bolt 29 N-m (3.0 kgf-m) (22 lb-ft) Hose block joint on high pressure side 12 N-m (1.2 kgf-m) (9 lb-ft) Hose block joint on low pressure side 12 N-m (1.2 kgf-m) (9 lb-ft)

Oil quantity remaining inside circuit

Example (B)

A

Suppose that the oil quantity (A) removed from the compressor to be replaced is 100 cm3. See figure 1.

A Fig. 1 97ZV73005

To avoid overloading the circuit; 1. Remove the oil from the removed (old) compressor, measure and record the oil quantity. (Approximately 20 cm3 (0.7 oz) of oil cannot be removed, and remains inside the compressor.)................ A cm3 2. The compressor can hold about 180 cm3 (6.1 oz; or 0.76 cup) of oil. Determine the system’s remaining oil quantity using the following equation. Oil quantity remaining inside circuit is: = 180 cm3 - (Oil quantity A discharged; see fig. 1. from removed compressor + 20 cm3) 3. Drain as much oil from the compressor as the quantity remaining inside the refrigerant circuit. When finished, mount the new compressor. Compressor lubricating oil ND-OIL 8 (Nihon Denso oil 8; Polyalkalene glycol (PAG) oil)

IMPORTANT - Oil (180 cm3; or 0.76 cup) required for the cooling circuit is sealed inside a new compressor. Prior to replacing the compressor, excess oil should be drained from the new compressor. - The compressor oil can come to absorb moisture. Seal the compressor immediately after adjusting the oil quantity with a plastic cap. - Never use ester based oil. Use only PAG oil.

Oil quantity remaining inside circuit (B) = 180 cm3 - (100 + 20) = 60 cm3 Remove 60 cm3 from the new compressor to avoid overloading the circuit.

80ZV-2 EU 73-4 73 Check & Adjustment Operator Station Group Air Conditioner

When the evaporator is replaced

When the condenser is replaced Quantity of lubricating oil lost by replacement of condenser is approximately 40 cm3 (1.35 oz).

1

When replacing the condenser core, add 40 cm3 (1.35 oz) of compressor oil (ND-OIL 8) to a new condenser. : (1): 25 N-m (2.5 kgf-m) (18 lb-ft) : (2): 15 N-m (1.5 kgf-m) (11 lb-ft)

Evaporator

When the receiver dryer is replaced Quantity of lubricating oil lost by replacement of receiver dryer is approximately 20 cm3 (0.7 oz).

Expansion valve

The amount of oil loss by replacement of the receiver dryer is within the allowable range, and adding oil is not needed if this is the first replacement of the condenser core. At the next time the dryer is replaced and from then on, add 20 cm3 (0.7 oz) of compressor oil (ND-OIL 8) to a new receiver dryer.

97ZV73006

Quantity of lubricating oil lost by replacement of evaporator core is approximately 40 cm3 (1.35 oz). When replacing the evaporator, add 40 cm3 (1.35 oz) of compressor oil (ND-OIL 8) to a new evaporator. : (1): 12 N-m (1.2 kgf-m) (9 lb-ft)

: (1): 7 N-m (0.7 kgf-m) (5 lb-ft) : (2): 15 N-m (1.5 kgf-m) (11 lb-ft)

80ZV-2 EU 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 dimension A between rotor end face and hub end face while magnetic clutch is "OFF". 3. Apply the battery voltage directly on the connector of the magnetic clutch, and measure the size of B in the same way as step 2 above. Note the difference.

Position while magnetic clutch is OFF

A (OFF status) Position while magnetic clutch is ON

Reference plane Air gap 0.50±0.15 mm (0.020±0.006 in)

Standard (normal dimension) of air gap (A - B) 0.50±0.15 mm (0.020±0.006 in) If the obtained value does not agree with the criteria, loosen the head bolt, remove the hub, and adjust the air gap by adjusting the thickness of the washer plate between the hub and the shaft.

B (ON status)

Hub Head bolt Washer plate

Rotor

95ZVE73002

WARNING Shut off the engine to do this procedure. If you try to adjust air gap while engine is "ON", a serious accidents would occur. Turn starter switch "OFF", stop rotation of engine tag out unit, pull out starter key, then start adjustment. Use a "Do Not Start" tag on the machine when performing this work.

80ZV-2 EU 73-6 73 Check & Adjustment Operator Station Group Air Conditioner

Compressor V-belt adjustment 7

1

6

2

2 3

A 5

1

7 3

5

4

6 4

A

A-A K80V2U73002

1. Compressor 2. Bracket mounting bolt 3. Lock nut 4. Adjusting nut 5. V-belt 6. Bracket 7. Bolt

80ZV-2 EU 73-7 73 Check & Adjustment Operator Station Group Air Conditioner

Belt adjustment procedure 1. Loosen four bracket mounting bolts (2). : Bracket mounting bolt (2): 53.0 N-m (5.4 kgf-m) (39 lb-ft) 2. Loosen lock nut (3). Turn adjusting nut (4) clockwise to tighten V-belt (5) by sliding bracket (6) upward. Turn adjusting nut (4) counterclockwise to loosen the V-belt. : Lock nut (3): 53.0 N-m (5.4 kgf-m) (39 lb-ft) Adjusting nut (4): 53.0 N-m (5.4 kgf-m) (39 lb-ft) 3. After the adjustment, tighten the lock nut, adjusting nut and the bracket mounting bolts securely.

Belt adjustment value

A

85V2E73002

Adjust the V-belt tension so that the belt tension at A part is 353±88 N (36±9 kgf) (79±20 lbf) by using tension gauge. Note The V-belt tension should be 559±108 N (57±11 kgf) (125±24 lbf) when the belt is replaced with new one.

80ZV-2 EU 73-8 73 Check & Adjustment Operator Station Group Air Conditioner

Parts to be replaced periodically

Receiver dryer

Air filters

Replacement Once every 3 years or 6,000 hours

Air filter for outside air Cleaning Once every 2 weeks or when required. However, if the operating environment is severe (with much sand, dust, etc.) and the air filter is easily clogged, clean it more frequently. To clean, blow filter with compressed air of 196~294 kPa (2~3 kgf/cm2) (28~43 psi) mainly from inside of filter. Replacement Once each year or when required. When air flow volume is so small as to affect air movement even after the filter has been cleaned, or when the air filter has been cleaned 20 times, replace it.

Air filters for inside air Cleaning Once each month However, if the air filters are easily clogged, clean them more frequently. To clean, blow filter with compressed air of 196~294 kPa (2~3 kgf/cm2) (28~43 psi) mainly from inside of the filter. Replacement Once every 3 years When air flow volume is so small as to affect air movement even after the filter has been cleaned, or when the air filter has been cleaned 6 times, replace it.

Note When replacing the receiver dryer, do not release the refrigerant into the atmosphere.

INDEX 1st speed clutch ................................................................32-9 4th speed clutch ..............................................................32-10

A Accelerator pedal ............................................................62-34 Accelerator pedal installation ..........................................62-36 Accumulator ......................................................................52-9 Accumulator (for ride control) .........................................42-55 Accumulator function ......................................................42-55 Accumulator low pressure sensor .....................................52-8 Adapter (Orifice) .............................................................42-46 Adjustable declutch preset switch ...................................62-48 Adjusting set pressure ........................................ 42-38, 42-40 Adjusting shim ..................................................................13-4 Adjusting tooth contact .....................................................23-8 Adjustment ........................................................................13-3 Adjustment method .........................................................42-84 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 Adjustment procedure .....................................................53-11 After power-off (clutch disengaged status) .....................32-27 After power-off (high clutch pressure status) ..................32-29 After power-on (clutch engaged status) ..........................32-28 After power-on (just after switching clutch) .....................32-30 Air compressor (with magnetic clutch) ............................72-17 Air Conditioner ...................................................... 72-13, 73-2 Air conditioner functions of components .........................72-24 Air conditioner specifications (system performance) ......72-13 Air conditioner troubleshooting .......................................72-69 Air conditioner unit ..........................................................72-31 Air distributor (hood & defroster selection box) ...............72-16 Air filters ............................................................................73-8 All setting reset .............................................................62-101 Alternator ........................................................................62-22 Alternator R terminal wire ...............................................62-18 Automatic shift ................................................................62-45 Axle ...................................................................................23-5 Axle Assembly ...................................................... 22-11, 92-2 Axle nut tightening procedure ...........................................23-5 Axle Support ...................................................................22-12

B Back-up alarm .................................................................62-49 Battery relay ....................................................................62-17 Battery relay operation ....................................................62-17 Bearing (#8) installation ....................................................23-7 Belt adjustment procedure ................................................73-7 Belt adjustment value .......................................................73-7 Bleeding air from brake pipes and axle housing hubs ....................................................................................52-17 Bolt tightening torque ......................................................00-13 Boom cylinder .................................................................42-19 Boom spool operation .....................................................42-43

Brake Circuit ..................................................................... 92-5 Brake circuit air bleeding procedure ............................... 52-17 Brake Circuit Check Valve .............................................. 52-24 Brake Circuit Oil Pressure ................................................ 53-2 Brake lining abrasion check ........................................... 53-11 Brake System Outline ....................................................... 52-2 Brake Units Layout ........................................................... 52-3 Brake Valve .................................................................... 52-11 Brake valve oil pressure ................................................... 53-4 Brake valve oil pressure measurement ............................ 53-4 Brake valve outline ......................................................... 52-13 Brake valve performance ................................................. 53-5 Brake valve performance chart ...................................... 52-12 Bucket cylinder ............................................................... 42-19 Bucket leveler ............................................................... 62-104 Bucket spool operation ................................................... 42-41

C Cabin ................................................................................ 72-2 Caution for diode check method ................................... 62-112 Cautions on Hydraulic Parts Replacement ....................... 42-3 Cautions on installing brake discs .................................... 53-8 Cautions on Safety ........................................................... 03-2 Cautions regarding parts removal .................................. 00-18 Cautions regarding reassembly ...................................... 00-18 Cautions regarding welding repair service ..................... 00-20 Center Pin ............................................................... 12-8, 13-4 Changing display from one function to next ................... 62-66 Changing from forward 1st speed to reverse 1st speed .................................................................................... 32-24 Charge of refrigerant ...................................................... 72-52 Check valve ...................................................................... 42-6 Clear active fault log (error pop up) (S/N 9001~9101, 9103, 9104 only) ............................ 62-81 Clear fault log ................................................................. 62-80 Clutch combination ........................................................... 32-4 Clutch control oil pressure curve .................................... 32-22 Clutch engagement starting ........................................... 32-26 Clutch Oil Pressure .......................................................... 33-2 Clutch Pack ...................................................................... 32-7 Clutch Solenoid Valve .................................................... 32-27 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 ................................... 72-40 Compressor V-belt adjustment ......................................... 73-6 Condenser unit .................................................... 72-17, 72-43 Connection diagram ....................................................... 62-23 Connector ....................................................................... 62-38 Continuity check mode ................................................. 62-112 Control panel .................................................................. 72-24 Control schematic drawing ............................................. 72-23 Control unit ..................................................................... 72-18 Control Valve .................................................................. 32-19

Coolant ........................................................................... 00-10 Coolant specification ...................................................... 00-10 Cooling circuit ................................................................. 72-22 Cooling unit .................................................................... 72-14 Cylinder natural drift ....................................................... 43-14 Cylinders .......................................................................... 42-4

D Denso air conditioner components ................................. 72-13 Denso air conditioner structure ...................................... 72-14 Detent solenoid ............................................... 62-105, 62-110 Differential Gear ............................................................. 22-14 Differential gear adjustment procedure ............................ 23-6 Diode ............................................................................ 62-111 Diode check method .................................................... 62-112 Diode check mode ....................................................... 62-112 Diode unit ....................................................................... 62-18 Directional control valve ................................................... 42-6 Display language ............................................................ 62-78 Downshift button operation ................................... 32-4, 62-47 Dust seal .......................................................................... 12-9

E ECM (Engine Controller) ................................................ 62-23 ECM safety features ....................................................... 62-17 Efficient Loading System ................................................ 42-85 Efficient loading system ................................................... 42-9 Efficient loading system operation ................................. 42-88 Efficient loading system outline ...................................... 42-85 Electrical Cable Color Codes ........................................... 62-8 Electrical circuit .............................................................. 72-23 Electrical Circuit Diagram (Cabin Air Conditioner) ......... 92-37 Electrical Circuit Symbols ................................................. 62-9 Electrical Connection Diagram (1/2) (S/N 9001~9100) .................................................................................... 92-28 Electrical Connection Diagram (1/2) (S/N 9101~9200) .................................................................................... 92-30 Electrical Connection Diagram (1/2) (S/N 9201~9350) .................................................................................... 92-32 Electrical Connection Diagram (1/2) (S/N 9351~) .......... 92-34 Electrical Connection Diagram (2/2) (S/N 9001~9100) .................................................................................... 92-29 Electrical Connection Diagram (2/2) (S/N 9101~9200) .................................................................................... 92-31 Electrical Connection Diagram (2/2) (S/N 9201~9350) .................................................................................... 92-33 Electrical Connection Diagram (2/2) (S/N 9351~) .......... 92-35 Electrical Detent Circuit ................................................ 62-104 Electrical Equipment Layout ........................................... 92-39 Electrical Equipment Layout (K-Lever) ........................... 92-52 Electrical Wiring Diagram ............................................... 92-21 Electrical Wiring Diagram (1/3) (S/N 9001~9038) ............ 92-6 Electrical Wiring Diagram (1/3) (S/N 9039~9100) ............ 92-9 Electrical Wiring Diagram (1/3) (S/N 9101~9200) .......... 92-12 Electrical Wiring Diagram (1/3) (S/N 9201~9350) .......... 92-15 Electrical Wiring Diagram (1/3) (S/N 9351~) .................. 92-18 Electrical Wiring Diagram (2/3) (S/N 9001~9038) ............ 92-7 Electrical Wiring Diagram (2/3) (S/N 9039~9100) .......... 92-10 Electrical Wiring Diagram (2/3) (S/N 9101~9200) .......... 92-13

Electrical Wiring Diagram (2/3) (S/N 9201~9350) .......... 92-16 Electrical Wiring Diagram (2/3) (S/N 9351~) .................. 92-19 Electrical Wiring Diagram (3/3) (S/N 9001~9038) ............ 92-8 Electrical Wiring Diagram (3/3) (S/N 9039~9100) .......... 92-11 Electrical Wiring Diagram (3/3) (S/N 9101~9200) .......... 92-14 Electrical Wiring Diagram (3/3) (S/N 9201~9350) .......... 92-17 Electrical Wiring Diagram (3/3) (S/N 9351~) .................. 92-20 Electrical Wiring Diagram (CAB) ....................................92-25 Electrical Wiring Diagram (Cabin Air Conditioner) .......... 92-36 Electrical wiring diagram abbreviation chart ................... 92-23 Engine ..............................................................................23-2 Engine / Transmission ...................................................... 22-3 Engine / transmission mount ............................................22-3 Engine diagnostic switch (option) ................................... 62-25 Engine fault log navigation .............................................62-80 Engine Start Circuit ......................................................... 62-14 Engine start circuit diagram ............................................ 62-14 Equipment Operation Table (Cabin Air Conditioner) ......92-38

F Failure diagnosis ............................................................ 62-25 Failure diagnostic chart ..................................................62-26 Fan motor ............................................................42-95, 42-99 Fan Motor Line ............................................................... 42-90 Fan Motor System .......................................................... 42-89 Fan motor system .............................................................42-9 Fault diagnosis procedure .............................................. 72-69 Fault log history check .................................................... 62-78 Fault Log Monitor ............................................................ 62-78 Flanged hexagon bolt .....................................................00-16 Floor board ....................................................................... 12-7 Floor board mount ............................................................ 12-7 Flow amplifier notch and pilot orifice .............................. 42-75 Flow control solenoid valve ............................................ 42-94 Flow control valve ..................................................42-5, 42-93 Flushing Hydraulic Circuit ................................................. 42-2 For forward/reverse and speed clutches ........................ 32-27 For trimmer ..................................................................... 32-29 Forward 1st speed power flow path ................................ 32-11 Forward 2nd speed power flow path .............................. 32-11 Forward 3rd speed power flow path ...............................32-12 Forward 4th speed power flow path ...............................32-12 Forward and 3rd speed clutches ......................................32-7 Forward/reverse (F/R) shifting and speed change ......... 62-43 Friction plate: mm (in) .......................................................32-6 From cooler to lubrication circuit .....................................32-16 From torque converter gear pump to torque converter ....................................................................................32-16 From torque converter to cooling circuit .........................32-16 Front Chassis ...................................................................12-2 Front differential – Transmission ......................................22-9 Front wiper ........................................................................72-6 Fuel level sensor ............................................................ 62-63 Fuel tank (S/N 9001~9128) .............................................. 12-5 Fuel tank (S/N 9129~) ...................................................... 12-6 Function of ECM ............................................................. 62-23 Function of T.P.D ............................................................ 22-16 Fuse ................................................................................ 62-11 Fuse box .........................................................................62-11 Fusible link ......................................................................62-13

G

L

Gauge circuit ...................................................................62-61 Gear pump specifications .................................................32-3 Gear train and number of teeth .........................................32-5 Glass .................................................................................72-3

Layout of Hydraulic Units ............................................... 42-10 Layout of main components ............................................. 00-4 Left turn position ............................................................. 42-67 Lift kickout .................................................................... 62-106 Lift kickout & lower kickout ........................................... 62-106 Limited Slip Differential (option) ..................................... 22-18 Liner ................................................................................. 13-2 Linkage Pin ....................................................................... 13-2 Liquid gasket and screw lock agent ............................... 00-18 Loading circuit relief valve setting pressures .................... 43-2 Loading linkage ................................................................ 12-2 Loading linkage pin .......................................................... 12-4 Loading System .............................................................. 42-22 Loading system ................................................................ 42-8 Loading/Steering Circuit Relief Valve/Ride Control Circuit Reducing Valve (OPT) ...................................... 43-2 Location ........................................................................ 62-106 Lower center pin ............................................................... 12-8 Lower kickout ............................................................... 62-107 Low-pressure holding ..................................................... 32-25 LSD function ................................................................... 22-21 LSD operation ................................................................ 22-21 LSD structure ................................................................. 22-18 Lubrication chart ............................................................. 00-11

H Heater and accessories ..................................................72-16 Hexagon bolt ...................................................................00-13 Hose band tightening torque ...........................................00-17 How to Use Electrical Wiring Diagram ..............................62-2 How to Use Manual ..........................................................00-2 How to wind a seal tape ..................................................00-19 Hydraulic & Brake Circuit ..................................................92-4 Hydraulic circuit ..............................................................42-80 Hydraulic circuit (fan motor normal rotation) ...................42-92 Hydraulic Circuit Diagram ...............................................32-15 Hydraulic Circuit Symbols .................................................42-4 Hydraulic Cylinder ............................................... 42-19, 43-14 Hydraulic cylinder specifications .....................................42-21 Hydraulic line ..................................................................42-82 Hydraulic line diagram ....................................................42-81 Hydraulic lines ..................................................................42-4 Hydraulic oil level check .................................................42-11 Hydraulic Pump ..............................................................42-16 Hydraulic pump bushing lubrication ................................42-18 Hydraulic pump oil amount and steering force ...............42-62 Hydraulic pump principle ................................................42-17 Hydraulic pump specifications ........................................42-16 Hydraulic pump wear plate .............................................42-18 Hydraulic System Diagram .............................................32-14 Hydraulic System Operation .............................................42-8 Hydraulic system operation outline ...................................42-8 Hydraulic Tank ................................................................42-11 Hydraulic Tank (S/N 9001~9250) ...................................42-12 Hydraulic Tank (S/N 9251~) ...........................................42-14 Hydraulic tank breather valve (tank cap) (S/N ~9250) ....42-13 Hydraulic tank breather valve (tank cap) (S/N 9251~) ....42-15 Hydraulic tank specifications ..........................................42-11

I Increment decrement switch (option) ..............................62-27 Information Monitor .........................................................62-68 Information monitor display .............................................62-68 In-Line Filter ....................................................................52-10 Input/Output Monitor .......................................................62-85 Input/Output monitor display ...........................................62-85 Inspection and maintenance table ....................................00-5 Install position ...................................................................23-2 Installing bearing cover .....................................................13-4 Installing bearing outer ring ..............................................13-5 Instrument panel .............................................................62-57 Instrument Panel and Switch ..........................................62-57 Instrument panel rear surface .........................................62-59 Items to be monitored and operation condition ...............62-55

K K-Lever (OPT) ................................................................42-80

M Machine control unit (MCU) ............................................ 62-37 Machine control unit (MCU) connection diagram (S/N 9001~9350) ....................................................... 62-39 Machine control unit (MCU) connection diagram (S/N 9351~) ............................................................... 62-41 Machine control unit (MCU) failure warning ................... 62-52 Machine control unit (MCU) function .............................. 62-43 Machine fault log navigation ........................................... 62-80 Machine speed sensor ................................................... 62-46 Magnetic switch .............................................................. 62-20 Main relief valve operation ............................................. 42-37 Make-up valve operation ..........................42-39, 42-40, 42-73 Measurement instrument .................................................. 23-2 Measuring clutch oil pressure ........................................... 33-2 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) .................................................................................... 43-13 Measuring ride control circuit reducing pressure .............. 43-8 Measuring steering circuit main relief pressure .............. 43-11 Measuring steering circuit overload relief pressure ........ 43-12 Miscellaneous hydraulic symbols ..................................... 42-7 Modalità di utilizzo dello schema dei collegamenti elettrici (ITALIANO) ...................................................... 62-5 MODM ............................................................................ 62-65 MODM function .............................................................. 62-65 MODM: Input/Output Monitor - Input/Output Signal Correspondence Table .............................................. 92-62 Modulation Mechanism .................................................. 32-21

Monitor Changeover ....................................................... 62-65 Monitor lamp test ............................................................ 62-24 Monitoring system .......................................................... 62-55 Mounting of fan motor .................................................... 42-89 Mounting of the ELS valve ............................................. 42-86 Mounting of the variable kickout sensor ......................... 42-87 Multiple Control Valve (KML28/2T102) .......................... 42-35 Multiple control valve boom spool .................................. 42-43 Multiple control valve bucket spool ................................ 42-41 Multiple control valve main relief valve ........................... 42-37 Multiple control valve make-up valve ............................. 42-40 Multiple control valve overload relief valve (with make-up function) ............................................. 42-38 Multiple control valve specifications ............................... 42-36

N Neutral ............................................................................ 42-59 Neutral position (steering spool in "Neutral") ................. 42-66 Neutral relay ................................................................... 62-19 Neutral starter ................................................................ 62-14

Power Flow Path in the Transmission ............................32-11 Power Generating/Charging Circuit ................................ 62-22 Power Line ........................................................................22-2 Pre-detent and detent magnet solenoid ..............42-29, 42-34 Preload adjustment ........................................................... 23-7 Preparation mode (ride control switch is OFF) ............... 42-48 Preset height adjustment .............................................. 62-110 Pressure control valve ...................................................... 42-5 Pressure holding ............................................................. 32-23 Pressure increase ...........................................................32-26 Pressure relief valve ....................................................... 72-49 Pressure sensor (for Declutch) ............................52-26, 52-27 Pressure Sensor (for stop lamp and declutch) ............... 52-25 Pressure sensor (for stop lamp) .....................................52-25 Pressure switch (for declutch) ........................................ 52-25 Pressure switches .......................................................... 72-47 Principle of cooling ......................................................... 72-19 Propeller Shaft .........................................................22-8, 23-3 Propeller shaft phase ........................................................ 23-3 Proximity switch ............................................................ 62-104 Pumps & motors ............................................................... 42-4 Purpose of flushing ........................................................... 42-2

O Oil Flow .......................................................................... 32-16 Oil flow in the torque converter line ................................ 32-16 Oil flow to the clutch ....................................................... 32-16 Oil seal (#9) installation .................................................... 23-7 Operation methods ........................................................... 42-5 Operation monitor lamps ................................................ 62-56 Operation of T.P.D ......................................................... 22-17 Operator Seat ................................................................... 72-9 Orbit rotor operation principle ......................................... 42-63 Orbitrol® .......................................................................... 42-57 Orbitrol® feed-back mechanism operation ..................... 42-61 Orbitrol® operation .......................................................... 42-59 Orbitrol® specification ..................................................... 42-58 Orbitrol® structure ........................................................... 42-57 Outline .............................................................................. 00-4 Outline of MODM (Machine Operation Diagnostic Module) Operation ................................................................... 92-53 Overload relief valve operation ........................... 42-39, 42-73

P Parameter change .......................................................... 62-97 Parameter Setting Monitor ............................................. 62-89 Parameter setting monitor display .................................. 62-89 Parking Brake ........................................................ 52-18, 53-9 Parking brake ........................................................ 52-2, 62-50 Parking brake clearance adjustment .............................. 53-10 Parking Brake Manual Release ...................................... 52-21 Parking brake operation ................................................. 52-19 Parking brake performance check ................................... 53-9 Parking brake solenoid valve ......................................... 52-20 Parking Brake Spring Chamber ..................................... 52-23 Parts to be replaced periodically ...................................... 73-8 Pilot Valve (S/N 9001~9205) .......................................... 42-24 Pilot Valve (S/N 9206~) .................................................. 42-30 Pilot valve function .............................................. 42-27, 42-32 Pilot valve operation (modulated position) .......... 42-27, 42-32 Power flow path ................................................................ 32-2

Q Quantum fault code information .....................................62-28

R Radiator (S/N 9001~9100) ................................................ 22-4 Radiator (S/N 9101~) ........................................................ 22-6 Radiator mount ........................................................22-5, 22-7 Rear Chassis .................................................................... 12-5 Rear wiper ........................................................................72-6 Receiver dryer .......................................................72-45, 73-8 Recommended lubricants ................................................. 00-8 Recommended mixture of antifreeze .............................. 00-10 Reducing Valve (for Orbitrol®) ........................................ 42-78 Reducing Valve (for Pilot Pressure) ...............................42-23 Refrigerant ......................................................................72-20 Refrigerant characteristics .............................................. 72-21 Refrigerant charging procedure ...................................... 72-58 Refrigerant charging tools .............................................. 72-55 Refrigerant hose ............................................................. 72-51 Relay A ........................................................................... 72-50 Relay B ........................................................................... 72-50 Releasing forward clutch and feeding initial oil to reverse clutch ............................................................. 32-24 Replacement interval pop-up ..........................................62-77 Replacement interval set (timer reset) ............................62-76 Replacement Monitor .....................................................62-72 Replacement time check ................................................62-72 Resistance check mode ............................................... 62-113 Reverse 1st speed power flow path ...............................32-13 Reverse 2nd, 3rd, and 4th speeds power flow paths ..... 32-13 Reverse and 2nd speed clutches ..................................... 32-8 Reversing Fan Motor Line (OPT) ................................... 42-98 Ride Control (OPT) ......................................................... 42-47 Ride control circuit reducing valve setting pressures (OPT) ...........................................................................43-7 Ride control function ....................................................... 42-47

Ride control hydraulic circuit ...........................................42-47 Ride control operation .....................................................42-48 Ride control system (OPT) ...............................................42-9 Ride control valve assembly ...........................................42-50 Rotor part ........................................................................42-58 Running mode (ride control switch is ON) ......................42-49

S Safety precautions ............................................................00-2 Safety valve (with suction function) ................................42-92 Screw lock agent application procedure .........................00-19 Second propeller shaft alignment .....................................23-3 Second propeller shaft assembly ......................................22-9 Secondary Steering ......................................................42-103 Secondary steering function ...........................................62-53 Secondary steering motor and pump ............................42-105 Secondary steering operation .......................................42-104 Selection of machine fault log and engine fault log ........62-79 Sensor assy ..................................................................62-108 Sensor Mount .................................................................62-10 Service Brake ....................................................... 52-15, 53-6 Service brake ....................................................................52-2 Service brake friction plate .............................................52-16 Service brake friction plate wear measurement ................53-7 Service brake operation ..................................................52-15 Service brake performance check ....................................53-6 Service brake steel plate ................................................52-16 Shift lever ........................................................................72-12 Shift lever forward/reverse (F/R) position .......................62-15 Shift lever neutral (N) position ........................................62-14 Shift lever position ............................................................32-4 Sight glass ......................................................................72-47 Solenoid valve ................................................................42-53 Solenoid valve assembly (1/2) ........................................42-83 Solenoid valve assembly (2/2) ........................................42-84 Solenoid valve operation ................................................52-20 Solenoid valve specifications ..........................................52-20 Specification Setting Monitor ..........................................62-98 Specification setting monitor display ...............................62-98 Standard measurement value ...........................................23-2 Standard Measurement Values for Performance Check ......................................................................................03-3 Starter switch ..................................................................62-16 Steering and Transmission Shift Lever ...........................72-10 Steering circuit relief valve setting pressures ...................43-9 Steering cylinder .............................................................42-20 Steering Line Filter ..........................................................42-79 Steering pilot circuit and its operation .............................42-74 Steering plunger variable throttle ....................................42-68 Steering speed and flow rate control ..............................42-62 Steering System .............................................................42-56 Steering system ................................................................42-8 Steering Valve (KVS25-A3.0/20) ....................................42-64 Steering valve flow control plunger .................................42-69 Steering valve main relief valve ......................................42-70 Steering valve operation .................................................42-66 Steering valve overload relief valve ................................42-72 Stop Valve .......................................................... 42-76, 43-16 Stop valve adjustment procedure ...................................43-16 Stop valve function .........................................................42-77

Stop valve operation ....................................................... 42-77 Surge voltage and surge suppression diodes .............. 62-114 Switching from automatic to manual .............................. 62-47 Symbols ............................................................................ 00-3 System diagram ............................................................. 32-20

T T/C and T/M Oil Circulation ............................................ 32-17 The operation condition of ELS ...................................... 42-85 Third propeller shaft assembly ....................................... 22-10 Tightening torque ............................................................. 23-4 Tilt case .......................................................................... 72-11 To forward and reverse clutches .................................... 32-16 To speed clutch .............................................................. 32-16 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 Torque proportioning type .............................................. 22-14 Transmission .................................................................... 32-4 Transmission – Rear differential ..................................... 22-10 Transmission Control Circuit and Monitor Circuit ........... 62-37 Traveling at forward 1st speed ....................................... 32-23 Trimmer engagement ..................................................... 32-25 Troubleshooting using the gauge manifold .................... 72-64 Turn ................................................................................ 42-60

U Unit conversion and language selection ......................... 62-71 Unloader Valve ................................................................. 52-4 Unloader valve operation ................................................. 52-6 Unloader valve setting pressure ....................................... 53-2 Unloader valve setting pressure measurement ................ 53-3 Upper center pin ............................................................... 12-8 Utilisation des schémas des câblages électriques (FRANÇAIS) ................................................................ 62-3

V Valve part ....................................................................... 42-57 Valve Unit ......................................................................... 52-7 Verwendung des elektrischen Schaltplans (DEUTSCH) ................................................................. 62-4 Viscous mount .................................................................. 12-7 Voltage relay .................................................................. 62-21

W Way of looking at connectors ......................................... 92-21 Weight of main components ........................................... 00-12 When the compressor is replaced .................................... 73-3 When the condenser is replaced ...................................... 73-4 When the evaporator is replaced ..................................... 73-4 When the pressure exceeds the preset value ................ 42-71 When the pressure is at the preset value or less ........... 42-70 While the ELS is not operating ....................................... 42-88 While the ELS is operating ............................................. 42-88 While the valve is not operating ..................................... 52-13 While the valve is operating ........................................... 52-14

While the valve is releasing ............................................ 52-14 Wiper motor ...................................................................... 72-7 Wiper mount ..................................................................... 72-6 Work procedure .............................................................. 72-53

MEMO

Maintenance Log Date

Machine hours

Service performed

Date

Machine hours

Service performed

Date

Machine hours

Service performed

Date

Machine hours

Service performed

Notes

80ZV-2 EU 92-1 92 Drawing & Diagrams

92 Drawing & Diagrams Axle Assembly ......................................................................................................................... 92-2 Torque Converter and Transmission........................................................................................ 92-3 Hydraulic & Brake Circuit......................................................................................................... 92-4 Brake Circuit ............................................................................................................................ 92-5 Electrical Wiring Diagram (1/3) (S/N 9001~9038) ................................................................... 92-6 Electrical Wiring Diagram (2/3) (S/N 9001~9038) ................................................................... 92-7 Electrical Wiring Diagram (3/3) (S/N 9001~9038) ................................................................... 92-8 Electrical Wiring Diagram (1/3) (S/N 9039~9100) ................................................................... 92-9 Electrical Wiring Diagram (2/3) (S/N 9039~9100) ................................................................. 92-10 Electrical Wiring Diagram (3/3) (S/N 9039~9100) ................................................................. 92-11 Electrical Wiring Diagram (1/3) (S/N 9101~9200) ................................................................. 92-12 Electrical Wiring Diagram (2/3) (S/N 9101~9200) ................................................................. 92-13 Electrical Wiring Diagram (3/3) (S/N 9101~9200) ................................................................. 92-14 Electrical Wiring Diagram (1/3) (S/N 9201~9350) ................................................................. 92-15 Electrical Wiring Diagram (2/3) (S/N 9201~9350) ................................................................. 92-16 Electrical Wiring Diagram (3/3) (S/N 9201~9350) ................................................................. 92-17 Electrical Wiring Diagram (1/3) (S/N 9351~) ......................................................................... 92-18 Electrical Wiring Diagram (2/3) (S/N 9351~) ......................................................................... 92-19 Electrical Wiring Diagram (3/3) (S/N 9351~) ......................................................................... 92-20 Electrical Wiring Diagram ...................................................................................................... 92-21 Electrical Wiring Diagram (CAB)............................................................................................ 92-25 Electrical Connection Diagram (1/2) (S/N 9001~9100) ......................................................... 92-28 Electrical Connection Diagram (2/2) (S/N 9001~9100) ......................................................... 92-29 Electrical Connection Diagram (1/2) (S/N 9101~9200) ......................................................... 92-30 Electrical Connection Diagram (2/2) (S/N 9101~9200) ......................................................... 92-31 Electrical Connection Diagram (1/2) (S/N 9201~9350) ......................................................... 92-32 Electrical Connection Diagram (2/2) (S/N 9201~9350) ......................................................... 92-33 Electrical Connection Diagram (1/2) (S/N 9351~) ................................................................. 92-34 Electrical Connection Diagram (2/2) (S/N 9351~) ................................................................. 92-35 Electrical Wiring Diagram (Cabin Air Conditioner)................................................................. 92-36 Electrical Circuit Diagram (Cabin Air Conditioner)................................................................. 92-37 Equipment Operation Table (Cabin Air Conditioner).............................................................. 92-38 Electrical Equipment Layout .................................................................................................. 92-39 Electrical Equipment Layout (K-Lever) .................................................................................. 92-52 Outline of MODM (Machine Operation Diagnostic Module) Operation.................................. 92-53 MODM: Input/Output Monitor - Input/Output Signal Correspondence Table ......................... 92-62

80ZV-2 EU 92-2 92 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.

4

10 16 28 26

23

13 11 12

25

2

3

14

1

44

PT-1/4 24

22

30

39 40

Brake oil inlet

37 9 8 29 5

17 45 27 42 34 41•35

43

33 36

21

20

19 32 18 31

15 • 41

38

15•41

7

35•41

6

K80ZV2201

1. Differential assembly 2. Axle housing assembly 3. Wheel hub 4. Spider (planetary carrier) 5. Cover 6. Axle shaft 7. Axle shaft 8. Sun gear 9. Disc gear 10. Planetary gear 11. Internal gear 12. Internal gear hub 13. Snap ring 14. Planetary pin 15. Plug 16. Wear ring 17. Wear ring 18. Piston 19. Steel plate 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. Needle cage 29. Snap ring 30. Floating seal 31. O-ring 32. O-ring 33. O-ring 34. O-ring 35. Magnet plug 36. Spring pin 37. Bolt 38. Bleed screw 39. Ring 40. O-ring 41. Seal washer 42. Bolt 43. O-ring 44. O-ring 45. Bolt

80ZV-2 EU 92-3 92 Drawing & Diagrams Torque Converter and Transmission

Torque Converter and Transmission (Model: Kawasaki CT180E01)

1 10

2

9

3

11 8

5 21

20

19

17

16

18

15

14

4

23 22 24

6

25 7 26 27

34 36

35 28 29 30 33

12 13

31 32

80V2E92002

1. Pump impeller 2. Turbine impeller 3. Stator 4. Turbine shaft 5. Stator shaft (Fixed) 6. Front cover 7. Input plate (drive ring) (attached to flywheel) 8. P.T.O. drive gear A 9. P.T.O. drive gear B 10. Torque converter gear pump 11. P.T.O. shaft (For Hyd. pump) 12. Idle gear 13. Idle shaft 14. Forward clutch gear 15. Forward clutch 16. 3rd speed clutch gear 17. 3rd speed clutch 18. Counter gear A 19. Counter shaft A 20. Counter gear B 21. 4th speed clutch 22. Counter shaft B 23. 4th speed clutch gear 24. 1st speed clutch gear 25. 1st speed clutch 26. Counter gear C 27. Counter shaft C 28. Counter shaft D 29. Reverse clutch gear 30. Reverse clutch 31. Counter gear D 32. 2nd speed clutch gear 33. 2nd speed clutch 34. Output shaft gear 35. Output shaft 36. Parking brake (Drum type)

80ZV-2 EU 92-4 92 Drawing & Diagrams Hydraulic & Brake Circuit

Hydraulic & Brake Circuit

Stop lamp turns on when pressure rises. S/N 9001~9100 0.5 0.1MPa (74 14.5 psi) S/N 9101~ 0.26 0.1 MPa (37 14 psi)

Port size Rc......PT G........PF (with O-ring) (G).......PF (without O-ring)

K80V2E92005

1. Hydraulic pump Front..........Steering Center........Loading Rear...........Brake and Pilot 2. — 3. Multiple control valve (loading circuit) 4. Steering valve 5. Boom cylinders 6. Bucket cylinder 7. — 8. Steering cylinders 9. — 10. — 11. Check valve (oil cooler bypass) 12. Return filter 13. Relief valve (return filter bypass) 14. Orbitrol® 15. Stop valve 16. Pilot valve (for loading) 17. — 18. Reducing valve (Orbitrol® circuit) 19. Adapter (orifice, slow spool return) 20. — 21. Breather valve (oil filling port) 22. Unloader valve 23. Brake valve 24. — 25. — 26. — 27. — 28. — 29. — 30. — 31. — 32. Check valve 33. Accumulator 34. — 35. Solenoid valve (for parking brake) 36. — 37. — 38. Reducing valve (pilot, parking brake) 39. — 40. — 41. — 42. — 43. — 44. — 45. — 46. — 47. — 48. —

49. Pressure sensor (for brake oil pressure) (for secondary steering) (for efficient loading system) 50. — 51. Pressure sensor (for declutch & stop lamp) 52. — 53. — 54. — 55. Oil cylinder (for parking) 56. — 57. — 58. — 59. — 60. — 61. — 62. Relief valve 63. Check valve 64. Solenoid valve (for efficient loading system) 65. — 66. — 67. — 68. — 69. — 70. — 71. Fan motor 72. — 73. — 74. — 75. — 76. — 77. — 78. — 79. — 80. — 81. Line filter 82. — 83. Suction strainer 84. — 85. — 86. — 87. — 88. — 89. — 90. — 91. Motor and pump (for secondary steering) 92. Check valve 93. Check valve 94. — 95. Valve (for safety lock)

80ZV-2 EU 92-5 92 Drawing & Diagrams Brake Circuit

Brake Circuit 1. Hydraulic pump Front..........Steering Center........Loading Rear...........Brake and Pilot 2. — 3. — 4. — 5. — 6. — 7. — 8. — 9. — 10. — 11. Check valve (oil cooler bypass) 12. Return filter 13. Relief valve (return filter bypass) 14. — 15. — 16. — 17. — 18. — 19. — 20. — 21. Breather valve (oil filling port) 22. Unloader valve 23. Brake valve 24. — 25. — 26. — 27. — 28. — 29. — 30. — 31. — 32. Check valve 33. Accumulator 34. — 35. Solenoid valve (for parking brake) 36. — 37. — 38. Reducing valve (pilot, parking brake) 39. —

40. — 41. — 42. — 43. — 44. — 45. — 46. — 47. — 48. — 49. Pressure sensor (for brake oil pressure) 50. — 51. Pressure sensor (for declutch & stop lamp) 52. — 53. — 54. — 55. Oil cylinder (for parking) 56. — 57. — 58. — 59. — 60. — 61. — 62. — 63. — 64. — 65. — 66. — 67. — 68. — 69. — 70. — 71. — 72. — 73. — 74. — 75. — 76. — 77. — 78. — 79. — 80. — 81. Line filter 82. — 83. Suction strainer

Port size Rc......PT G........PF (with O-ring) (G).......PF (without O-ring)

80ZV-2 EU 92-6 92 Drawing & Diagrams Electrical Wiring Diagram (1/3) (S/N 9001~9038)

Electrical Wiring Diagram (1/3) (S/N 9001~9038) 3

HAZARD 1 3 4 6

2 5

4

5

1

2

INSTRUMENT PANEL

4

1 3 4 6

2

6 5

7

7

WT

C

AC

TT

+

EP

BP

CE

(+)

5 7 8 5

4

5

6

1

2

3

8 RO RO BP B911 A815 G803 321 H109 323 RBr RBr BP B910 A814 G803 322 H119 323

5

1

4

4

7

4

8

1

5

6

2

3 8

Lg D103 013 GyW S823 200

B

4

8

1

5

6

2

3

5 Lg D103 013 GL S822 265

B

4

8

1

5

6

2

3

LgY A803 167 YO B001 176

B

4

1

ES

EG2 EG1 EG3

FR

FR WTM TTM

+

FM

−

GND

1

2

3

4

N

A

AB

P

W

GND

20 7

12 B LY LG LO LW SbW B S518 S502 S505 S508 B502 141 142 143 144 163 Lg GR D103 S529 135 013 1 6 1

11 RB YBr B601 H107 404 C305 Lg O RL BrB BrW BrR LgB YB BrW D103 S512 S532 H729 H719 H739 S524 S734 S721 013 241 235 731 732 730 224 401 402 10

A5

B

4

1

8

GyG Gy LgY LgW S515 S519 S528 F903 753 749 173 102 WG LgW GyL H125 S527 S516 H740 192 190

8

B

4

A2

7

5

8

B

1

A1

7

5

DECLUTCH

3

5

6

1 3 4 6

2

A6

SM

SM H

TC

PH

L

R

WL

HM GND

1

2

REAR WORKING LAMP

FRONT WORKING LAMP

EFFICIENT LOADING SYSTEM (ELS)

9

16

GyB B S514 103 LgR GY WL S521 S520 S624 130 169 400

B

RY RBr RO F403 A102 A107 307 326 324 LgY BG RGy A007 H124 B101 167 H738 B201

8

4

5

6

8

1

2

3 8

1

A8

4

7

4

5

6

8

1

2

3

B4

1

1

7

4

5

6

8

1

2

3

YV A401 231

B

5

8

4

8

4

1

B1

B3

5

R RGy D109 C306 002 H138 R RGy D109 A801 002 310

1

A9

COMBINATION S/W FOR LAMPS

A0

R D602 023 R D601 024

HORN S/W TB

TL

TR

HU

EL

LT

LH

P RBr RO RW G703 A103 A106 F401 320 322 321 304

B

RB RY F601 F501 301 302

B

A

1

T3

B2

1 YV T307 231 B

1

A3

1 3 4 6

2

5

RG RLg D113 C302 006 H106 RG RGy D113 A801 006 310

B

1

A7

5

7

F/R S/W SELECTION (EU STANDARD)

1 3 4 6

2

5

YSb S506 403

FUEL EFFICIENT MODE SELECTION

B

L C101 801 L C102 802

B YV S918 231

HL

F801

1

8 GW

PARKING S/W G Y B

5

R

LR LBr B S911 S904 126 128 LW B S912 120 LY LG LO S910 S903 S905 121 122 123

G

2

2

3

1 3

B5

LLg

6

7

4

5

6

2

3

8

1

2

3

BW F003 271

B

BrG F002 255

LP F001 168

B

4

CAB

1

T7

THROTTLE PEDAL 6

4 GyY GyW BL H734 H724 H713 736 737 741 YV BLg BrW H715 H705 H725 734 735 733

C0 12

C3

1

Y

V

R

R G B O Y V

O

B

G

3 3

3

CAB (AIRCON) 4

Sb GO WR 6 H907 H908 H909

DATA LINK CONNECTOR

C4

RB BrB LgY F604 H912 H911 300

DECLUTCH SENSOR 1

6

WP LgR PL BR BL 10 C5 H910 H913 H015 C802 H008 H011 B WG OL BrW BG H014 H013 H012 H007

4

−

+

(BLACK)

(BLACK)

F1

F2

NEUTRAL RELAY

HORN RELAY

BW BrG S813 S922 271 255 B LP S915 168

V BY S709 S707 100 114 LgR S727 166

2

AIR PROBE (TH AM )

H

A

BACK LAMP (OPT)

(BLACK)

F5

F6

RL S510 330

1

4

(BLACK)

(BLUE)

(BLACK)

F7

F8

F9

X5

2

T8

S2L H708

B

AIR-SUS. 3

5 B 2

1

DIAG INC/DEC S/W 2

1

YSb S917 125

1

4

7 2

H1

G0

T0

Br D110 003

1 (BLUE) Br

1

G2

BrR

G3

H4

H5

1 G D107 010

G4

BrB

G5

1 4

914 D002 R 915 D001 R

2

3

1

4

G6

G7

2

4

901 E201 W

2

3

6

703 C201 C202 C203 747 F704 T406 T405 T404 T403 RL S2H S2L S2S YL 015 732 204 F104 748 D101 A606 S534 F204 T402 WR BrW SbLg RLg YO 731 181 220 160 H016 A607 S811 S723 S716 YR BrB BrY GyO Y 705 730 720 752 159 A503 A605 A802 F301 S708 WG BrR BG GyR Y 40 36

9

1

H0 1

D804 D802 H102 H112 R RB RW Y

C501 C510 BG BL

B

D803 D701 H730 C508 C504 C503 C502 C509 RG RL YR PL WG OL BrW BR 18

B 10

G8

4 10

10

C404 C405 C406 C506 Sb GO WR WP

20

BP G A101 D107 A108 010 B 1

C607 C608 C609 C610 LO GW BY BrY

C606 C605 C604 C603 C602 D701 C601 C507 C402 C401 P LgR BrB LgY WY V PB YB VW RL 11

B

H7

BY YGy E701 E704 114 242 SbR V E702 E703 240 100

1

1 912 D401 R 913 D901 R

L

P R B909 D111 320 004 B

LgSb X504 112

H9

E

H6 1

910 D301 R 911 D402 R

HAZARD

B

3

Br BrW

L

B B

2

G9

G1

Br D110 003

AIRCON UNIT

1

R

G V805

H8

LP LBr LR S517 S604 S613 149 148 146 LY LG LO LW S518 S502 S505 S508 141 142 143 144 1

BZ

KICK OUT

POSITIO -NER

Br D110 003 Br

B

1

172 003 100 S722 D110 H003 S709 SbY Br RW V 703 171 251 015 F704 S730 S826 H004 D101 Y RL SbY BrR WR 705 720 250 261 267 A503 A802 G302 S504 S501 WG BG BrW LgL GB 182 012 221 266 S806 D105 S702 S801 LgL BW LgB GyB 35 31

T9

E

H2 H3

140 325 308 404 311 S507 A107 F404 A614 B108 LLg RO RW YBr RLg 114 327 306 170 S707 A102 F403 S614 BY RBr RY WR 303 330 329 180 F604 S510 F804 S731 RB RL GW GyL 707 331 312 162 754 S724 S619 B208 B506 S625 WL RG RGy LgG GyG 40 36

(BLUE)

TURN SIGNAL

B

1

T5

FLOAT

SHIFT HOLD S/W (OPT)

PG PW H733 H723 739 740 BrG BL H714 H713 738 741

1

OY D114 007

S2H W H709 D506 6

8

5

1

4

(BLACK)

CAB ALARM BUZZER

PILOT VALVE MAGNETS

4 YL YO H706 S2S H716 H707

C9

6

BrR L G202 D205 272 005-a B L S610 273 1

4

2

3

BrB L G402 D205 257 005-a B BrB S611 258

(BLACK)

3

C8

LOWER KICKOUT RELAY

2

3

Lg Lg D103 D103 013 013 LgSb LgBr G601 S609 112 104 1

4

2

3

LgW L A508 D205 102 005-a B LgW S612 101 1

4

2

3

E

T4

10

1

4

(BLACK)

LIFT KICKOUT RELAY

BUZZER RELAY

F

BY G S707 S732 114 415

AIR TEMP. PROBE (MCU)

R R D108 D108 001 001 RB RB C403 B914 H129 301 1

F4

DOWNSHIFT BUTTON

D

G

1 1

F3

2

3

C

2

WY V PB YB VW P H920 H919 H918 H917 H916 H914 6

4

2 R R D108 D108 001 001 RY RY F402 B915 305 302

B

C6

1

3

MCU FAULT RELAY

G G D107 D107 010 010 GW GL H127 B801 329 328 1

4

2

3

G L D102 D205 014 005-a RL SbP H710 S618 H115 145

1

4

2

3

F0

J

C7

2

YL

LO GW BY BrY Y RL 12 H901 H902 H903 H904 C801 D701

3

(BLUE)

S914

7

1

1

4

6 RW R H108 D108 308 001 RY RY RW A813 F504 B912 H118 305 304

1

1

S

BR Y C509 C611

5

4

Gy GyR S816 H721 750 751 B GyR H737 752 1

4

2

3

Sb SbP H704 S509 205 202 RLg B H717 206 1

4 8

1

T6

168 T607 B LP 271 255 T706 T708 BW BrG

B 1

2

3

5

4

1

7

C2

C1

5

1

2

3

SbY SbR H711 S608 209 208 RLg B H717 206

B7

G WBr RLg O RGy RB B208 A611 D107 D604 B108 D610 520 300 010 022 521 020 PB PL OR OL OW OG H722 H732 D609 D608 D607 D606 500 506 H712 018 017 016

1

2

WIDTH LAMP RELAY

B0

1

B6

S2L S2H H708 H709 S720 S729 1

3

6

S2S H707

L B402 802 L B401 801

RB A611 300

4

8

8

2

3

3

7

5

1

2

257 T903 BrB

6 L LgG D206 H137 005-b 162 GO SbW B S901 A712 164 163 1 3 4

1

S921

Y

L

HEAD LAMP RELAY

DECLUTCH SET-UP

1 3 4 6

2

A002

B

LIFT KICKOUT SET-UP/ LOWER KICKOUT SET-UP

B

YO

CAN (RESISTOR)

B GB

Hi-BEAM RELAY

250 H123 BrW

R

B9

DECLUTCH CUT-OFF S/W

G GR

E/G OIL PRESS. S/W RELAY

1

B8

GY

TORQUE SELECTION RELAY

272 T003 BrR

L

GL

E/G IDLE SELECTION RELAY

GL

SHIFT LEVER

A4

5

1

735 205 203 172 171 C002 F203 S615 S722 S730 BLg Sb SbW SbY SbY 734 738 C004 019 209 C001 G004 G001 C309 F103 YV BrG BL OR SbY 733 737 740 500 751 C003 C005 G002 C307 F302 BrW GyW PW PB GyR 012 736 739 506 161 D105 C006 G003 C308 S715 BW GyY PG PL W 35 31

This page illustrates the transmission is in neutral and key switch is in OFF position.

80ZV2-09709-08372 EU 1/3 80V2E92016

80ZV-2 EU 92-7 92 Drawing & Diagrams Electrical Wiring Diagram (2/3) (S/N 9001~9038)

Electrical Wiring Diagram (2/3) (S/N 9001~9038) 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

A1

OPT B

A3

A4

A5

A6

A7

A8

A12

A13

A14

A15

A16

A17

A18

A19

A20

A21

A22

A23

A24

A25

A27

A28

A29

A30

A31

A32

B1

A9

A11

A26

A33

B2

B5

B6

B7

B9

B10

B11

B12

B13

B14

B15

B16

B17

B18

B19

B20

A34

B4

B3

B8

B21

B22

B23

B24

B25

E2

E1

B26

E3

E4

E5

E6

E7

E8

E9

E10

E11

E12

E13

E14

E15

E16

E17

E18

E19

E20

E21

E22

E23

E24

E25

E26

E27

E28

E29

E30

E31

E32

E33

C2

C1

E34

C3

C4

C6

C5

C7

C8

C9

C10

C11

C12

C13

C14

C15

C16

C17

C18

C19

C20

C21

C22

C23

C24

C25

C26

C27

C28

C29

C30

C31

D12.SL_A D13.SS_N D14.KD D15.INCH_S D16.OD_SW D17.SH D18.SS_SW D19.SS_F D20.TMP D21.INCH D22.KO_S D23.SC D24.AR D25.SM_SW D26.SS_R

C31.BSL C32.EG_M C33.DD_S C34.AFR D 1.PRK D 2.AM_SW D 3.SL_2 D 4.SL_R D 5.SL_3 D 6.S_UP D 7.S_DOWN D 8.EG_SW D 9.M_SW D10.SL_1 D11.SL_F

C16.EP C17.F C18.ASUB1 C19.ASUB2 C20.1/2 C21.1/8 C22.2S C23.EG_H C24.IP_SW C25.FR C26.KO_P C27.ES_SE C28.3/4 C29.1/4 C30.DC

C 1.2S_SE C 2.DSUB2 C 3.DSUB4 C 4.BSLC 5.TT C 6.AC C 7.ET C 8.BL C 9.BD C10.DSUB1 C11.DSUB3 C12.DR C13.BSL+ C14.TF C15.WL

E31.TT_SE E32.OT_SE E33.OUT_RSE E34.ET_M

C32

C33

D1

D2

D5

D6

D7

D9

D10

D11

D12

D13

D14

D15

D16

D17

D18

D19

D20

C34

D4

D3

D8

D21

D22

D23

D24

D25

D26

B

EU 3

A2

A10

E16.SPD E17.BATT E18.CANL1 E19.SS_P E20.CANLO E21.TM_M E22.B_SE2 E23.WT_SE E24.ALT E25.RXD1 E26.TGSP E27.INCH_SE E28.SC_P E29.CANHO E30.B_SE1

E 1.SSR_SO E 2.FC_SO E 3.KEY E 4.KEY E 5.GND E 6.GND E 7.GND E 8.GND E 9.+5V E10.TGEG E11.KEY E12.KEY E13.CANH1 E14.EGR2 E15.EGR1

B12.X_R B13.F_SO B14.B_SO B15.EG_SW2 B16.RIN1 B17.OUT_MD2 B18.N_R B19.BR_L B20.CAN_R1 B21.CAN_R2 B22.DOUT1 B23.OUT_FEW B24.MT B25.ET_SE B26.TXD1

A31.1/4_L A32.FR_L A33.3/4_L A34.EG_SW1 B 1.H_SO B 2.PWM_SO B 3.IP_SO B 4.R_SO B 5.MO_SO B 6.FR_SO B 7.SSL_SO B 8.BSL_SO B 9.BZ B10.BSL_R B11.KO_R

A16.TT_L A17.D_SO A18.1_SO A19.EP_L A20.AB_L A21.A_L A22.1/2_L A23.E_L A24.SS_L A25.SC_SW A26.TF_L A27.AC_L A28.BP_L A29.N_L A30.SC_L

SPEEDOMETER DIVIDING ODOMETER RATIO SELECTION SELECTION

JPN PL P 2 S803 S802 108 107 B

B

A/M SELECTION

B

PW S925 111

1

B

PB S916 110 1

(BLUE)

PG S902 109 1

1

(BLUE)

GR WL GyG T103 A806 H136 811 400 754 WR SbW GL SbP RG H117 H703 T104 F701 H139 170 203 810 145 331 SbR LgBr BrB LgW LR L F102 X501 T001 T901 F901 H205 208 104 273 258 101 146 LgL BL LBr H206 E502 E001 148 225 237 9

1

LgR C703 166

7

1

S3

S4

S5

BrR SbR H113 E802 251 240

S2H SbY GyL G YB C201 H114 H126 C901 A603 401 H701 180 415 G S2L BrW SbY GyO WL E003 C202 A602 H104 H727 H140 234 402 H702 220 707 L L W Y G D203 D204 H731 H726 D107 005-C 005-D 161 160 010 V BR LgB L L B BY Y B E002 H132 D201 D202 H736 236 221 005-A 005-B 159 1

(BLACK)

S2

S1

LgW LgY GR SbLg RL A502 A507 A701 A608 H718 192 173 135 235 204 LY Gy Gy LgR LgB A708 A506 A807 A808 A604 224 H201 749 169 130 0 RL GyB GyG GyL LP A609 H128 A809 A505 A501 H207 241 103 753 190 149 T801 LO YSb LLg LW SbP GB LG YGy LgL H121 A709 E804 H122 A710 A901 H110 A711 F202 267 H202 242 261 H203 403 140 H204 202

S6

S7

Y GyW LgY B T202 E603 E501 105 260 223 GL GyW Lg A302 A202 E503 265 200 222 BW BrY R Gy F303 H728 T203 F003 181 106 271 750 GyB P PL LgL H135 H131 S102 S103 266 107 108 182

100 C702 E803 E004 H101 T101 9

114 C701 E007 C902 H120 E801 T102

LLg BrG LB PW YW B002 F002 E006 S201 E012 165 255 230 111 233 YL LP PB YSb YV YO G101 F001 S301 G901 A401 E005 124 168 110 125 231 232 LR LY LW B703 B709 B706 121 126 120 GO PG LG LBr LO B503 S401 B702 B708 B701 164 109 122 128 123 9

1

7

1

S8

S9 T1

FUSE BOX (CAB)

4

R5

FUSE BOX (MAIN) R5

R5

16

R5

BW BG

R1 BR S2L B ACC R2 C

STARTER S/W WRx2 WBx2 G

W3 W5 BW

WR

WR

BG

WB

WB

G

W

W D506 060 W H601 901

WR WR D501 D503 063 065 BW D504 062

G D502 064

2

3

4

5

6

7

8

R

Y

B

L

G

Br

O WR

RL

RG

LR

W

R

Y

B

001 8 R F406 F502 F503 F602 G F603

R B202 B207

Br

R G702 004

LW

YR

YW

G

Br

9

10

11

12

13

BW H134 H735

19

20

21

22

23

24

25

26

27

29

28

30

Y

B

L

G

Br

O

WR RL

RG

LR

YR

LW

R5

YW

YR

LW

R5

R5

LR

RG

RL

R H301 910

R H302 911 R H401 912

WR L

O

4

6

G

Br

W

R

3

O

WR

RG

YR

YW

B

L

RL

LR

LW

OL OR O 10 D608 D609 D610

OG D606 L V808

6 BW W E104 E202 062 T407 WR G WR E107 E101 E106 065 064 063

Y

5

R R D602 D601

RL 1

V9

(EU:STANDARD)

1

5 1

V801 W

3

RG RB H018 H002

2

R5

R H402 913

R H501 914 R H502 915

DC-DC CONVERTOR (EC : STANDARD)

B

V902 V901 R R

5

2

DIAG. S/W CONNECTION

1 E

OUT

B

IN

G G501

L V904

8

5

O 10 OG OW OL OR C312 C311 C310 C309 C301 016 017 018 019 020 WBr R R B301 B302 C303 022 023 024

6

D5

D4

R Y S812 S830 106 105

YW

C612 H915 H017

V906 V804 V908 V909 V910 Y OL OR O 10 6 OG

D3

3

R5 R5

R H001 1 4

1 B

2

RS232C

YW

15

14

1 4

R

W

14 OY L RG B102 T501 B107 007 WR Lg G F703 H111 014 H720 1 A207 A307 3 4 5 1 6 A610 2 L A706 L L L L L E008 E601 S703 S704 S711 S712 F702 B504 X502 005-A 005-B 005-C 005-D F902 005-b X503 T902 013 D1 T002 005-a

7 C304 F802 F803 G501 G802 S717 010

W

STARTER SWITCH

1 W

18

3

RL RG LR LW YR YW

003 G201 G301 G401 H103

17

1 V GL S616 S709 810 100 GR BY S622 S707 811 114

R5

R5

T2

Y D607

B

W D604 1

4

1

1

E1

E2

D6

D7

D8

D9

D0 V8

REVERSAL FAN S/W 3

Lg LgL S825 S606 222 225 B LgY S834 223

4

SECONDARY STEERING (EU : STANDARD)

RIDE CONTROL S/W

4

2 GyW S833 260 Lg B D103 013 1

1

2

YGy V H804 H803 242 100 SbR H802 240 BY H801 114

3

1

6

3

YGy V S709 S503 100 242 SbR S827 240 BY S707 114

1

4 1

F/R SWITCH/ STICK STEERING

6 12

E5

E6

E7

E8

6

BL BR G V YO LB S607 S701 S719 S709 S919 S924 237 236 234 100 232 230 YW B L BY S926 D205 S707 233 005-a 114

This page illustrates the transmission is in neutral and key switch is in OFF position.

7

E0

A

80ZV2-09709-08372 EU 2/3 80V2E92017

80ZV-2 EU 92-8 92 Drawing & Diagrams Electrical Wiring Diagram (3/3) (S/N 9001~9038)

Electrical Wiring Diagram (3/3) (S/N 9001~9038) 40

RBr

K103

RB

K106

1

1

K801 K802 K803

B 327 303

4

−

LBr H206 148

B

−

LY H201 141

+

− W

B

GB H121 267

B

6

GyB H131 266 BY V H120 H101 114 100

1

2

−

LG H202 142

+

−

B

2

J4

2

P4

B W

L8

B

B

BrR L203

A

BY L202

2

B

B K104

LW H204 144

+

−

YBr H107 404

B

J6

2

−

D

4 4

B

WR H720 015 GyR H721 751

S2L S2H P902 P901 46

H713 H717 R902 741

−

+

1 BrG GyY H714 H734 738 736 GyW SbY H724 H711 209 737 PW PG BLg BrW H723 H733 H705 H725 740 739 735 733 BL Sb H704 205 BrB BrR GyR W H729 H739 H737 H731 731 730 752 161 45 41

S2S P903

50

S −

+

5

P8

1

1

LP H207 149

+

−

Y

B

B

2

2

1

L3 1

V L301

1

BY L303

BrR L302

2

B 1

1

3

L0

L9

LgL R801 R803

R8 LgL L401

B

2

1 B

LgL K204 261

L4

B

R

3

B

2

70A

M

AIR CLEANER

C B

T/M OIL TEMP. SENSOR (MCU)

E/G WATER TEMP. SENSOR (MCU)

WV N403 700

1

BW N501 702

R H301 H302 H401 H402 H501 H502 910915

R N502 701

ELECT. FAN CONDENSER

B

R

2 B

1

4

1

2

N3 BATTERY RELAY

BW N501 702

N7 MAGNETIC S/W

R N502 3 701

4

N8 VOLTAGE RELAY 4 2

N4

W H601 N001 086 901

WG 4 N903 704

WG N903 704

B

3 B

WL N901 706

LgG BY H137 H120 162 114 LgB V H132 H101 221 100

4

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

33

34

35

36

37

38

39

40

41

42

43

44

45

46

47

48

49

50

45

4

1

3

2

M6

50

1 2 2

3 1

3

B

4

3

3 3

B WR WP H111 N901 015 708 BW BG H134 H124 012 720

6

M7

RGy

2

G M001 M002 W N101 086

3

1

B WG H125 704 RL WL/WP H115 M704 703 P602

4

N0

R102

REAR WORKING LAMP 1

R4 B

R501 R502

1

330 R103 RL R104

BACK UP ALARM RB

303

LICENSE LAMP

B

RH BATTERY − +

2

M0

P5

2 2

R7

1

N9

RGy

2

2

1 703 706 N701 N804 RL WL N801 N704 WG B

312

2

RL RGy H128 H138 330 312 RB B H129 303

G G N002 N002 036 036 1

REAR WORKING LAMP

B

R1

P803 P803 P804 P804 G G

2

R102

B

R3

4

114 L702 M201 M301

1

303 R501 RB B 330 R301 R401 R201 RL RGy

1

P6

312

1

LH BATTERY −

M5

46

ECM

R6

012 720 N601 N602 BW BG 015 708 N401 N402 WR WP

4

1 RL N904 703

3

3

1 221 M202 P101 M302 LgB V 162 M101 LgG BY

1

6

2

DIODE UNIT

2

3

30A

1

L

GyG BY H136 H120 754 114 1

8

R2

3

1

700 N301 WV 015 708 P605 P602 WR WP

WL N901 H140

2

7

3

4

SECONDARY STEERING MOTOR PUMP

4

BY GyL H120 H126 114 180

6

+ −

FUSE

ALTERNATOR

E

5

1

R9

AIE HEATER

3

P0 STARTER

BG P601 720

HEATER RELAY

1 1

BW P606 012

70A

2

YGy H804 242

N2 FUSIBLE LINK

30A

1

G M001 M002 G M001 M002

S2L H708 S2S P747 H707 S2H P737 H709 P746

P9 SECONDARY STEERING MOTOR RELAY

B

N1 FUSIBLE LINK

B

2

LgL L806 182

1

R BW N703 N702 701 702

W 1

2

B L802

B

1

2

N6

RW Y L803 L804

LgL L401

2 BW R P001 P002 702 701

FUEL LEVEL SENSOR

1

2

SECONDARY STEERING OIL ORESS. SENSOR

N5

6

2

RIDE CONTROL SOLENOID (OPT)

4

CAN (RESISTOR)

P3 182 L002 LgL

L2

3

2

L903 B

V K202 BrR 100 K205 BY 251 K203 114

10

6

2

41

BRAKE OIL PRESS. (MAIN)

L902 L901 RW Y

1

5 1

−

+

J7

1

4 B

PARKING SOLENOID

+

3

P7

V BY P501 P502 100 114 SbY H702 172

S

BY V H803 H801 100 114 SbR H802 240

P2

P1

M4

S

RW Y H102 H112

1

−

4

W

1

2

1

2

1

70A

V L201

2

1

LgL H135 182

3

C

J5

+ 6

L1

2

+

B

J8

1

Br K201 003 BrW B K206 250

Br

−

LO H203 143

−

B

L

BOOM ANGLE SENSOR

B

3

K0

1

BUCKET LEVELER

L6

L5

RW RY K108 K102 308 306 B

R

BY V P501 P502 100 114 SbY H701 171

6 YV YL H706 H715 747 734 YO SbW H716 R901 748 203

M3 1

2

LgG P503 162

1

+ 2

1 B

B

FRONT HEAD LAMP (OUTSIDE)

M2

+

2 2

1

10

M1

1

2

M9

J3

B

2

1

2

1

2

1

2

B

YR

Y Y H726 H736 160 159

1

LgB P504 221

BrY H728 181

L7

+ S

1

GROUND SPEED SENSOR

+

K2

GyO BY H727 P502 220 114

1

B

(BLUE)

J2

2

3 PL H732 506

B

R

1

+

− −

K9

311

K105

4

6

2

R

4

J1

YR H730

Br

M8

REAR COMBINATION LAMP (R. H)

3

RLg

BY V Br H120 H101 H103 114 100 003 LgL BrR BrW H122 H113 H123 261 251 250

B

+

1

3

Br V BY L103 L201 L202 003 100 114 BrW BrR LgL L102 L203 L401 250 251 261

JPN:CONNECT EU :DISCONNECT WORKING LAMP (INSIDE)

3

LR H205 146

+

PB PL

B

COMBINATION LAMP

− −

EFFICIENT LOADING SYSTEM (ELS) SOLENOID VALVE

8

8

1

GW K601

K1

+

F

OR

OR PB H722 H712 500 019

WASHER MOTOR (OPT)

T/M SOLENOID VALVE

EFFICIENT LOADING SYSTEM (ELS) OIL PRESS. SENSOR

1

R

K6

H7 2

G

GW K107 329

4

H6

REAR COMBINATION LAMP (L. H)

+

R

5 B

H5

G

B

H4

1

GW K702 K704

1

H3

3

K7 B

1

H2

F

4

2 2

1

FAN SPEED CONTROL SOL. VALVE

HYD. OIL LEVEL S/W

2

1

5

1

GW K601

3 240 100 P403 P402 SbR V 114 242 P401 P301 BY YGy

H8

325 K002 327 K502 K302 K802 RO RY RBr B K003 329 K803 K901 K303 K601 K503 K401 RW GW RB RLg

B

HORN (H)

K106

JPN:CONNECT EU :DISCONNECT

HORN (L)

H1

1

2

SbW BL P719 P734 203 741

RB

303

1

141 142 143 144 J302 J402 J502 J602 LY LG LO LW 149 148 146 J702 J202 J102 B LR LP LBr

B

K101

8

K202 L602 P501 100

4

RO

325

W N101 901

COMPRESSOR CLUTCH (EC C )

HYD. OIL TEMP SENSOR

GR

B

K203 L601 M502 M602 P502 114

4

1

R N201 915 R N201 914

31 GyY PG PL W P701 P724 M803 P741 736 739 506 161 BrW GyW PW PB GyR P722 P711 P725 M802 P749 733 737 740 500 751 YV BrG BL OR SbY P709 P702 P734 M801 P713 734 738 741 019 209 SbY SbY BLg Sb P723 P731 M303 M203 735 205 172 171 5 1

RY

K501 K502 K503

R N201 913 R N201 912

35

B

COMBINATION LAMP

R N201 911 R N201 910

36 BrR Y GyR P743 P742 M901 730 752 159 YR BrB BrY GyO Y P201 P744 M401 L701 M902 731 181 220 160 WR BL YO P739 P734 P720 015 741 748 S2H S2L S2S YL P901 P902 P903 P710 747 10 6

B

B

40

GR

R103 R602 R702 330

K4

311

K105

31 LgL BW LgB GyB L806 P606 P504 L603 182 012 221 266 WG BG BrW LgL GB N903 P601 K206 K204 L501 704 720 250 261 267 Y RL BrR WR N904 K205 L804 P605 703 251 015 Br RW V K201 L803 003 5 1

RY

3 RLg

35

1

WORKING LAMP (INSIDE)

1

36 WL RG RGy LgG GyG M704 R605 R102 P503 M601 707 R705 312 162 754 RB RL GW GyL K107 M501 329 180 BY RBr RY K103 K102 R703 306 RO RW YBr RLg K101 K108 J802 K105 R603 308 404 311 10 6

5

W

303 K106 R104 R604 R704

K3

325 330 H109 H128 RO RL 303 331 H129 H139 RB RG

RW RY K108 K102 308 306 B

B

327 330 H119 H128 RBr RL 303 331 H129 H139 RB RG

2 R

RW GW RB RLg H108 H127 H129 H106 308 329 303 311 RO RY RBr B H109 H118 H119 L802 325 H118 327

FRONT HEAD LAMP (OUTSIDE)

This page illustrates the transmission is in neutral and key switch is in OFF position. 80ZV2-09709-08372 EU 3/3 80V2E92018

80ZV-2 EU 92-9 92 Drawing & Diagrams Electrical Wiring Diagram (1/3) (S/N 9039~9100)

Electrical Wiring Diagram (1/3) (S/N 9039~9100)

1 3 4 6

5

3 4

5

3

6

6 WT

7 5

5

7

4

5

6

7

4

5

6

7

4

5

6

8

1

2

3

8

1

2

3

8

1

2

3

8 RO RO BP B911 A815 G803 321 H109 323 RBr RBr BP B910 A814 G803 322 H119 323

5

1

4

4

8 Lg D103 013 GyW S823 200

B

5 Lg D103 013 GL S822 265

B

5

B

1

A2

8 LgY A803 167 YO B001 176

4

1

A1

8

B

5

2 5

1 3 4 6

1 3 4 6

2 5

4

5

7

INSTRUMENT PANEL

DECLUTCH (DISCONNECT)

F/R S/W SELECTION (EU STANDARD)

REAR WORKING LAMP

1 3 4 6

2

1

2

B

C

AC

TT

+

EP

BP

CE

(+)

8 GyG Gy LgY LgW S515 S519 S528 F903 753 749 173 102 WG LgW GyL H125 S527 S516 705 192 190

11

1

10

4

FR

EG2 EG1 EG3

SS

+

WTM TTM

FM

−

GND

1

2

3

4

N

A

AB

P

W

GND

20 7

RB YBr B601 H107 404 C305 Lg O RL BrB BrW BrR LgB YB BrW D103 S512 S532 H729 H719 H739 S524 S734 S721 013 241 235 731 732 730 224 401 402

A5

B

4

ES

B

12 LY LG LO LW SbW S518 S502 S505 S508 B502 141 142 143 144 163 Lg GR D103 S529 013 135 1 6 1

SM

TC

PH

L

R

H

9

B

A6

SM

GyB B S514 103 LgR GY WL S521 S520 S624 130 169 400

B

WL

HM GND

HAZARD 2

1

2

FRONT WORKING LAMP

EFFICIENT LOADING SYSTEM (ELS)

16 RY RBr RO F403 A102 A107 307 326 324 LgY BG RGy A007 H124 B101 F002 H738 B201

8

4

5

6

7

4

5

6

7

4

5

8

1

2

3

8

1

2

3

8

1

2

3

YV A401 231

B

5 B

1

1

A7

7

YSb S506 403

FUEL EFFICIENT MODE SELECTION

A8

8 RG RLg D113 C302 006 H106 RG RGy D113 A801 006 310

5

1

4

4

A9

B1

B3

B4

1

1

8 R RGy D109 C306 002 H138 R RGy D109 A801 002 310

5

1

4

8

COMBINATION S/W FOR LAMPS

R D602 023 R D601 024

HORN S/W TB

TL

TR

HU

EL

LT

LH

P RBr RO RW G703 A103 A106 F401 320 322 321 304

B

RB RY F601 F501 301 302

B

A

1

T3

B2

1 YV T307 231 B

1

A0

A3

6

B

L C101 801 L C102 802

B YV S918 231

HL

F801

1

8

B8

GY

B9

1 3 4 6

2

PARKING S/W L

GR

G Y B

R

CAN (RESISTOR)

GB

B

6 L LgG D206 H137 005-b 162 GO SbW B S901 A712 164 163 1 3 4

2

2

3

1 3

B5

Sb GO WR 6 H907 H908 H909

1

2

3

BW F005 271

B

BrG F004 255

1 4 GyY GyW BL H734 H724 H713 736 737 741 YV BLg BrW H715 H705 H725 734 735 733

C0 12 1

Y R

V

O

B

G

R G B

4 4

O Y V

3

DATA LINK CONNECTOR DECLUTCH SENSOR

6

10 WP LgR PL BR BL C5 H910 H913 H015 C802 H008 H011 B WG OL BrW BG H014 H013 H012 H007

−

+

1

2

3

B

LgY F002 167 YO F003 176

V BY S709 S707 100 114 LgR S727 166

VOLTAGE RELAY

BrG YO S922 B001 255 176 BW LgY S813 A803 271 167 B LP S915 168

A

Lg LB D103 S510 013 138 RL B H128 T801

C9 1

4

4 4

2

3

V1

6 140 325 308 404 311 S507 A107 F404 A614 B108 LLg RO RW YBr RLg 114 327 306 170 S707 A102 F403 S614 BY RBr RY WR 303 330 329 180 F604 V204 F804 S731 RB RL GW GyL V102 331 312 162 754 S724 S619 B208 B506 S625 WL RG RGy LgG GyG 40 36

S2L H708

B

8

V2

F8

AIR-SUS. 3

5 OY D114 007

S2H W H709 6 D506

DIAG INC/DEC S/W 2 PG PW H733 H723 739 740 BrG BL H714 H713 738 741

B 2

1

T5

2

LgB V303 221 LgB V304 226

4

V4

1

1

LgB H132 221 LgB S702 226

BrR L G202 D205 272 005-a B L S610 273 1

4

1

4

2 2

3 3

2

3

(BLACK)

(BLACK)

(BLUE)

F9

X5

T9

T0

1

4

V3

CAB ALARM BUZZER

1 1

4

G0

G1

H4

H5

1

1

1

YSb S917 125

B

1

2

Br D110 003

Br D110 003

Br D110 003

Br

G2

1 (BLUE) Br

BrR

G3

1

G4

910 D301 R 911 D402 R

912 D401 R 913 D901 R

914 D002 R 915 D001 R

H9

B

20

2

G5

3

P R B909 D111 320 004 B

LgSb X504 112 1

G6

RL V204 330

T8

1

4

2 BP G A101 D107 A108 010 B

4

1

4

2

3

6 703 C201 C202 C203 747 F704 T406 T405 T404 T403 RL S2H S2L S2S YL 015 732 204 F104 748 D101 A606 S534 F204 T402 WR BrW SbLg RLg YO 731 181 220 160 H016 A607 S811 S723 S716 YR BrB BrY GyO Y 705 730 720 752 159 V103 A605 A802 F301 S708 Y WG BrR BG GyR 40 36

D804 D802 H102 H112 R RB RW Y

C501 C510 BG BL

B

D803 D701 H730 C508 C504 C503 C502 C509 RG RL YR PL WG OL BrW BR

B

18

10

G8

G7

H7

10

9

1

H0

H6

901 E201 W

C404 C405 C406 C506 Sb GO WR WP

B

G D107 010

BY YGy E701 E704 114 242 V SbR E702 E703 240 100

10

C607 C608 C609 C610 LO GW BY BrY

C606 C605 C604 C603 C602 D701 C601 C507 C402 C401 WY V PB YB VW RL P LgR BrB LgY 11

E L

B

3

BrB

HAZARD

E L

B

Br

BrW

BACK LAMP (OPT)

R

G V805

1

1

4

1

TURN SIGNAL

G9

H3

AIRCON UNIT

BZ

H8

B LP LBr LR S517 S604 S613 149 148 146 LY LG LO LW S518 S502 S505 S508 141 142 143 144 1

2 BrB L G402 D205 257 005-a B BrB S611 258

1

4

KICK OUT

FLOAT POSITIO -NER

SHIFT HOLD S/W (OPT)

H2

1 172 003 100 S722 D110 H003 S709 SbY Br RW V 703 171 251 015 F704 S730 S826 H004 D101 WR RL SbY BrR Y V103 720 250 261 267 A503 A802 G302 S504 S501 WG BG BrW LgL GB 182 012 221 266 V303 S801 S806 D105 LgB GyB LgL BW 35 31

LOWER KICKOUT RELAY

(BLUE)

PILOT VALVE MAGNETS

T4

5

F6

3

Lg Lg D103 D103 013 013 LgSb LgBr G601 S609 112 104 1

4

(BLACK)

F7

7

H1

10

1

4

(BLACK)

2

3

LgW L A508 D205 102 005-a B LgW S612 101

DOWNSHIFT BUTTON

4 YL YO H706 S2S H716 H707

1

1

F5 LIFT KICKOUT RELAY

BUZZER RELAY

2

3

G G D107 D107 010 010 GW GL H127 B801 329 328 1

4

2

3

G L D102 D205 014 005-a RL SbP H710 S618 H115 145

(BLACK)

(BLUE)

MCU FAULT RELAY

HORN RELAY

E

2

3

WG WL H125 H140 H740 707 B B

1

AIR TEMP. PROBE (MCU)

BY G S707 S732 114 415

1

2

3

(BLACK)

3

3

2

6

F4

F

2

4

1

4

(BLACK)

3

D

G

C8

2

3

226 V404 LgB 221 V403 LgB

1

6

1

C

H

BACK RELAY (OPT)

2

WY V PB YB VW P H920 H919 H918 H917 H916 H914

F3

2 4

R R D108 D108 001 001 RB RB C403 B914 H129 301 1

4

1

B

C6

F2

3

1A

1 3

4

YL

LO GW BY BrY Y RL 12 H901 H902 H903 H904 C801 D701

AIR PROBE (TH AM )

F1

S914

7

1

(BLUE)

NEUTRAL RELAY

F0

J

C7

BR Y C509 C611

5

1

4

(BLACK)

2

3

R R D108 D108 001 001 RY RY F402 B915 305 302

RW R H108 D108 308 001 RY RY RW A813 F504 B912 H118 305 304

(BLACK)

2

3

6

3 1

T6

4

Gy GyR S816 H721 750 751 B GyR H737 752 1

4

2

3

Sb SbP H704 S509 205 202 RLg B H717 206 1

4

2

3

SbY SbR H711 S608 209 208 RLg B H717 206

8

1

S

2 2

3 3

6

1 168 T606 B LP 271 167 T706 T608 BW LgY 255 176 T708 T601 BrG YO

B 1

2 1

5

LP F001 168

4

1

T7

THROTTLE PEDAL 6

C4

RB BrB LgY F604 H912 H911 300

8 5

8

6

CAB

WIDTH LAMP RELAY

FUSE

B0

C3

3

4

B

CAB (AIRCON) 4

5

1

C2

7

6

4

4

7

C1

5

1

RGy RB G WBr RLg O B208 A611 D107 D604 B108 D610 520 300 010 022 521 020 PB PL OR OL OW OG H722 H732 D609 D608 D607 D606 500 506 H712 018 017 016

1

2

HEAD LAMP RELAY

1 3 4 6

2

B7

6

S2L S2H H708 H709 S720 S729 1

3

B6

S2S H707

L B402 802 L B401 801

RB A611 300

5

S921

LR LBr B S911 S904 126 128 LW B S912 120 LY LG LO S910 S903 S905 121 122 123

G

LLg

YO R

A002 F003

Y

L

Hi-BEAM RELAY

1A 7 8

B

1

5

DECLUTCH CUT-OFF S/W

E/G OIL PRESS. S/W RELAY

257 T903 BrB

B

TORQUE SELECTION RELAY

250 H123 BrW

GL

G

1

E/G IDLE SELECTION RELAY

DECLUTCH SET-UP

272 T003 BrR

GW

LIFT KICKOUT SET-UP/ LOWER KICKOUT SET-UP

GL

SHIFT LEVER

A4

5

1 735 205 203 172 171 C002 F203 S615 S722 S730 BLg Sb SbW SbY SbY 734 738 C004 019 209 C001 G004 G001 C309 F103 YV BrG BL OR SbY 733 737 740 500 751 C003 C005 G002 C307 F302 BrW GyW PW PB GyR 012 736 739 506 161 D105 C006 G003 C308 S715 BW GyY PG PL W 35 31

This page illustrates the transmission is in neutral and key switch is in OFF position.

80ZV2-09709-08771 EU 1/3 80V2E92019

80ZV-2 EU 92-10 92 Drawing & Diagrams Electrical Wiring Diagram (2/3) (S/N 9039~9100)

Electrical Wiring Diagram (2/3) (S/N 9039~9100) MCU A16.TT_L A17.D_SO A18.1_SO A19.EP_L A20.AB_L A21.A_L A22.1/2_L A23.E_L A24.SS_L A25.SC_SW A26.TF_L A27.AC_L A28.BP_L A29.N_L A30.SC_L

A 1.2S_SO A 2.2_SO A 3.ES_R A 4.DD_SO A 5.3_SO A 6.HM A 7.LU_SO A 8.4_SO A 9.EG_SW1 A10.R_L A11.F_L A12.ST_L A13.WL_L A14.CW_L A15.ET_L

OPT B

A4

A6

A5

A7

A8

A9

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

B2

B1

B3

B5

B4

B6

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.ASUB2 E29.CANHO E30.B_SE1

E1

B7

E2

E3

E4

E5

E31.TT_SE E32.OT_SE E33.OUT_RSE E34.ET_M

E6

E7

C 1.2S_SE C 2.POD_SW1 C 3.POD_SW2 C 4.DSUB4 C 5.TT C 6.AC C 7.ET C 8.BL C 9.BD C10.DSUB1 C11.HYDOL C12.DR C13.BSL_S C14.TF C15.WL

E9

E8

C2

C1

C16.EP C17.F C18.ASUB1 C19.TMP_SE C20.1/2 C21.1/8 C22.2S C23.EGM C24.IP_SW C25.FR C26.KO_P C27.ES_SE C28.3/4 C29.1/4 C30.DC

C3

C4

C5

C6

C7

C31.BSL C32.DSUB3 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

C8

D1

C9

D12.SL_A D13.DSUB2 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

D2

D3

D4

D5

D6

D7

A10

A11

A12

A13

A14

A15

A16

A17

B8

B9

B10

B11

B12

B13

E10

E11

E12

E13

E14

E15

E16

E17

C10

C11

C12

C13

C14

C15

C16

C17

D8

D9

D10

D11

D12

D13

A18

A19

A20

A21

A22

A23

A24

A25

B14

B15

B16

B17

B18

B19

E18

E19

E20

E21

E22

E23

E24

E25

C18

C19

C20

C21

C22

C23

C24

C25

D14

D15

D16

D17

D18

D19

A26

A27

A29

A28

A30

A31

A33

A32

A34

B20

B21

B22

B23

B24

B25

E26

B26

E27

E28

E29

E30

E31

E32

E33

E34

C26

C27

C28

C29

C30

C31

C32

C33

D20

C34

D21

D22

D23

D24

D25

D26

B

EU 3

A3

A2

A1

A31.1/4_L A32.FR_L A33.3/4_L A34.EG_SW3 B 1.H_SO B 2. B 3.IP_SO B 4.R_SO B 5.MO_SO B 6.FR_SO B 7.SSL_SO B 8.ISW_R B 9.BZ B10.BSL_R B11.KO_R

ODOMETER SELECTION

JPN 2 PL P S803 S802 108 107 B 1

A/M SELECTION

B

B

PB S916 110

PG S902 109 1 (BLACK)

1

(BLUE)

S1

S3

9

1

S4

YG LgR S2H SbY GyL G YB C703 C201 H114 H126 C901 S202 A603 166 H701 180 415 116 401 G S2L BrW SbY GyO WL YL E003 C202 A602 H104 H727 H140 S204 234 402 H702 220 707 117 L L W Y G D203 D204 H731 H726 D107 005-C 005-D 161 160 010 BR LgB L L B BY Y V B H736 E002 V304 D201 D202 236 226 005-A 005-B 159

YB GR WL GyG YO T103 S203 A806 H136 S205 811 115 400 754 118 WR SbW GL YBr SbP RG H117 H703 T104 S201 F701 H139 170 203 810 119 145 331 SbR LgBr L BrB LgW LR F102 X501 T001 T901 F901 H205 208 104 273 258 101 146 LBr LgL BL H206 E502 E001 148 225 237

LgW LgY GR RL SbLg A502 A507 A701 A608 H718 192 173 135 235 204 LY Gy Gy LgR LgB A708 A506 A807 A808 A604 224 H201 749 169 130 0 LB GyB GyG GyL LP A609 V202 A809 A505 A501 H207 241 103 753 190 149 138 GB LG YGy LgL LO YSb LLg LW SbP H121 A709 E804 H122 A710 A901 H110 A711 F202 267 H202 242 261 H203 403 140 H204 202 1

7

S5

1

S6

S7

B Y GyW LgY T202 E603 E501 105 260 223 Lg GL GyW E503 A302 A202 265 200 222 BW BrY R Gy H728 T203 F005 F303 181 106 271 750 GyB P PL LgL H131 S102 S103 H135 266 107 108 182 BrR SbR H113 E802 251 240

100 C702 E803 E004 H101 T101 9

114 C701 E007 C902 H120 E801 T102

LLg BrG LB YW B002 F004 E006 E012 165 255 230 233 YL LP PB YSb YV YO G101 F001 S301 G901 A401 E005 124 168 110 125 231 232 LY LW LR B703 B709 B706 121 126 120 GO PG LG LBr LO B503 S401 B702 B708 B701 164 109 122 128 123 9

1

7

1

S8

S9 T1

S2 3

FUSE BOX (CAB) R5

FUSE BOX (MAIN) R5

R5

16

R5

BW BG

R1 BR S2L B ACC R2 C

STARTER S/W

WRx2 WBx2 G

W 3W5 BW

WR

WR

BG

WB

WB

G

W

W D506 060 W H601 901

WR WR D501 D503 063 065 BW D504 062

G D502 064

2

3

4

5

6

7

8

9

W

R

Y

B

L

G

Br

O

WR

RG

LR

LW

W

R

Y

B

001 8 R F406 F502 F503 F602 G F603

R B202 B207

Br

R G702 004 Lg

BW H134 H735

7 C304 F802 F803 G501 G802 S717 010

W

STARTER SWITCH

1

RL

D1

YR

YW

G

Br

10

11

12

13

W

R5

YW

YR

LW

L

O

R5

R5

LR

RG

RL

R H301 910

R H302 911 R H401 912

D2

5

5

6

8

1

2

3

5

E1

Br R

22

23

24

B

L

G

Br

25

26

O

WR RL

RG

Y

O

WR

RG

YR

YW

B

L

RL

LR

LW

OL OR O 10 D608 D609 D610

5

RL 1

1

5 1

V801 W

3

R R D602 D601

V9

(EU:STANDARD)

27

28

29

30

LR

LW

YR

MCU SELECTION

YW

RG RB H018 H002

R R 2

5

R H402 913

R H001 1 4

R

6

D3

5

R H501 914 R H502 915

RS232C

3

R Y S812 S830 106 105

2

DIAG. S/W CONNECTION

DC-DC CONVERTOR (EU : STANDARD)

1 B

V902 V901 R R

5

2

YW

C612 H915 H017

E

OUT

B

IN

G G501

L V904

8

5

OG OW OL OR O 10 C312 C311 C310 C309 C301 016 017 018 019 020 WBr R R C303 B301 B302 022 023 024

6

D5

D4

3

5

V906 V804 V908 V909 V910 Y OL OR O 10 6 OG

E2

6

FR SWITCH (EU : STANDARD) B

1

1

YO E306

Y D607

B

W D604 1

4

1

D6

D7

D8

D9

D0

B

YW E412

YW E308

12

7 1

E4

F/R SWITCH/ STICK STEERING

6

3

Lg LgL S825 S606 222 225 B LgY S834 223

4

SECONDARY STEERING (EU : STANDARD)

RIDE CONTROL S/W

REVERSAL FAN S/W

BL BR G V YO LB S607 S701 S719 S709 S919 S924 237 236 234 100 232 230 YW B L BY S926 D205 S707 233 005-a 114

8

4

21

V8

4

B

G W OG D606

4

5 6 2 L L L L L E008 L S703 S704 S711 S712 F702 B504 005-A 005-B 005-C 005-D F902 005-b T902 T002 005-a

1 3 4 6

7

YO E405

Y

L V808

W BW E202 E104 062 T407 G WR WR E107 E101 E106 065 064 063 3

3

1

R

6

4 L

6

1

2

20

1 B

1

4

FR SWITCH (EU : STANDARD)

19

T2 1

V GL S616 S709 810 100 GR BY S622 S707 811 114

15

14

WR

14 RG OY B102 T501 B107 007 WR G F703 H111 014 H720 1 A207 A307 A610 A706 E601 X502 X503 V203 013

18

4 RL RG LR LW YR YW

003 G201 G301 G401 H103

17

4

YG YBr YB S623 S733 S617 115 116 119 YL YO B S725 S626 117 118

R5

R5

1

4

2 GyW S833 260 Lg D103 013

B 1

1

2

YGy V H804 H803 242 100 SbR H802 240 BY H801 114

6

3

3

1

1

YGy V S709 S503 100 242 SbR S827 240 BY S707 114

4

This page illustrates the transmission is in neutral and key switch is in OFF position.

6

7 7

12

E0

E5

E6

E7

E8

E3

A

80ZV2-09709-08771 EU 2/3 80V2E92020

80ZV-2 EU 92-11 92 Drawing & Diagrams Electrical Wiring Diagram (3/3) (S/N 9039~9100)

Electrical Wiring Diagram (3/3) (S/N 9039~9100) 40

COMBINATION LAMP

K6

1

K801

B RBr

K103

RB

K106

303

JPN:CONNECT EU :DISCONNECT WORKING LAMP (INSIDE) RLg

4

LR H205 146

+

−

B

H7

3

PB PL

M8 GyO BY H727 P502 220 114

1

1

B

(BLUE)

2

−

R

LBr H206 148

+

− −

B

K2

−

1

W

B

GB H121 267

B

6

GyB H131 266 V BY H120 H101 114 100

1

2

LY H201 141

J3

B

2

Br

M1

M2

1 B −

2

+

−

B

2

J4

2

LgG P503 162

1 B

P4

B

L8

M3

10

W

1

2

1

2 BY V P501 P502 100 114 SbY H702 172

BY V P501 P502 100 114 SbY H701 171

P7

WR H720 015 GyR H721 751

L1

BY L202

2

1 B

B K104

LW H204 144

+

−

YBr H107 404

B

J6

2

−

D

4 4

B

−

+

+

PARKING SOLENOID

1

L3 1

V L301 BY L303

V K202 BrR 100 K205 BY 251 K203 114

BrR L302

LP H207 149

+

−

Y

B

2

2

1

6

3

L0

L9

RIDE CONTROL SOLENOID (OPT)

RW Y L803 L804

LgL R801 R803

R8 LgL L401

B

2

1 B

LgL K204 261

B

2

1

LgL L806 182

1

2

2

70A

P0 STARTER C B

1

BW N501 702

R H301 H302 H401 H402 H501 H502 910915

R N502 701

ELECT. FAN CONDENSER

E

B

R

1

2

WV N403 700

B

BY GyL H120 H126 114 180 2

GyG BY H136 H120 754 114 1

1

2

WL H140 707

2

WP P602 708

N7 MAGNETIC S/W

4

R N502 3 701

1 RL N904 703

30A

N4

6

2

4

W H601 N001 901 086

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

41

42

43

44

45

46

47

48

49

50

45

B

3 3

B

6

4

1

3

2

1 2 1

3

LgG BY H137 H120 162 114 LgB V H132 H101 221 100

4

303 R501 RB B 330 R301 R401 R201 RL RGy

2 2

2

RL RGy H128 H138 330 312 RB B H129 303

3 G M001 M002 W N101 086

3

1

N0

RGy R102

REAR WORKING LAMP

2

R4

1 B

R501 R502

1

330 R103 RL R104

BACK UP ALARM RB

303

LICENSE LAMP

B

RH BATTERY − +

2

M0 1

1 703 N701 RL 705 N704 WG

REAR WORKING LAMP

B

G G N002 N002 036 036 1

312

2

R1

P803 P803 P804 P804 G G

R102

RGy B

R3

4

114 L702 M201 M301

312

1

P5

2 2

WG H125 705 RL H115 703

R7

1

4

N9

LH BATTERY −

M6

50

2 3

1

P6 M5

46

ECM

R6 4

WR WP H111 M702 015 708 BW BG H134 H124 012 720

DIODE UNIT

WG 4 N903 705

1 221 M202 P101 M302 LgB V 162 M101 LgG BY

1 012 720 N601 N602 BW BG 015 708 N401 N402 WR WP

4 1

BW 2 N501 702

N3 BATTERY RELAY

FUSE

1

10

21

R2

3

3

700 N301 WV 015 708 P605 P602 WR WP

I

9

3

4

3

M7 ALTERNATOR

8

1

R9

N2 FUSIBLE LINK

3

AIR CLEANER

G M001 M002 G M001 M002

S2L H708 S2S P747 H707 S2H P737 H709 P746

P9

3

70A

2

M

1

B

R 1

E/G WATER TEMP. SENSOR (MCU)

SECONDARY STEERING MOTOR RELAY

AIR HEATER

B

T/M OIL TEMP. SENSOR (MCU)

B

SECONDARY STEERING MOTOR PUMP

L4 30A

7

2

B

BG P601 720

N6 HEATER RELAY

N1 FUSIBLE LINK

3

6

+ -

BW P606 012

W

B L802

B

R BW N703 N702 701 702

YGy H804 242

JPN:OPT EU :STANDARD

1

2

1

2

LgL L401

2

5

CAN (RESISTOR)

SECONDARY STEERING OIL PRESS. SENSOR

BW R P001 P002 702 701

FUEL LEVEL SENSOR

4

41

1

N5 1

3

BRAKE OIL PRESS. (MAIN)

−

P3

2

10

2

4

2

+

J7

182 L002 LgL

B

1

B

L903 B

L2

H713 H717 R902 741

P8

L902 L901 RW Y

1

46

6

5 1

−

1

+

3

S2L S2H P902 P901

S

RW Y H102 H112

1

−

4

S2S P903

50

BY V H803 H801 100 114 SbR H802 240

+ 6 LgL H135 182

S

S

1

2

1 BrG GyY H714 H734 738 736 GyW SbY H724 H711 209 737 PW PG BLg BrW H723 H733 H705 H725 740 739 735 733 BL Sb H704 205 BrB BrR GyR W H729 H739 H737 H731 731 730 752 161 45 41

REAR COMBINATION LAMP (R.H)

3

A

J5 1

1

5

1

BrR L203

B

2

6 YV YL H706 H715 747 734 YO SbW H716 R901 748 203

1

B

LO H203 143

+

J8

3

V L201

−

3

1

2

C

L6

70A

L

P1

M9

1

LG H202 142

−

1

BUCKET LEVELER

P2

1

2

+

2

1

L5

B

M4

L7

Y Y H726 H736 160 159

1

+

−

K0

Br K201 003 BrW B K206 250

2

2

+ S

K9

RW RY K108 K102 308 306 B

W

1

+

2 R

BrY H728 181

2

1

B

YR

+

B

LgB P504 221

GROUND SPEED SENSOR

J2

2

YR H730

Br

PL H732 506

J1

B

FRONT HEAD LAMP (OUTSIDE)

BOOM ANGLE SENSOR

4 R

−

OR

+

1

3 BY V Br H120 H101 H103 114 100 003 LgL BrR BrW H122 H113 H123 261 251 250

4

6

311

K105

3 Br V BY L103 L201 L202 003 100 114 BrW BrR LgL L102 L203 L401 250 251 261

K802 K803

327

8

8

1

COMBINATION LAMP

WASHER MOTOR (OPT)

+

F

1

OR PB H722 H712 500 019

F

B

EFFICIENT LOADING SYSTEM (ELS) SOLENOID VALVE

1

GW K601

2

H6

T/M SOLENOID VALVE

EFFICIENT LOADING SYSTEM (ELS) OIL PRESS. SENSOR

K1

H5

R

GW K107 329

H4

G

B

H8 H3

+

REAR COMBINATION LAMP (L.H) R

B

4

FAN SPEED CONTROL SOL. VALVE

HYD. OIL LEVEL S/W

G

GW K702 K704

1

H2

COMPRESSOR CLUTCH (ECc ) HYD. OIL TEMP. SENSOR

B

K7 B

1

1

4

3 240 100 P403 P402 SbR V 114 242 P401 P301 BY YGy

8

LBr B LP J202 J702 148 149 LO LG LY J502 J402 J302 143 142 141

B

5 4

2 2

1

LR J102 146 LW J602 144

GR

1

1

5

W N101 901

3

GW K601

325 K002 327 K502 K302 K802 RO RY RBr B K003 329 K803 K901 K303 K601 K503 K401 RW GW RB RLg

B

R N201 915 R N201 914

31 GyY PG PL W P701 P724 M803 P741 736 739 506 161 BrW GyW PW PB GyR P722 P711 P725 M802 P749 733 737 740 500 751 OR SbY YV BrG BL P709 P702 P734 M801 P713 734 738 741 019 209 SbY SbY BLg Sb M303 M203 P723 P731 735 205 172 171 5 1

RY

303

H1

4

K106

1

K202 L602 P501 100

5

RB

K502 K503

325

RW GW RB RLg H108 H127 H129 H106 308 329 303 311 RO RY RBr B H109 H118 H119 L802 325 H118 327

K101

JPN:CONNECT EU :DISCONNECT

HORN (L)

HORN (H)

RO

K203 L601 M502 M602 P502 114

R N201 913 R N201 912

35

B

K501

B

2 R N201 911 R N201 910

36 Y BrR GyR P743 P742 M901 730 752 159 Y YR BrB BrY GyO P201 P744 M401 L701 M902 731 181 220 160 WR BL YO P739 P734 P720 015 741 748 S2H S2L S2S YL P901 P902 P903 P710 747 10 6

B

B

40

GR

R103 R602 R702 330

K4

311

K105

31 LgL BW LgB GyB L806 P606 P504 L603 221 266 182 012 WG BG BrW LgL GB N903 P601 K206 K204 L501 705 720 250 261 267 BrR WR RL Y K205 L804 P605 N904 703 251 015 Br RW V K201 L803 003 5 1

RY

3 RLg

35

1

WORKING LAMP (INSIDE)

1

36 WL RG RGy LgG GyG M701 R605 R102 P503 M601 707 R705 312 162 754 RB RL GW GyL K107 M501 329 180 BY RBr RY K103 K102 R703 306 RO RW YBr RLg K101 K108 J802 K105 R603 308 404 311 10 6

325 330 H109 H128 RO RL 303 331 H129 H139 RB RG

W

303 K106 R104 R604 R704

K3

327 330 H119 H128 RBr RL 303 331 H129 H139 RB RG

RW RY K108 K102 308 306 B

B

2

2 R

SbW BL P719 P734 203 741

FRONT HEAD LAMP (OUTSIDE)

This page illustrates the transmission is in neutral and key switch is in OFF position. 80ZV2-09709-08771 EU 3/3 80V2E92021

80ZV-2 EU 92-12 92 Drawing & Diagrams Electrical Wiring Diagram (1/3) (S/N 9101~9200)

Electrical Wiring Diagram (1/3) (S/N 9101~9200)

1

2

3

4

4

5

3

6

6

DECLUTCH (DISCONNECT)

5

4

5

3

INSTRUMENT PANEL

6

7

WT

7

C

AC

TT

+

EP

BP

CE

(+)

5 7 8 5

4

5

6

1

2

3

8 RO RO BP B911 A815 G803 321 H109 323 RBr RBr BP B910 A814 G803 322 H119 323

5

1

4

4

7

4

8

1

5

6

2

3 8

Lg D103 013 GyW S823 200

B

4

8

1

5

6

2

3

5

5

8

B

Lg D103 013 GL S822 265

B

1

A1

7

8 LgY A803 167 YO B001 176

B

4

1

A2

8 GyG Gy LgY LgW S515 S519 S528 F903 753 749 173 102 WG LgW GyL H125 S527 S516 705 192 190 4 1

B

ES

FR

EG2 EG1 EG3

WTM TTM

−

GND

11

1

2

3

4

N

A

AB

P

W

GND

20 7

RB YBr B601 H107 404 C305 Lg O RL BrB BrW BrR LgB YB BrW D103 S512 S532 H729 H719 H739 S524 S734 S721 013 241 235 731 732 730 224 401 402 10

B

12 LY LG LO LW SbW S518 S502 S505 S508 B502 141 142 143 144 163 Lg GR D103 S529 013 135 1 6 1 B

A6

SM

SM

TC

PH

L

R

H

9 GyB B S514 103 LgR GY WL S521 S520 S624 130 169 400 8

B

A7

WL

HM

16 RY RBr RO F403 A102 A107 307 326 324 LgY BG RGy A007 H124 B101 F002 H738 B201 1

1

5

6

F/R S/W SELECTION (EU STANDARD)

1

1

2

3 4

3 4

5

6

6

7

4

5

6

7

4

5

6

7

4

5

6

8

1

2

3

8

1

2

3

8

1

2

3

YV A401 231

B

5

8 RG RLg D113 C302 006 H106 RG RGy D113 A801 006 310

5

1

4

4

A9

B1

B3

4

4

B

A8

2

3

5

+

FM

A5

B

SS

REAR WORKING LAMP

1

2

1 2

GND

1 2

HAZARD

FRONT WORKING LAMP

EFFICIENT LOADING SYSTEM (ELS)

YSb S506 403

FUEL EFFICIENT MODE SELECTION

8 R RGy D109 C306 002 H138 R RGy D109 A801 002 310

5

1

4

8

1 YV T307 231 B

B4

1

A3

1

COMBINATION S/W FOR LAMPS

A0

HORN S/W TB

TL

TR

HU

EL

LT

LH

P RBr RO RW G703 A103 A106 F401 320 322 321 304

B

RB RY F601 F501 301 302

B

1

R D602 023 R D601 024

A

1

T3

B2

B

L C101 801 L C102 802

B YV S918 231

HL

F801

1

8

B8

GY

B9

1

GB

G

4 1

2

L LgG D206 H137 005-b 162 GO SbW B S901 A712 164 163 3 1

3

1

2

6

RB A611 300

3

B5

1

1

BW F005 271

B

CAB

1

−

+

4 GyY GyW BL H734 H724 H713 736 737 741 YV BLg BrW H715 H705 H725 734 735 733

C0

1

Y R

V

O G

B

R G B

4 4

O Y V

3

LO GW BY BrY Y RL 12 H901 H902 H903 H904 C801 D701

C6

AIR PROBE (THAM)

VOLTAGE RELAY

A

LgY F002 167 YO F003 176

2

3

Sb SbP H704 S509 205 202 RLg B H717 206

4

1

2

4

1

RW R H108 D108 001 308 RY RY RW A813 F504 B912 H118 305 304 3 1

Gy GyR S816 H721 750 751 B GyR H737 752

4

1

4

(BLACK)

(BLACK)

(BLUE)

F1

F2

F3

6

3

2

3

R R D108 D108 001 001 RY RY F402 B915 305 302 4

2

2 4

1

2

3

4

R R D108 D108 001 001 RB RB C403 B914 H129 301 1

4

1

(BLACK)

(BLACK)

F5

F6

F4

NEUTRAL RELAY

BrG YO S922 B001 255 176 BW LgY S813 A803 271 167 B LP S915 168

6

2

Lg LB D103 S510 013 138 RL B H128 T801

C9 1

4

YL YO H706 S2S H716 H707

1

(BLUE)

(BLACK)

V1

V2

3 3

2

3

G L D102 D205 014 005-a RL SbP H710 S618 H115 145 4

2

3

LgW L A508 D205 102 005-a B LgW S612 101

4

1

2

3

G G D107 D107 010 010 GW GL H127 B801 329 328 1

4

3

2

1

4

3

2

V4

1

1

4

1

4

1

2 2

3 3

2

LgB H132 221 LgB S702 226

BrR L G202 D205 272 005-a B L S610 273

BrB L G402 D205 257 005-a B BrB S611 258

Lg Lg D103 D103 013 013 LgSb LgBr G601 S609 112 104

1

(BLACK)

(BLACK)

(BLUE)

(BLACK)

(BLACK)

(BLUE)

F7

F8

F9

X5

T9

T0

1

4

V3

CAB ALARM BUZZER

PILOT VALVE MAGNETS

8

4

AIR-SUS.

S2H W H709 D506

3

5 OY D114 007

6

DIAG INC/DEC S/W

2

PG PW H733 H723 739 740 BrG BL H714 H713 738 741

B

1

2

4

1

YSb S917 125

1

7

1

T4

T5

G0

POSITIO -NER

FLOAT

SHIFT HOLD S/W (OPT)

G1

Br D110 003

Br D110 003

B Br

1 (BLUE) Br

G2

BrR

G3

H4

H5

G D107 010 BrB

4

910 D301 R 911 D402 R

1 912 D401 R 913 D901 R

L

901 E201 W

2

B

10

C404 C405 C406 C506 Sb GO WR WP

20

G5

2

3

P R B909 D111 320 004 B

LgSb X504 112 1

RL V204 330

G6

T8

4

2 BP G A101 D107 A108 010 B

1

G7

4

10

6 703 C201 C202 C203 747 F704 T406 T405 T404 T403 RL S2H S2L S2S YL 015 732 204 F104 748 D101 A606 S534 F204 T402 WR BrW SbLg RLg YO 731 181 220 160 H016 A607 S811 S723 S716 YR BrB BrY GyO Y 705 730 720 752 159 V103 A605 A802 F301 S708 WG BrR BG GyR Y 40 36

1

H0 1

9 C501 C510 BG BL

B

D803 D701 H730 C508 C504 C503 C502 C509 YR PL WG OL BrW BR RG RL 18

B

D804 D802 H102 H112 R RB RW Y

10

G8

4

3

C607 C608 C609 C610 LO GW BY BrY

C606 C605 C604 C603 C602 D701 C601 C507 C402 C401 P LgR BrB LgY WY V PB YB VW RL 11

E

B

H7

BY YGy E701 E704 114 242 SbR V E702 E703 240 100

1 914 D002 R 915 D001 R

H9

H6 1

1

E L 3

1

G4

HAZARD

B B

Br

BrW

TURN SIGNAL

BACK LAMP (OPT)

H8

LP LBr LR S517 S604 S613 149 148 146 LY LG LO LW S518 S502 S505 S508 141 142 143 144 1

1

AIRCON UNIT

1

R

G V805

2

G9

B

5

BZ

KICKOUT

Br D110 003

H2

1 172 003 100 S722 D110 H003 S709 SbY Br RW V 015 703 171 251 F704 S730 S826 H004 D101 Y RL SbY BrR WR V103 720 250 261 267 A503 A802 G302 S504 S501 WG BG BrW LgL GB 182 012 221 266 S806 D105 V303 S801 LgL BW LgB GyB 35 31

4

3

1

H3 6 140 325 308 404 311 S507 A107 F404 A614 B108 LLg RO RW YBr RLg 114 327 306 170 S707 A102 F403 S614 BY RBr RY WR 303 330 329 180 F604 V204 F804 S731 RB RL GW GyL V102 331 312 162 S724 S619 B208 B506 WL RG RGy LgG 40 36

LOWER KICKOUT RELAY

226 V404 LgB 221 V403 LgB

DOWNSHIFT BUTTON

S2L H708

B

1

4

LIFT KICKOUT RELAY

4

E

2

3

WG WL H125 H140 H740 707 B B

1 BY G S707 S732 114 415

2

BUZZER RELAY

2

LgB V303 221 LgB V304 226

F

C8

3

MCU FAULT RELAY

HORN RELAY

1A

1 3

3 1

T6

D

G

H1

10

B

SbY SbR H711 S608 209 208 RLg B H717 206

8

3

2

AIR TEMP. PROBE (MCU)

3

3

C

H

BACK RELAY (OPT)

2

WY V PB YB VW P H920 H919 H918 H917 H916 H914 1

2

2

F0

J

C7

BR Y C509 C611

1

1

3

1 168 T606 B LP 271 167 T706 T608 BW LgY 255 176 T708 T601 BrG YO

B 1 V BY S709 S707 100 114 LgR S727 166 1

S

8

4

1

THROTTLE PEDAL 6

12

2

10 BR BL WP LgR PL C5 H910 H913 H015 C802 H008 H011 WG OL BrW BG B H014 H013 H012 H007

6

LP F001 168

6

DECLUTCH SENSOR

6

5

5

8

BrG F004 255

T7

DATA LINK CONNECTOR

1

6

3

4

B

C4

3

7

2

7

B0

C3

RB BrB LgY F604 H912 H911 300

5

1

1

C2

Sb GO WR 6 H907 H908 H909

8 5

CAB (AIRCON) 4

6

4

7

C1

5

1

G WBr RLg O RGy RB B208 A611 D107 D604 B108 D610 520 300 010 022 521 020 PB PL OR OL OW OG H722 H732 D609 D608 D607 D606 500 506 H712 018 017 016

S2L S2H H708 H709 S720 S729 2

4

B7

6

S2S H707

L B402 802 L B401 801

3

B6

6

257 T903 BrB

L

LR LBr B S911 S904 126 128 LW B S912 120 LY LG LO S910 S903 S905 121 122 123

7

S921

R

LLg

YO Y

FUSE

4

1A

B

A002 F003

B

WIDTH LAMP RELAY

B

Y

CAN (RESISTOR)

HEAD LAMP RELAY

3

5

6

250 H123 BrW

GR

G

R

4

Hi-BEAM RELAY

1

2

3

5

E/G OIL PRESS. S/W RELAY

272 T003 BrR

L

DECLUTCH CUT-OFF S/W

TORQUE SELECTION RELAY

B

B

2

PARKING S/W

YL

GL

G

1

E/G IDLE SELECTION RELAY

DECLUTCH SET-UP

S914

GW

LIFT KICKOUT SET-UP/ LOWER KICKOUT SET-UP

GL

SHIFT LEVER

A4

5

1 735 205 203 172 171 C002 F203 S615 S722 S730 BLg Sb SbW SbY SbY 734 738 C004 019 209 C001 G004 G001 C309 F103 YV BrG BL OR SbY 733 737 740 500 751 C003 C005 G002 C307 F302 BrW GyW PW PB GyR 012 736 739 506 161 D105 C006 G003 C308 S715 BW GyY PG PL W 35 31

This page illustrates the transmission is in neutral and key switch is in OFF position.

80ZV2-09709-09330 EU 1/3 80V2E92022

80ZV-2 EU 92-13 92 Drawing & Diagrams Electrical Wiring Diagram (2/3) (S/N 9101~9200)

Electrical Wiring Diagram (2/3) (S/N 9101~9200) 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.EG_SW1 A10.R_L A11.F_L A12.ST_L A13.WL_L A14.CW_L A15.ET_L

A2

A1

OPT

A3

A4

A6

A5

A7

A8

A11

A12

A13

A14

A15

A16

A17

A18

A19

A20

A21

A22

A23

A24

A25

A27

A28

A29

A30

A31

A32

B1

A9

A10

A26

(WHITE)

A31.1/4_L A32.FR_L A33.3/4_L A34.EG_SW3 B 1.H_SO B 2. B 3.IP_SO B 4.R_SO B 5.MO_SO B 6.FR_SO B 7.SSL_SO B 8.ISW_R B 9.BZ B10.BSL_R B11.KO_R

A16.TT_L A17.D_SO A18.1_SO A19.EP_L A20.AB_L A21.A_L A22.1/2_L A23.E_L A24.SS_L A25.SC_SW A26.TF_L A27.AC_L A28.BP_L A29.N_L A30.SC_L

A33

B2

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

B7

E1

B4

B3

B5

B6

B8

B9

B10

B11

B12

B13

B14

B15

B16

B17

B18

B19

B20

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

B21

B22

B23

B24

B25

E2

E3

E4

E6

E5

E8

E7

E11

E12

E13

E14

E15

E16

E17

E18

E19

E20

E21

E22

E23

E24

E25

E27

E28

E29

E30

E31

E32

E33

C1

E34

C3

C2

C4

C6

C5

C11

C12

C13

C14

C15

C16

C17

C18

C19

C20

C21

C22

C23

C24

C25

C27

C28

C29

C30

C31

C32

C33

D1

C9

C8

C7

C10

C26

D12.SL_A D13.DSUB2 D14.KD D15.INCH_S D16.OD_SW D17.SH D18.SS_SW D19.SS_F D20.TMP D21.INCH D22.KO_S D23.SC D24.AR D25.SM_SW D26.SS_R

C31.BSL C32.DSUB3 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

C16.EP C17.F C18.ASUB1 C19.TMP_SE C20.1/2 C21.1/8 C22.2S C23.EGM C24.IP_SW C25.FR C26.KO_P C27.ES_SE C28.3/4 C29.1/4 C30.DC

C 1.2S_SE C 2.POD_SW1 C 3.POD_SW2 C 4.DSUB4 C 5.TT C 6.AC C 7.ET C 8.BL C 9.BD C10.DSUB1 C11.HYDOL C12.DR C13.BSL_S C14.TF C15.WL

E9

E10

E26

B26

E31.TT_SE E32.OT_SE E33.OUT_RSE E34.ET_M

E16.SPD E17.BATT E18.CANL1 E19.SS_P E20.CANLO E21.TM_M E22.B_SE2 E23.WT_SE E24.ALT E25.RXD1 E26.TGSP E27.INCH_SE E28.ASUB2 E29.CANHO E30.B_SE1

D2

D5

D7

D6

D9

D10

D11

D12

D13

D14

D15

D16

D17

D18

D19

D20

C34

D4

D3

D8

D21

D22

D23

D24

D25

D26

(BLUE) B

B

EU 3

JPN PL P S803 S802 108 107 B

AUTO/FULL AUTO SELECTION

F23 CHANGE POINT SELECTION

F34 CHANGE POINT SELECTION

ODOMETER SELECTION

A/M SELECTION

B

B

B

B

B

2

PW S831 111

1

VG S925 157

VY S913 158

PB S916 110

1

1

1

(BLUE)

(BLUE)

(GREEN)

(BROWN)

S1

W7

W8

W9

PG S902 109 1

YB GR WL GyG YO T103 S203 A806 W301 S205 811 115 400 754 118 WR SbW GL YBr SbP RG H117 H703 T104 S201 F701 H139 170 203 810 119 145 331 L BrB LgW LR SbR LgBr F102 X501 T001 T901 F901 H205 208 104 273 258 101 146 LgL BL LBr H206 E502 E001 148 225 237

LgW LgY GR RL SbLg A502 A507 A701 A608 H718 192 173 135 235 204 LY Gy Gy LgR LgB A708 A506 A807 A808 A604 224 H201 749 169 130 0 LB GyB GyG GyL LP V202 A809 A505 A501 H207 A609 138 241 103 753 190 149 GB LG YGy LgL LO YSb LLg LW SbP H121 A709 E804 H122 A710 A901 H110 A711 F202 267 H202 242 261 H203 403 140 H204 202

1

1

9

1

YG LgR S2H SbY GyL G YB C703 C201 H114 H126 C901 S202 A603 166 H701 180 415 116 401 YL G S2L BrW SbY GyO WL E003 C202 A602 H104 H727 H140 S204 234 402 H702 220 707 117 L L W Y G D203 D204 H731 H726 D107 005-C 005-D 161 160 010 V B BR LgB L L B BY Y E002 V304 D201 D202 H736 236 226 005-A 005-B 159 7

1

(BLACK)

S3

S4

S5

S6

S7

100 C702 E803 E004 H101 T101 9

114 C701 E007 W302 C902 H120 E801 T102

LLg BrG LB VG YW B002 F004 E006 W801 E012 165 255 230 157 233 YL LP YO PB YSb YV G101 F001 S301 G901 A401 E005 124 168 110 125 231 232 LR VY LY LW B703 B709 B706 W901 121 126 120 158 GO PG LG LBr LO B503 S401 B702 B708 B701 164 109 122 128 123

PW Y GyW LgY T202 W701 E603 E501 105 111 260 223 GL GyW Lg A302 A202 E503 265 200 222 BW BrY R Gy F303 H728 T203 F005 181 106 271 750 GyB P PL LgL H135 H131 S102 S103 266 107 108 182 BrR SbR H113 E802 251 240

1

1

9

7

S8

S9 S2 3

FUSE BOX (CAB) R5

R5

003 G201 G301 G401 H103 RL W

R1

BW

B BG

R2

BR

WRx2

ACC C

WBx2

STARTER S/W

001 8 R F406 F502 F503 F602 G F603

G

W3 W5 BW

WR

WR

BG

WB

WB

G

W

W D506 060 W H601 901

WR WR D501 D503 063 065 G D502 064

BW D504 062

2

3

4

5

6

7

8

9

W

R

Y

B

L

G

Br

O

WR

LR

LW

R

Y

B

R B202 B207

Br

R G702 004

YR

BW H134 H735

Lg

D1

RL

RG LR LW YR YW

10

11

12

13

14

W

R5

WR L

Br

14 RG OY B102 T501 B107 007 WR G F703 H111 014 H720 1

O

5

R

R H301 910

R H302 911 R H401 912

R

5

YW

YR

LW

LR

RG

RL

D2

6

5

E1

4

5

6

8

1

2

3

5 B

FR SWITCH (EU : STANDARD)

6 B

1

1

1

YW E308

12

7 4

Y

22

23

24

L

G

Br

25

26

O

WR RL

RG

O

WR

RG

YR

YW

B

L

RL

LR

LW

O 10 OL OR D608 D609 D610 RL 1

V9

1

5 1

V801 W

3

R R D602 D601

27

28

29

30

LR

LW

YR

R

RG RB 2 H018 H002

R5

R H402 913

R H501 914 R H502 915

D4

6

D5

1

E/G WATER TEMP. SENSOR (FOR INSPECTION)

B

3

R Y S812 S830 106 105

2

SPARE

YW

DC-DC CONVERTOR (EU : STANDARD)

1

C612 H915 H017

BOUT

V906 V804 V908 V909 V910 Y OL OR O 10 6 OG

D3

1

5

R5

R H001 1 4

RS232C

2

T2

BY GyG S707 S625 114 754

2

3

MCU SELECTION

YW

1 V GL S616 S709 810 100 GR BY S622 S707 811 114

6

V902 V901 R R

E

OUT

BIN

IN

G G501

L V904

5

OG OW OL OR O 10 C312 C311 C310 C309 C301 016 017 018 019 020 WBr R R C303 B301 B302 022 023 024 5

E4

F/R SWITCH/ STICK STEERING

8

Y D607

B

W D604

4

1

1

6

12

3

Lg LgL S825 S606 222 225 B LgY S834 223

4

4

2 GyW S833 260 Lg D103 013

B 1

2

1

YGy V H804 H803 242 100 SbR H802 240 BY H801 114

6

3

3

1

1

YGy V S709 S503 100 242 SbR S827 240 BY S707 114

E5

E6

E7

D8

D9

D0

4

This page illustrates the transmission is in neutral and key switch is in OFF position.

6

7

E0

D7

V8

SECONDARY STEERING (EU : STANDARD)

RIDE CONTROL S/W

REVERSAL FAN S/W

BL BR G V YO LB S607 S701 S719 S709 S919 S924 237 236 234 100 232 230 YW B L BY S926 D205 S707 233 005-a 114

YO E306 B

YW E412

B

D6

8 YO E405

R

(EU : STANDARD)

E2

1 3 4 6

7

Br

OG D606

4

5 6 2 L L L L L L E008 S703 S704 S711 S712 F702 B504 005-A 005-B 005-C 005-D F902 005-b T902 T002 005-a

G W

5

1

2

21

W3

1

4

FR SWITCH (EU : STANDARD)

20

19

Y

L V808

BW W E202 E104 062 T407 WR G WR E107 E101 E106 065 064 063 3

3

R

6

4 L

1

A207 A307 A610 A706 E601 X502 X503 V203 013

18

15

YW

G

17

4

1

7 C304 F802 F803 G501 G802 S717 010

W

STARTER SWITCH

RG

16

R5

R5

4

1 YG YBr YB S623 S733 S617 115 116 119 YL YO B S725 S626 117 118

R5

FUSE BOX (MAIN) R5

T1

E8

E3

A

80ZV2-09709-09330 EU 2/3 80V2E92023

80ZV-2 EU 92-14 92 Drawing & Diagrams Electrical Wiring Diagram (3/3) (S/N 9101~9200)

Electrical Wiring Diagram (3/3) (S/N 9101~9200)

K6

1

K801

B RBr

K103

RB

K106

303

JPN:CONNECT EU :DISCONNECT WORKING LAMP (INSIDE) RLg

4

−

F

LR H205 146

+

−

B

J1

−

1

LBr H206 148

+

− −

PB PL

M8

B

1

B

K2

W

−

1

L7

Y Y H726 H736 160 159

1

LY H201 141

+

− W

B

GB H121 267

B

6

GyB H131 266 BY V H120 H101 114 100

1

2

J3

B

2

M1

B −

2

LG H202 142

+

−

B

2

J4

2

M2

LgG P503 162

1 B

P4

B

M3

10

W

1

2

1

2

V BY P501 P502 100 114 SbY H701 171

V BY P501 P502 100 114 SbY H702 172

S

S

B

B K104

L1

P7

WR H720 015 GyR H721 751

LW H204 144

+

−

YBr H107 404

B

J6

2

4 B

1 1 V L301 BY L303

V K202 BrR 100 K205 BY 251 K203 114

BrR L302

−

LP H207 149

+

−

Y

B

2

P8

2

6 1

3

L9 RIDE CONTROL SOLENOID (OPT)

RW Y L803 L804

1

2 LgL R801 R803

R8

B

2

LgL L806 182

B

1 B

LgL K204 261

N1 FUSIBLE LINK

L4

30A

B

P0 STARTER

AIR CLEANER

C B

T/M OIL TEMP. SENSOR (MCU)

BW N501 702 R N502 701

20

30 FOR COLD LATITUDES

M7 ALTERNATOR

E

B

R

I

N6 HEATER RELAY

BW P606 012

1

2

WV N403 700

B

20

BY GyL H120 H126 114 180 2

GyG BY H136 H120 754 114 1

1

2

20

WL H140 707

WP P602 708

BG P601 720

M6

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

33

34

35

36

37

38

39

40

41

42

43

44

45

46

47

48

49

50

45

4

1

3

2

46

50

ECM

3

N3 BATTERY RELAY

2

BW N501 702

4

R N502 3 701 3

1 30A

N4

6

2

4

W H601 N001 901 086

LgG BY H137 H120 162 114 LgB V H132 H101 221 100

4

B

3 3

B

6

2

3 G M001 M002 W N101 086

3

1

B

N0

REAR WORKING LAMP

RGy R102

2

1

R4 B

R501 R502

1

330 R103 RL R104

BACK UP ALARM RB

303

B

LICENSE LAMP

RH BATTERY − +

2

M0

P5

2 2

WG H125 705 RL H115 703

R7

1

4

1

P6

312

2 2

RL RGy H128 H138 330 312 B RB H129 303

G G N002 N002 036 036 1

REAR WORKING LAMP

RGy R102

B

R1

P803 P803 P804 P804 G G

2

312

R3

4

114 L702 M201 M301

1

303 R501 RB B 330 R301 R401 R201 RL RGy

1 703 N701 RL 705 N704 WG

3

1

R6 4

WR WP H111 M702 015 708 BW BG H134 H124 012 720

DIODE UNIT

WG 4 N903 705

1 221 M202 P101 M302 LgB V 162 M101 LgG BY

1 012 720 N601 N602 BW BG 015 708 N401 N402 WR WP

700 N301 WV 015 708 P605 P602 WR WP

RL N904 703

2 1

R2

SECONDARY STEERING MOTOR PUMP

N7 MAGNETIC S/W

1 2 3

N9

LH BATTERY −

M5

7

3

4

FUSE

1 2

B

3

R H301 H302 H401 H402 H501 H502 910915

6

1

R9

AIR HEATER

4 1

G M001 M002 G M001 M002

S2L H708 S2S P747 H707 S2H P737 H709 P746

P9

+ −

1

ELECT. FAN CONDENSER

30 FOR COLD LATITUDES

R BW N703 N702 701 702

120A FOR COLD LATITUDES

3

10

6

4 B

3

70A

2

5

2

YGy H804 242

JPN:OPT EU :STANDARD

N2 FUSIBLE LINK

70A

2

M

1

B

R

3 1

1

2

4

BRAKE OIL PRESS. (MAIN)

SECONDARY STEERING OIL PRESS. SENSOR

W 1

2

B L802

B

LgL L401

LgL L401

FUEL LEVEL SENSOR

1

2

2 BW R P001 P002 702 701

3

CAN (RESISTOR)

N5

2

L0

1

B

SECONDARY P3 STEERING MOTOR RELAY

1

2

41

1

182 L002 LgL

B

H713 H717 R902 741

2 −

+

J7

5 1

−

PARKING SOLENOID

L903 B

L2

46

1

REAR COMBINATION LAMP (R.H)

3

L3 1

S2L S2H P902 P901

S

D

4

+

1 BrG GyY H714 H734 738 736 GyW SbY H724 H711 209 737 PW PG BLg BrW H723 H733 H705 H725 740 739 735 733 BL Sb H704 205 BrB BrR GyR W H729 H739 H737 H731 731 730 752 161 45 41

1

+

3

−

+

5

S2S P903

50

V BY H803 H801 100 114 SbR H802 240

1

L902 L901 RW Y

BY L202

A

−

4

RW Y H102 H112

1

BrR L203

B

2

1

1

2

2

6 YL YV H706 H715 747 734 YO SbW H716 R901 748 203

REAR COMBINATION LAMP (L.H)

1

V L201

J5

+ 6 LgL H135 182

3

C

+

−

B

J8

1

2

−

3

LO H203 143

70A

L

L6

L8

Br K201 003 BrW B K206 250

P2

P1

M4

M9

1 1

K0

1 Br

2

1

1

2

+

2

1

L5

B

2

+ S

K9

RW RY K108 K102 308 306 B

R

2

1

B

+

2

B

LgB P504 221

BrY H728 181

YR

J2

2

YR H730

Br GyO BY H727 P502 220 114

+

FRONT HEAD LAMP (OUTSIDE)

BOOM ANGLE SENSOR

3

GROUND SPEED SENSOR

B

BUCKET LEVELER

H7

(BLUE)

2

R

OR

PL H732 506

B

R

+

1

3 BY V Br H120 H101 H103 114 100 003 LgL BrR BrW H122 H113 H123 261 251 250

4

6

311

K105

3 Br V BY L103 L201 L202 003 100 114 BrW BrR LgL L102 L203 L401 250 251 261

K802 K803

327

8

8

COMBINATION LAMP

4

+

EFFICIENT LOADING SYSTEM (ELS) SOLENOID VALVE

1

1

GW K601

K1

WASHER MOTOR (OPT)

T/M SOLENOID VALVE

1

OR PB H722 H712 500 019

F

B

GW K107 329

2

H6

R

B

B

EFFICIENT LOADING SYSTEM (ELS) OIL PRESS. SENSOR

H5

G

GW K702 K704

B

H4

3

K7 HORN (H)

1

H8 H3

R

5 4

2 2

1

4

2

GW K601

325 K002 327 K502 K302 K802 RO RY RBr B K003 329 K803 K901 K303 K601 K503 K401 RW GW RB RLg

B

1

G

K106

JPN:CONNECT EU :DISCONNECT

HORN (L)

H1

1

4

B

303

1

FAN SPEED CONTROL SOL. VALVE

HYD. OIL LEVEL S/W

GR

RB

K502 K503

325

K101

1

240 100 P403 P402 SbR V 114 242 P401 P301 BY YGy

8

LBr B LP J202 J702 148 149 LO LG LY J502 J402 J302 143 142 141

H2

K202 L602 P501 100

4

RO

1

LR J102 146 LW J602 144

RY

B

K203 L601 M502 M602 P502 114

5

W N101 901

B

K501

R N201 915 R N201 914

COMPRESSOR CLUTCH (ECC)

HYD. OIL TEMP. SENSOR

B

COMBINATION LAMP

R N201 913 R N201 912

31 GyY PG W PL P701 P724 M803 P741 736 739 506 161 BrW GyW PW PB GyR P722 P711 P725 M802 P749 733 737 740 500 751 YV BrG BL OR SbY P709 P702 P734 M801 P713 734 738 741 019 209 BLg Sb SbY SbY P723 P731 M303 M203 735 205 172 171 5 1

GR

K105

B

R N201 911 R N201 910

3

35

RY

RLg

R103 R602 R702 330

K4

311

2

36 GyR BrR Y P742 M901 P743 730 752 159 YR BrB BrY GyO Y P201 P744 M401 L701 M902 731 181 220 160 WR BL YO P739 P734 P720 015 741 748 S2H S2L S2S YL P901 P902 P903 P710 747 10 6

1

1

3

40

325 330 H109 H128 RO RL 303 331 H129 H139 RB RG

WORKING LAMP (INSIDE)

31 LgL BW LgB GyB L806 P606 P504 L603 221 266 182 012 WG BG BrW LgL GB N903 P601 K206 K204 L501 705 720 250 261 267 Y RL BrR WR N904 K205 L804 P605 703 251 015 Br RW V K201 L803 003 5 1

327 330 H119 H128 RBr RL 303 331 H129 H139 RB RG

W

35

SbW BL P719 P734 203 741

B

36 WL RG RGy LgG GyG M701 R605 R102 P503 M601 707 R705 312 162 754 RB RL GW GyL K107 M501 329 180 BY RBr RY K103 K102 R703 306 RO RW YBr RLg K101 K108 J802 K105 R603 308 404 311 10 6

5

RW RY K108 K102 308 306 B

40 303 K106 R104 R604 R704

K3

1

2 R

RW GW RB RLg H108 H127 H129 H106 308 329 303 311 RO RY RBr B H109 H118 H119 L802 325 H118 327

FRONT HEAD LAMP (OUTSIDE)

This page illustrates the transmission is in neutral and key switch is in OFF position.

+

80ZV2-09709-09330 EU 3/3 80V2E92024

80ZV-2 EU 92-15 92 Drawing & Diagrams Electrical Wiring Diagram (1/3) (S/N 9201~9350)

Electrical Wiring Diagram (1/3) (S/N 9201~9350)

&

& !

&

(')

*

& !

! !

,! ," * * & ," * *

& !

&

"

!

&

&

!

!

"

"

, $ / (" # )

"

%

( " )

! & ! &

! ! & &

( # 2 ) & ( # 2)

, / &

% &

! % &

&

&

&

( " )

( * )

!

!

" # ! *

&

& !

# *

&, $ ( )

!

"

( " )

*

&

!

&

!

!

,! ," *

-

%

( " )

( " )

!

!

& ," *

( * )

&

!*

( # 2)

&

%

3

-

( " )

( * )

( " )

&

, " # *#,

* # , #

" $ ( )

% +

" ! % % % %

"

" " " ! & & &

& & %

&

" "

" " " " & &

" " " !

" " " & &

! !

" %

" " " " " " " " " & &

"

" " " " &

" $ *

&

-

( * )

," *

, , #

( " )

%

&

+

!

&

, $ #

%

!

,! & ( )

, ,#" " &

( * )

&# ,! * #

, * /

( " )

!

&

&

-

$ ( )

0 $ (* )

&

#

!

( " )

!

%&

( " )

-

% %

" "

"

" , #

"

"

.

"

, ( $)

&

,# " ## "

"

1* " , #

&

"

'

& &

!

"

" * " # ( # 2)

% %

"

'

& "

"

"

" * " # ( # 2 )

!

!

" * " *

"

"

& " & &

$

, " , #

" ( , " #) % &

&

&

"

"

!

&

"

$

$

" * " "* !! &

&

& #

!

&

%

%&

# &

!

#

& %&

,# &

'

& $ $

" $ ,# , # & ! $

,!

" #( , )

#

& &

!$

!

& &

'

"

"

&

"

#

%

,# *$ # #

! & " , # ( * # )

"

& ,# $

! # & ,# $

!!,", # ,# $ ( )

!* !!,", # $ " , #

! &

" ! %

This page illustrates the transmission is in neutral and key switch is in OFF " position.

" " & &

80ZV-2 EU 92-16 92 Drawing & Diagrams Electrical Wiring Diagram (2/3) (S/N 9201~9350)

Electrical Wiring Diagram (2/3) (S/N 9201~9350) ( )

#! - /

)

( !+

# #

)! ) )! !+ *

* # +*! !+ *

* # +*! !+ *

( ! !+ *

( !+ *

#

#

#

- ) /

- ) /

- */

- */

"

"

$

- * . /

- * ./

$ # #

! - *. / - * ./

!

) % -( +*/

! !

1 1

!

% %

!

- )2 ! * /

# # "

#

!

*! !+ *

$

!

$

! ! (#& * - +* # !+ */

* !+ *

* ! - ) 2 ! * /

0

)!

)! +*

+*

$

$

"

This page illustrates the transmission is in neutral and key switch is in OFF position.

$

"

0

* ! +* - ) 2 ! * /

+ *!

*

+! !+ ! +*

+! - ) 2 ! * /

$

" ! !

# $

+! - ) 2 ! * /

- * ./

! ! +!

!

"

) % - /

" $

- * . / - * ./

" % ! !

$ " "#

" "# !

$ !

$ $ $ #

$ $

- /

& ' & ) & &+* ' & ' & & ' & ' &!(# &+* & ' & & & (' & '

& & ) & ' & &# & (' & ' & ' & ' & ')# & ' * & ' &(' & ' & '

& # & & ) &!(#' & & & & ( &+#' & & '# & ' & & &

& ' &# ' &# ' & ) &!! & & ! & & & ) & & & ' &! &

- ) /

- +! /

%# !

&!!' & !' & )!' & !'(

& # & !! & * & '# & * &!('( & ' & !' & ! & % &! # &+* ' & ) & * & '

& ' & ' & & & * & * & * & * &, &! & & & * & &

&%' & ' & ' & ' & +* & )!'( &*' & ' & *' & *' & )! & )!' &(! & !' &!%

& ' & ' & ' & ' & ' & &+#' & ' &( ' & ' & ' &+ ' & & ' & '

&!!' & ' & ' & #' & ' & ' & ' & ' & ' & ' &! ' & ' & #' &*' & '

& ' & ' & ' & ' & ' & ( & )' & ' & ' & ' & ' & !' & ' & ' & !'

80ZV-2 EU 92-17 92 Drawing & Diagrams Electrical Wiring Diagram (3/3) (S/N 9201~9350)

Electrical Wiring Diagram (3/3) (S/N 9201~9350) GW GyL K107 M501

WG BG BrW LgL GB N903 P601 K206 K204 L501

RBr

RY K102

180

705

720

250

RL N904

261

267

BrR Y WR K205 L804 P605

306

251

015

R N201

R N201

R N201

Br RW K201 L803

V

910

912

914

308

003

703 311

6

1

4

PB PL

M8

PL H732

220

L7

Y Y H726 H736

J2

160

M9 1

2

1 B

2

-

LG H202

+

B

1

2

LgG P503

J4

10

162

100

2

1 B

P4

1

2

V BY P501 P502

142

-

2

1

M3

V BY P501 P502

114

100

114

SbY H701

SbY H702

171

172

S

S

W

6

L6

-

+

BrG GyY H714 H734

216

738

734

YO SbW H716 R901 748

P7

207

306

B

6

2

1

LgL H135

B

4

YBr H107

250

740

WR H720

B

-

2

4 4

+

-

-

LP H207

+

+

J7

2

N5 1

BY K203 114

L9

1

1

2

R8

2

2

R BW N703 N702 701

701

B

B

LgL K204

LgL L806

261

1

N6 HEATER RELAY

P0 STARTER

AIR CLEANER

BW N501

20

701

30 FOR COLD LATITUDES

M7 ALTERNATOR

1

2

WV N403

B

R H301 H302 H401 H402 H501 H502

720

B

R

N4

6

20

BY GyL H120 H126 114

180

1

2

20

WP P602

707

708

N7 MAGNETIC S/W

33

34

35

42

43

44

45 45

4

1

3

2

703

N701 RL

4

W H601 N001

B

3 3

B

3 G

M001 M002

036

WP WR H111 M702 015

162

114

M101 LgG BY LgG BY H137 H120

RL H115 703

1

312

312

N0

N9

49

50

46

50

RB H129

B

REAR WORKING LAMP

R102

RGy

REAR WORKING LAMP

R102

RGy

1 330

B

R501

R4

R502

1

BACK UP ALARM

R103 RL

R104

RB

303

LICENSE LAMP

B

RH BATTERY

G

+

G G N002 N002 036

1

2

M0

R7

LH BATTERY -

M5

48

2

1

P6

47

B

2

RL RGy H128 H138 330

312

R301 R201 2

303

036

1

B

330

R401 RL RGy

4

G

2

100

R3

R501 RB

720

6

40

46

B

R1

L702 M201 M301 2

LgB V H132 H101 221

036

P803 P804

312

1

1

4

39

3

R2

1 M202 M302

114

4

2

38

2

2

WG H125

37

1

705

086

708

BW BG H134 H124 012

3

W N101

30

36

1

R9

P5

N704 WG

20

29

1

1

708

19

28

2 3

R6 4

18

27

ECM

REAR COMBINATION LAMP (R. H)

705

2

DIODE UNIT

V

720

N401 N402 WR WP

015

708

100

162

WG 4 N903 705

221

P101 LgB

1 012

901 086

WL H140

RL N904 703

N601 N602 BW BG

700

1 2

32

303

4

702

1

4 1

2 N501 R N502 3 701

17

3

4

3

P605 P602 WR WP

I

26

G 036

BW

N3 BATTERY RELAY

N301 WV

E

16

25

41

S2L H708 S2S P747 H707 S2H P737 H709 P746

SECONDARY STEERING MOTOR PUMP

AIR HEATER

30A

015

30 FOR COLD TEMP.

BG P601

012

3

910915

15

24

2

P9

FUSE

ELECT. FAN CONDENSER

14

23

CAN (RESISTOR)

B

1

R N502

41

10

M001 M002

P3 SECONDARY STEERING MOTOR RELAY

700

702

C

70A

3

B

T/M OIL TEMP. SENSOR

70A

2

M

1

31

9

036

3

B

13

+ -

BW P606

120A FOR COLD LATITUDES

70A

2

22

8

G

B

3

3

7

4

1

741

242

FPN/EXP:OPT EU:STANDARD

6

161

41

N2 FUSIBLE LINK

30A

L4

702

N1 FUSIBLE LINK

1

R

1

1

2

702

W 1

2

B L802

LgL L401

LgL R801 R803

2 BW R P001 P002

RW Y L803 L804

RIDE CONTROL SOLENOID (OPT)

B

FUEL LEVEL SENSOR

752

3

L0

730

45

BRAKE OIL PRESS. (MAIN)

YGy H804

12

21

10

5

REAR COMBINATION LAMP (L. H)

1

2

731

46

327

251

2

751

3

BY L301

L2

100

6

11

6

4

-

B

-

3

1

BY L202

BrR K205

BrB BrR GyR W H729 H739 H737 H731

2

SECONDARY STEERING OIL PRESS. SENSOR

L002 LgL

B 1

B

A

BrR L302

V K202

B

BrR L203

V L303

182

B

1

1

S2L S2H P902 P901

1

182

L3

Sb H704

149

-

Y

B

2

733

1

L902 L901 RW Y

3

735

BL

P8

L903 B V L201

737

S

D B

739

1

205

GyR H721

PARKING SOLENOID

240

+

3

GyW H724

209

H713 H717 R902

SbR H802

J6

SbY H711

S2S P903

114

144

404

3 1

LW H204

+

-

+

5

PW PG BLg BrW H723 H733 H705 H725

50

V BY H803 H801

1

1

736

015

1

2

143

2

100

RW Y H102 H112

L1

2

J5

1

SbR H703

747

2

B

3

B

LO H203

5

YL YV H706 H715

B

2 +

100

M2

M1

1

R

2

J3

B

141

2

G

LY H201

+

+

B

P2

P1

R

114

B K104

003

BrW K206

M4

159

SbW BL P719 P734

Br

2

G

GyB H131 BY V H120 H101

182

Br K201

2

YR

1

J8

1 B

B

1

B

B

K0 1

2

1

221

181

GR

B

L8 308

W

LgL L401

1

B

LgB P504

BrY H728

114

RY

-

-

RW RY K108 K102

R B

YR H730

Br

+

2

C

1

GyO BY H727 P502

148

1

266

6

L5

FRONT HEAD LAMP(OUTSIDE)

BOOM ANGLE SENSOR

5

FAN SPEED CONTROL SOL. VALVE

B

W

GB H121

250

B

L

3

171

GR

251

4

B

HYD. OIL LEVEL S/W

209

RY

261

4

LBr H206

-

LgL BrR BrW H122 H113 H123

261

H7

172

+

K2

003

OR

(BLUE)

2

019

331

251

6

100

1

216

GROUND SPEED SENSOR

1

+

741

205

506

146

-

738

303

114

B

J1

2

-

S

BY V Br H120 H101 H103

114

019

R B

LR H205

+

735

H129 H139 RG RB

100

500

4

+ -

734

OR PB H722 H712

F

WASHER MOTOR (OPT)

HYD. OIL TEMP. SENSOR

751

BLg Sb SbR SbY SbY P723 P731 P704 M303 M203 6

2

T/M SOLENOID VALVE

F

748

10

500

+

1

BUCKET LEVELER

4

H6

R

K9

311

1

740

B

327 306

8

1

003 250

K105

H5

741

737

YV BrG BL OR SbY P709 P702 P734 M801 P713

747

+

267

RLg

H4

1

3

BrW BrR LgL L102 L203 L401

JPN/EXP:CONNECT EU:DISCONNECT WORKING LAMP (INSIDE)

1

733

160

S2H S2L S2S YL P901 P902 P903 P710

COMPRESSOR CLUTCH (EC C )

161

331

303

K106

015

242

220

506

303

RB

114

181

739

BrW GyW PW PB GyR P722 P711 P725 M802 P749

BL YO P734 P720

P401 P301 BY YGy

141

4

-

3

Br V BY L103 L201 L202

K802 K803

327

K103

H3

EFFICIENT LOADING SYSTEM (ELS) SOLENOID VALVE

325

311 303 329

RO RY RBr B H109 H118 H119 L802

308

RW GW RB RLg H108 H127 H129 H106

RB

311 303

8

K801

RBr

142

731

WR P739

H8

EFFICIENT LOADING SYSTEM (ELS) OIL PRESS. SENSOR

K003 K303 1 B

1

143

100

P403 P402 SbR V

H2

100

K1

1

GW K601

COMBINATION LAMP

LW LO LG LY J602 J502 J402 J302

1

5

5 325

329

329

K002 K302

K601 GW

K6

K803 K503

RW

GW K107

B

RLg

4

B

1

B

1

240

8

B

149

K202 L602 P501

H1

308

2 2 GW K702 K704

901

148

736

YR BrB BrY GyO Y P201 P744 M401 L701 M902

K901 K401

327

1

146 144

5

K101 R603

LR LBr LP J102 J202 J702

31

GyY PG PL W P701 P724 M803 P741

H129 H139 RG RB

K103 R703

5

W N101

3

35

159

1

404

10

K802 RBr

B

915

RW YBr RLg K108 J802 K105

JPN/EXP:CONNECT EU:DISCONNECT

HORN (L)

R N201

913

RO

RY

K106

R N201

911

325

306

RB

303

R N201

327

K502 K503

325

K101

2

330

K502 RO

RO

B

RL

K501

B

K7

752

RB

40

266

K203 L601 M502 P502 114

GW K601

36 Y GyR P742 M901

730

182

330

COMBINATION LAMP

BrR P743

221

162

325

K4

311

K105

31

012

LgB GyB P504 L603

312

H109 H128 RO RL

RLg

BY

R103 R602 R702

B

35 LgL BW L806 P606

331

329

3

WORKING LAMP (INSIDE)

HORN (H)

707

330

306

B

1

36

WL RG RGy LgG M701 R102 P503

K106 R104 R604 R704

H119 H128 RBr RL

W

40

303

K3

308

RW RY K108 K102

B

741

R605 R705

2 R

207

FRONT HEAD LAMP(OUTSIDE)

This page illustrates the transmission is in neutral and key switch is in OFF position.

+

80ZV2-09709-10470 3/3

K80V292005

80ZV-2 EU 92-18 92 Drawing & Diagrams Electrical Wiring Diagram (1/3) (S/N 9351~)

Electrical Wiring Diagram (1/3) (S/N 9351~) FUEL EFFICIENT MODE SELECTION

1 3 4 6

2 5

1

2

HAZARD

4

324 325

5

4

+ BATT GND 1

8 5

4

5

6

1

2

3

323

322

4

8

1

5

6

2

3 8

Lg D103 B

323

013

GyW S823

7

4

8

1

5

B

6

2

3

YB YSb S734 S506 401 403 Lg G LY LG LO LW D103 D107 B S518 S502 S505 S508 013 010 141 142 143 144

8

12

013

GL S822

200

13 SbW WL B502 S624 163 400 O S512 241

36

1

18

A5

B

H

(+) TF

EG4 EG1 EG2 EG3

SM

BrW BrB BrR H719 H729 H739 732 731 730 RO RGy RY RB A107 F403 324 310 307 300

LgW F903 102

A

L

SUB2 BP

B101 B201

W AB TC PH

N

LgY Gy GyG GyL LgW WG S528 S519 S515 S516 S527 H125 173 749 753 190 192 705 LgR RBr GR GyB GY LgY BG S521 A102 S529 S514 S520 F002 130 326 135 103 169 167 720

B601 C305

BrW YBr S721 H107 402 404 LgB RL S524 S532 224 235

1

4

A2

HORN S/W EL

LT

LH

P RBr RO RW G703 A103 A106 F401

B

RB RY F601 F501

6

7

4

5

6

7

4

5

2

3

8

1

2

3

8

1

2

3

YV A401

B

5

8

RG RLg D113

R RGy D109

311 521

C302 H106

002

1

C306 H138

4

4

1

B4

YV T307

1

B

B

C102 802

YV S918

304

B

R

163

B

RB A613

1

022

521

020

500

506

019

018

017

016

D609 H712

7

C2

6

7

4

5

6

2

3

8

1

2

3

BW F005

B

BrG F004

LP F001

B

LgY F002

271

255

B0 6

12

C3

C0

GyY GyW BL H734 H724 H713

Y

V

O

YV BLg BrW H715 H705 H725

R G B

R

B

G

O Y V

736

737

741

735

733

1

C4

RLg H717

8 4

167

B

YO F003

1

271 255

4

3

4

166 114

BACK RELAY

4

750

1

BrG YO S922 B001

3

3

176

167

B

LP S915 168

4

1

6

G

(BLACK)

(BLUE)

F1

F2

F3

R RL D111 S619 004 245 RG B H139 331

D

F

2

3

013

4

114

138

RL

T801 H128

C9

1

4

205

203

060

8

140

325

308

404

311

6

S507 A107 F404 A620 B108 LLg RO RW YBr RLg

013

013

112

104

114

327

306

170

S707 A102 F403 S614 BY RBr RY WR 303

707

V102 S724

V4

40

330

329

180

36

703

003

100

171

251

705

WG

182

720 012

250

B

AIR-SUS. OY D114

B

6

DIAG INC/DEC S/W PG PW H733 H723 739

740

738

741

2

BrG BL H714 H713

007

2

1

261

267

221

266

1

31

3

305

302

2 001

001

RB

300

C305 C403

1

3

R R D108 D108

T5

301

H129

141

4

4

Br D110 YSb S917

1

003

B Br

125

1

G0

G1

G9

G2

B

4

(BLUE)

B

Br

1

Br

G3

BrW

G D107

G4

BrB

B

1

H4

H5

H6

148

146

142

143

144

910

4

1

912

1

914

D301 R

D401 R

D002 R

D402 R

D901 R

D001 R

911

913

915

E201 W

114

242

240

100

2

4

1

LgW L A618 D205

2

102 005-a

B

1

LgW S612 101

4

(BLACK)

F8

F7

1A

1

(BLUE)

F9

2

3

1A

1 3

2 4

1

2

3

4 2

LgB H132 221

LgB S702 226

1

1

4

T0

V3

HAZARD

1

E L

112

RL V204

1

G6

3 A101 A108

1

B

BP

G D107

323

B

4

330

2

004

L

2

10

C404 C405 C406 C506 Sb GO WR WP

9

1

H0

B

1

G7

T8

C607 C608 C609 C610 LO GW BY BrY

20

010

4

AIRCON UNIT

C606 C605 C604 C603 C602 D701 C601 C507 C402 C401 WY V PB YB VW RL P LgR BrB LgY 11

E

B

P R B909 D111 320

LgSb X504

010

G5

H9

3

10 206

F104 F204 V404

SbR V E702 E703

901

328

3

D804 D802 H102 H112 R RB RW Y

C501 C510 BG BL

B

D803 D701 H730 C508 C504 C503 C502 C509 RG RL YR PL WG OL BrW BR

B

18

10

G8

H7

BY YGy E701 E704

1

329

2

(BLUE)

TURN SIGNAL BACK LAMP (OPT)

4

1

LR LBr LP S517 S604 S613

273

010

FUSE

L S610

4

010

GW GL H127 B801

SbP S618 145

G G D107 D107

(BLACK)

272 005-a

BZ

Br D110

(BLUE)

BrR L G202 D205

T9

Br D110

003

3

3

2

CAB ALARM BUZZER

G V805

KICK OUT

1

2

(BLACK)

V1

703

F6

BrB S611 258

RL

H710 H115 1

LOWER KICKOUT RELAY

257 005-a

R B

003

BrB L G402 D205

G L D102 D205

(BLACK)

F5

H8

149

CONTROLLER FAILURE RELAY

HORN RELAY

014 005-a

RB B914

303 4

LIFT KICKOUT RELAY

1

2

LW LO LG LY S518 S502 S505 S508

015

V303 S801 LgB GyB

1

4

250

3

H3

1

A605 G302 S504 S501 BG BrW LgL GB

S806 D105 LgL BW 35

4

3

1

POSITIONER

SHIFT HOLD S/W (OPT) 272

5

T4

S722 D110 H003 S709 SbY Br RW V

F704 S730 S826 H004 D101 Y RL SbY BrR WR

F604 V204 F804 S731 RB RL GW GyL V103 A624 331 312 162

W404 B208 B506 WL RG RGy LgG

172

001

(BLACK)

X5

H2 5

001

RY RY F402 B915

304

3

(BLACK)

7

H1 10

305

2 3 H125 WG WL H740 705 H140 707 B B

PILOT VALVE MAGNETS

S2H W H709 D506

1

2

Lg Lg D103 D103

T003

1

(BLACK)

V2

RY RW F504 B912

2 R R D108 D108

F4

DOWNSHIFT BUTTON

S2L H708

B

RLg SbW H717 S615

(BLACK)

2

2

216 005-a

B

330

SbR L H703 D205

RY

3

6

001

VOLTAGE RELAY

LgSb LgBr G601 S609 4

1

1 2 1 415

BY G S707 S732

AIR TEMP. PROBE (CONTROLLER)

Lg LB D103 S510

3

R D108

308

H118 A614

BUZZER RELAY

W4

E

4 YL YO H706 S2S H716 747 H707 748

2 2

1

(BLACK)

(BLACK)

F0

C

A

H

C8 3

752

RW H108

3

3

BR Y C509 C611

AIR PROBE (TH AM) (OPT)

306 307

GyR H737

4

FLOAT

1

4

751

B

B

206

2

Gy GyR S816 H721

176

T708 T601 BrG YO

3 100

BY LgR V S707 S727 S709

E/G DROOP1 SELECTION RELAY

1

-

C6

WY V PB YB VW P H920 H919 H918 H917 H916 H914

B

J

C7

RLg H717 1

3

167

271

DECLUTCH SENSOR

NEUTRAL RELAY

T706 T608 BW LgY

DATA LINK CONNECTOR

1

B

2

202

BRAKE RELAY

168

1

+

Sb SbP H704 S509 205

206

1

T6

3

208

T606 LP

B

255

7 LO GW BY BrY Y RL 12 H901 H902 H903 H904 C801 D701

6

209

BW LgY S813 A606

6 WP LgR PL BR BL 10 C5 H910 H913 H015 C802 H008 H011 B WG OL BrW BG H014 H013 H012 H007 5

4

6

THROTTLE PEDAL

4

734

S

3

168

1

T7

RB BrB LgY F604 H912 H911 300

5

8

2

SbY SbR H711 S608

176

4

CAB (AIRCON) 4 Sb GO WR 6 H907 H908 H909

5

1

YL

C1

010

4

8 5

1

300

PB PL OR OL OW OG H722 H732 D608 D607 D606

1

2

1

CAB

RGy RB G WBr RLg O B208 D107 D604 B108 D610 520

3

7

S914

801

5

124

L B401

1

B7

A613 F604

6

S2S H707

123

3

B6

S2L S2H H708 H709 S720 S729

802

122

300

B5

L B402

121

WIDTH LAMP RELAY (LT)

HEAD LAMP RELAY (LH)

Hi-BEAM RELAY (UL)

B

164

B

LY LG LO S910 S903 S905

E/G OIL PRESS. S/W RELAY

1 3 4 6

2

120

162

168

GO SbW S901 A514

LW S912

5

TORQUE SELECTION RELAY

DECLUTCH SET-UP

1 3 4 6

2

DECLUTCH CUT-OFF S/W

LLg

LgG H137

005-b

B9

B

128

E/G IDLE SELECTION RELAY

LIFT KICKOUT SET-UP/ LOWER KICKOUT SET UP

1

S921

L D206

126

6

YO

4

3

LR LBr S911 S904

G

176

L

F003

Y

1

A4

302

8

B8 B

301

257

F801

B GB

321

T903 BrB

R

G GR

322

1

231

801

H123 BrW

G Y B

320

GL

L

GY

328

PARKING S/W

GL

A

1

T3

B2

231

GW

8

310

1

L C101

6

231

B3

024

HL

312 520

R RGy D109 A615

310

5

8

002

B1

R D601 HU

5

4

023

TR

4

006

A3 TL

5

1

RG RGy D113 A615

R D602

TB

1 3 4 6

2

8

006

COMBINNATION S/W FOR LAMPS

SHIFT LEVER

5

7 5

19

1

H124 H738

A6

F/R S/W SELECTION (EU STANDARD)

1 3 4 6

2

SS DD FR

C EWL SUB1 TTM FM

EP WT TT AC

265

1

326 327

5

Lg D103 B

4

1

A610 H119

A1

7 5

RBr RBr BP B910 G803 4

CANL P

R WL

CE

ES CANH

24

8 RO RO BP B911 G803 321

4

3 HM

WTM

A616 H109 7

2

6

7

7

REAR WORKING LAMP

1 3 4 6

2

3

5

6

INSTRUMENT PANEL

1

2

3

5

FRONT WORKING LAMP

EFFICIENT LOADING SYSTEM(ELS)

3

703 C201 C202 C203 747 F704 T406 T405 T404 T403 RL S2H S2L S2S YL 015

6

748

732

204

731

181

220

160

730

720

752

159

T402 D101 A635 S534 WR BrW SbLg RLg YO

5

735

205

216

172

171

1

C002 F203 V403 S722 S730 BLg Sb SbR SbY SbY 734

738

019

209

C001 G004 C309 F103 YV BrG BL OR SbY 733

737

740

500

751

012

736

739

506

161

H016 A634 S811 S723 S716 YR BrB BrY GyO Y

C003 C005 G002 C307 F302 BrW GyW PW PB GyR

V103 A633 A605 F301 S708 WG BrR BG GyR Y 40 36

D105 C006 G003 C308 S715 W BW GyY PG PL 35 31

705

741

C004 G001

This page illustrates the transmission is in neutral and key switch is in OFF position. 80ZV2-09709-10930 1/3 EU

80V2E92027

80ZV-2 EU 92-19 92 Drawing & Diagrams Electrical Wiring Diagram (2/3) (S/N 9351~)

Electrical Wiring Diagram (2/3) (S/N 9351~) (

& ' & ' & ' & ' & ' & ( & ' & ' & ' & ' & ' & !' & ' & ' & !'

&!!' & ' & ' & #' & ' & ' & ' & ' & ' & ' &! ' & ' & #' &)' & '

/ *! 0

/ +0

/ 0

%# !

# #

! ! !* )

) # *)! !* )

) # *)! !* )

( ! !* )

( !* )

#

#

#

&%' & ' & ' & ' & *) & !'( &)' & ' & )' & )' & ! & !' &(! & !' &!%

"

& # & !! & ) & '# & ) &!('( & ' & !' & ! & % &! # &*) ' & & ) & '

& ' & ' &+ &+ & ) & ) & ) & ) &, &! &+ &+ & ) & &

&!!' & !' & !' & !'(

& ' &# ' &# ' & &!! & & ! & & & & & & ' &! &

& # & & &!(#' & & & & ( &*#' & &+ '# & ' & & &

/ 0

/ 0

/

)0

/ )0

" % !

" "# !

$ $ $ #

$ !

$ " "#

$

/ +0

$ # #

$

$

!

!

#

"

! ! *!

. .

!

" ! !

!

)! # ( *! /) ! 0

$

!

! ! (#& ) / *) # !* )0

) !* )

) ! / 1 ! ) 0

#

!

!

*)

*)

-

* 2 )!

)

*! !* + ! *)

/ 1 ! ) 0

-

!

*! / 1 ! ) 0

% %

*! / 1 ! ) 0

! ! *!

# # "

!

% /( *)0

$

" $

!

" $

% / 0

& ' & &+ &*) ' & ' & & ' & ' &!(# &*) &+ ' & & & (' & '

& & & ' & &# + & (' & ' & ' & ' & ' # & ' ) & ' &(' & ' & '

( !*

#!

& ' & ' & ' & ' & ' & &*#' & ' &( ' & ' & ' &* ' & & ' &+ '

$

$

$

"

"

This page illustrates the transmission is in neutral and key switch is in OFF position.

) ! *) / 1 ! ) 0

80ZV-2 EU 92-20 92 Drawing & Diagrams Electrical Wiring Diagram (3/3) (S/N 9351~)

Electrical Wiring Diagram (3/3) (S/N 9351~)

2

100

BUCKET LEVELER

L

B

308

003

BrW K206

B

L8 1

1

3

6

B

182

D

4

B

BY L301

BrR L302

BrR K205 251

1

V K202

L2

100

1

2

1

2

RIDE CONTROL SOLENOID (OPT)

RW Y L803 L804

LgL L401

1

R8

2 LgL R801 R803

2

B

702

L4

LgL K204

1

2

B 1

2

T/M OIL TEMP.SENSOR (CONTROLLER)

3

AIR CLEANER

2

180

1

C

BW N501

N2 FUSIBLE LINK

70A

120A FOR COLD LATITUDES

N1 FUSIBLE LINK

701

B

AIR HEATER

R

20 30 FOR COLD LATITUDES

I

N4

910915

20

6

17

18

19

20

26

27

28

29

30

Sb H704

31

32

33

34

35

36

37

38

39

40

BrB BrR GyR W H729 H739 H737 H731

41

42

43

44

45

46

47

48

49

50

BL

731

45

730

1

P9

707

WP P602 708

012 015

N301 WV

1 RL N904

720

703

N7 MAGNETIC S/W

161

G

B

2

W H601 N001

4 4

036

G

036

M001 M002

3 G

M001 M002

036

708

720

6

P6

4

1

3

2

ECM

R9

1

S2L H708 S2S P747 H707 S2H P737 H709 P746

703

2

1

3

R2

221

P101 LgB 162

3 3

M101 LgG

100

V

114

BY

LgG BY H137 H120 162

114

221

100

036

1 M202 M302

P803 P804

L702 M201 M301 2 2

G

1

R3

RL RGy H128 H138

R301 R201 2 2

036

RGy R102

2

R4

REAR WORKING LAMP

B

R501 R502

1

1

330

B

R1

BACK UP ALARM

R103 RL R104

RB B

303

LICENSE LAMP

RH BATTERY

G

036

312

312

303

REAR WORKING LAMP

B

+

G G N002 N002 1

V LgB H132 H101

4

RGy R102 B

B

312

R401 RL RGy

RB H129

312

1

303 330

4

1

1

2

3

2

M0

P5

N704 WG

2 2

WG H125 RL H115

1

R7

4

703

1

1

N0

N9

LH BATTERY -

M5

50

3

705

086

BW BG H134 H124

DIODE UNIT

3

W N101

WR WP H111 M702 012

46

REAR COMBINATION LAMP (RH)

705

3

015

705

N701 RL 3

B

45

4

R6 4

708

B

41

41

R501 RB

WG 4 N903

1

N401 N402 WR WP

708

P605 P602 WR WP

901 086

WL H140

752

4

4

R N502 3 701

N601 N602 BW BG

700

1 2

BW 2 N501 702

30A

015

E

16

SECONDARY STEERING MOTOR PUMP

720

FUSE

10

15

2

B

700

R H301 H302 H401 H402 H501 H502

9

25

741

242

1

R N502

8

14

737

330

2 B

7

24

3 3

1 WV N403

10

6

13

H713 H717 R902

P3 SECONDARY STEERING MOTOR RELAY

YGy H804

N3 BATTERY RELAY

6

5

CAN(RESISTOR)

BG P601

012

4

23

733

205

46

3

22

735

BRAKE OIL PRESS. (MAIN)

702

M7 ALTERNATOR

20

114

HEATER RELAY

30A

ELECT. FAN CONDENSER

1

BY GyL H120 H126

P0 STARTER B

30 FOR COLD LATITUDES

S2L S2H P902 P901

2 12

739

2

N6

3

261

GyR H721

+ -

BW P606

GyW H724

1 11

740

S2S P903

5

1

736

B

-

P1

21

209

751

50

-

SbY H711

738

PW PG BLg BrW H723 H733 H705 H725

WR H720

1

BrG GyY H714 H734

SbR H703 216

P8

SECONDARY STEERING OIL PRESS. SENSOR

702

W

1 B

+

-

R BW N703 N702 701

207

S

JPN/EXP : OPT EU : STANDARD

1

2

748

5

YO SbW H716 R901

P7

172

PARKING SOLENOID

1

701

1

2

B L802

2

734

015

149

BW R P001 P002

FUEL LEVEL SENSOR

1

R

B

L0

L9

LgL L401

+

N5 1

747

S

J7

B

2

6

BY K203 114

2

L002 LgL

B

LP H207

+

M4

B

BY L202

V L303

-

Y

B

A

1

182

BrR L203

L3

1

114

6

YL YV H706 H715

114

240

182

LgL L806

B

L903 B

M

BOOM ANGLE SENSOR

V L201

2

171

W

+

SbR H802

J6

B

SbY H702

100

S

144

-

4

3

3

LW H204

+

+

L902 L901 RW Y

C

YBr H107

-

SbY H701

114

10

1

2 BY V P501 P502

100

V BY H803 H801

1

+

B

1 BY V P501 P502

1

2

143

404

3 1

+

J5

B

2

4

RW Y H102 H112

250

2

-

P4

100

2

1

1

LO H203

-

J8

LgL H135

B K104

L1

B

B

2

+

L6

M3

2

162

142

-

2

1

1

L7

M9

P2

B

1

114

+

-

LgG P503

2

2

R

267

2

B

B

221

1

1

M2

M1

J4

B

181

2

159

2

2 LG H202

LgB P504

BrY H728

114

YR

1

+

266

220

G

GyB H131 BY V H120 H101

GyO BY H727 P502 1

1

R

B

YR H730

Br

M8

G

B

1

B

6

171

B

160

J3

B

172

H7

Y Y H726 H736

141

216

GR

W GB H121

250

LY H201 2

205

506

1

+

-

735

RY

251

4

-

PB PL

J2

2

1

3

5

B

261

S

K2

003

PL H732

6

FAN SPEED CONTROL SOLENOID VALVE

HYD. OIL LEVEL S/W

GR

261

4

6

100

B

OR

148

+

209

RY

251

114

+

019

331

250

114

-

B

741

303

LgL BrR BrW H122 H113 H123

100

LBr H206

+

738

H129 H139 RB RG

BY V Br H120 H101 H103

BrW BrR LgL L102 L203 L401

-

734

HYD. OIL TEMP.SENSOR

B

Br V BY L103 L201 L202 003

R

019

1

GROUND SPEED SENSOR

1

+

1

3

2

500

R

146

-

OR PB H722 H712

4

J1

B

751

3

1 8

3

LR H205

747

2

F

500

BLg Sb SbR SbY SbY P723 P731 P704 M303 M203

10

WASHER MOTOR (OPT)

+

-

748

740

S2H S2L S2S YL P901 P902 P903 P710

181

COMPRESSOR CLUTCH (ECc)

331

4

EFFICIENT LOADING SYSTEM (ELS) SOLENOID VALVE

325

329

306

303

327

311

RO RY RBr B H109 H118 H119 L802

K1

K0

Br K201

Br

4

H8

+

70A

306

RW RY K108 K102

W

1

741

737

YV BrG BL OR SbY P709 P702 P734 M801 P713

015

H2

H6

F

2 B

242

733

BL YO P734 P720

731

31

303

H5

K105

R

1

4

114

160

161

BrW GyW PW PB GyR P722 P711 P725 M802 P749

P401 P301 BY YGy

141

220

506

YR BrB BrY GyO Y P201 P744 M401 L701 M902 WR P739

T/M SOLENOID VALVE

EFFICIENT LOADING SYSTEM (ELS) OIL PRESS. SENSOR

L5

FRONT HEAD LAMP(OUTSIDE)

142

100

739

H129 H139 RB RG

1

H4

143

240

P403 P402 SbR V

736

1

H3

144

8

B

GyY PG PL W P701 P724 M803 P741

330

100

149

LW LO LG LY J602 J502 J402 J302

914

1

148

35

325

1

1

K202 L602 P501

146

159

H109 H128 RO RL

003

912

LP LR LBr J102 J202 J702

901

3

752

1

910

V

5

W N101

915

730

330

015

R N201

913

70A

RLg

WORKING LAMP (INSIDE)

R N201

R N201

911

5

5 B

311 303

329

A701 K803 K503

8

1

K801 K802 327 RBr K103 K803 303 RB K106 JPN/EXP : CONNECT EU : DISCONNECT K9 311

COMBINATION LAMP

R N201

R N201

Br RW K201 L803

5

K003 K303

A7

303

K106

R N201

2

36 GyR Y P742 M901

BrR P743

327

6

1

RB

267

K101 R603

RW

K002 K302

329

GW K601

OPT

261

251

703

4 306

K6

GW K107

B

308

B

1

B

311

250

Y BrR WR K205 L804 P605

H1

327

2 2 GW K702 K704

RL N904

306

404

40

266

K901 K401

325

1

180

RW YBr RLg K108 J802 K105 308

720

31

221

H119 H128 RBr RL

K103 R703

705

LgB GyB P504 L603

3

325

10

114

329

012

WG BG BrW LgL GB N903 P601 K206 K204 L501

GW GyL K107 M501

RL

182

2

K203 L601 M502 P502

35 LgL BW L806 P606

162

741

RY K102

RO

K502 K802 RO RY RBr

GW K601

K7 HORN (H)

RBr 327

B

HORN (L)

BY

RB

330

K501 K502 325 RO K101 K503 303 RB K106 JPN/EXP : CONNECT EU : DISCONNECT

COMBINATION LAMP

312

207

K4

311

K105

331

K601 GW RB RLg

RLg

WORKING LAMP (INSIDE)

R103 R602 R702

707

SbW BL P719 P734

1

3

36

WL RG RGy LgG M701 R102 P503

308

B

308

W

40

303

K106 R104 R604 R704

RW GW RB RLg H108 H127 H129 H106

306

RW RY K108 K102

B

K3

1

R605 R705

2 R

FRONT HEAD LAMP(OUTSIDE)

+

REAR COMBINATION LAMP (LH)

This page illustrates the transmission is in neutral and key switch is in OFF 80ZV2-09709-10930 3/3 EU position. 80V2E92029

80ZV-2 EU 92-21 92 Drawing & Diagrams Electrical Wiring Diagram

Electrical Wiring Diagram Way of looking at connectors Machine control unit (MCU)

White (Male connector)

MCU 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

Female connector

A1

MCU

A2

A3

A4

A5

A6

A7

A8

A9

A10

A11

A12

A13

A14

A15

A16

A17

A18

A19

A20

A21

A22

A23

A24

A25

A26

A27

A28

A29

A30

A31

A32

A33

A34

B3

B4

B5

B6

B7

B8

B9

B10

B11

B12

B13

B14

B15

B16

B17

B18

B19

B20

SbO LgW LgY GR OSb YBr RL YB A612 A502 A507 A701 V204 A618 A608 A616 193 192 173 135 211 413 235 411 LY Gy GY LgR YL YG LgB GW A708 A506 A807 A808 A617 A619 A604 H707 H201 749 169 130 412 414 224 V212 0 RL YR Sb GyB GyG GyL LP H714 A615 A609 A504 A809 A505 A501 H208 T801 410 241 194 103 753 190 149 LO YSb LLg LW SbP GB LG YGy LgL H736 H202 E804 K204 A710 A901 H721 A711 F202 267 V303 242 261 H203 403 140 V302 202

B21

B22

B23

B24

B25

E1

B26

E3

E4

E5

S6

E7

E8

E13

E14

E15

E16

E17

E18

E19

E20

E21

E22

E23

E24

E25

E27

E28

E29

E30

E31

E32

E33

C1

E34

9

S7

C701 E007 C902 K203 E801 T102 114 H724

100 C702 E803 E004 K202 T101 H708

C2

C3

C4

C5

C6

C7

C8

C12

C13

C14

C15

C16

C17

C18

C19

C20

C21

C22

C23

C24

C25

C28

C29

C30

C31

C32

C33

D1

C9

C11

C27

D3

D4

D5

D6

D7

D9

D10

D11

D12

D13

D14

D15

D16

D17

D18

D19

D21

D22

D23

D24

D25

D26

PW YW PB LLg BrG GW LB H210 B002 F004 V201 E006 S201 E012 152 165 255 210 230 111 233 YL LP PB YSb YV YO G101 F001 S301 G901 A407 E005 124 168 110 125 231 232 LR B LY LW B703 B709 B706 121 126 120 GO PG LG LBr LO B503 S401 B702 B708 B701 164 109 122 128 123 9

S8

D2 D8

D20

C34

Y GyW LgY B BrR SbR YB YBr E603 E501 K205 E802 H716 H744 T202 251 240 406 408 105 260 223 YL YG GL GyW GB Lg H730 H701 A302 A202 V102 E503 407 409 265 200 277 222 BW SbO Sb YR BrY R Gy H726 T203 F005 H762 H748 F303 H702 181 106 271 183 184 750 405 GyB P PL LgL H754 H750 S102 S103 266 107 108 182 1

D12.SL_A D13.SS_N D14.KD D15.INCH_S D16.OD_SW D17.SH D18.SS_SW D19.SS_F D20.TMP D21.INCH D22.KO_S D23.SC D24.AR D25.SM_SW D26.SS_R

C31.BSL C32.EG_M C33.DD_S C34.AFR D 1.PRK D 2.AM_SW D 3.SL_2 D 4.SL_R D 5.SL_3 D 6.S_UP D 7.S_DOWN D 8.EG_SW D 9.M_SW D10.SL_1 D11.SL_F

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

C10

C26

S2H SbY GyL G YG YB C201 H725 H755 C901 T302 A603 171 180 415 116 401 G S2L BrW SbY GyO WL YL E003 C202 A602 H711 H740 H766 T304 234 402 172 220 707 117 L L W Y G D203 D204 H743 H720 D107 005-C 005-D 161 160 010 V BR LgB L L B B BY Y E002 H751 D201 D202 H734 236 221 005-A 005-B 159 1

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

E9

E12

Male connector S5

E6

E11

LgR C703 166

7

1

E2

E10

E26

GR YB WL GyG YO T103 T303 A806 H769 T305 811 115 400 754 118 WR SbW GL YBr SbP RG H739 X601 T104 T301 F701 H770 170 203 810 119 145 331 L BrB LgW LR SbR LgBr F102 X501 T001 T901 F901 H204 208 104 273 258 101 146 LB GB LBr LgR LgL BL H205 V101 H206 H209 E502 E001 147 278 148 150 225 237 9

1

B2

B1

E31.TT_SE E32.OT_SE E33.OUT_RSE E34.ET_M

E16.SPD E17.BATT E18.CANL1 E19.SS_P E20.CANLO E21.TM_M E22.B_SE2 E23.WT_SE E24.ALT E25.RXD1 E26.TGSP E27.INCH_SE E28.SC_P E29.CANHO E30.B_SE1

E 1.SSR_SO E 2.FC_SO E 3.KEY E 4.KEY E 5.GND E 6.GND E 7.GND E 8.GND E 9.+5V E10.TGEG E11.KEY E12.KEY E13.CANH1 E14.EGR2 E15.EGR1

B12.X_R B13.F_SO B14.B_SO B15.EG_SW2 B16.RIN1 B17.OUT_MD2 B18.N_R B19.BR_L B20.CAN_R1 B21.CAN_R2 B22.DOUT1 B23.OUT_FEW B24.MT B25.ET_SE B26.TXD1

A31.1/4_L A32.FR_L A33.3/4_L A34.EG_SW1 B 1.H_SO B 2.PWM_SO B 3.IP_SO B 4.R_SO B 5.MO_SO B 6.FR_SO B 7.SSL_SO B 8.BSL_SO B 9.BZ B10.BSL_R B11.KO_R

A16.TT_L A17.D_SO A18.1_SO A19.EP_L A20.AB_L A21.A_L A22.1/2_L A23.E_L A24.SS_L A25.SC_SW A26.TF_L A27.AC_L A28.BP_L A29.N_L A30.SC_L

1

7

S9

Black (Female connector)

Female connector 115V2E92016

80ZV-2 EU 92-22 92 Drawing & Diagrams Electrical Wiring Diagram

40 poles connector

6 poles connector

Female connector Male connector

Male connector

Female connector

Black (Female connector) H7

Female connector

10

6 C201 C202 C203 F704 T406 T405 T404 T403 RL S2H S2L S2S YL D101 A606 S534 T402 WR BrW SbLg RLg YO H808 A607 S811 S723 S716 WY BrB BrY GyO Y

A503 A605 A802 S708 WG BrR BG GyR Y 40 36

5

1

C002 F203 S615 S722 S730 BLg Sb SbW SbY SbY C404 C001 G004 C309 F103 BL YV BrG OR SbY C402 C003 C005 G002 C307 F302 BrW GyW PW PB GyR C403 D105 C006 G003 C308 S715 PL BW GyY PG W 35 31

C401 C004 G001

PARKING S/W

Male connector

L

B

40

36

GyY PG W PL P701 P724 M803 P741

Y WY BrB BrY GyO P201 P744 M401 L701 M902

BrW GyW PW PB GyR P722 P711 P725 M802 P749

BL YO P734 P720

OR SbY YV BrG BL P709 P702 P734 M801 P713

WR P739

BLg Sb P723 P731

YL S2H S2L S2S P901 P902 P903 P710 10

6

5

Y B

Y

R

L

G

L D206

LgG H137

6

4

31

GyR Y P742 M901

BrR P743

Male connector

35

GO SbW S901 A712

Female connector

SbY SbY M303 M203 1

White (Male connector)

G

R

B 1

3

B5

H7

White (Male connector)

Black (Female connector)

90V2U92009

80ZV-2 EU 92-23 92 Drawing & Diagrams Electrical Wiring Diagram

Electrical wiring diagram abbreviation chart (S/N 9001~9350) INSTRUMENT PANEL —

INSTRUMENT PANEL A

AUTO lamp —

MCU

MCU

MCU

MCU

A22

—

B26

Communication TXD1

C5

T/M oil temperature switch (not used)

D7

A23

—

E1

S/S solenoid valve R

C6

Air cleaner clogging switch

D8

E/G speed sensor selection

Reversal fan indicator lamp

E2

Fan speed control solenoid valve

Meter selection

Slip control selection

E3

Power supply +24 V

E/G coolant temperature switch (not used)

D9

A25

C7

D10

Shift lever 1

A26

—

E4

Power supply +24 V

C8

—

D11

Shift lever F

—

D12

Shift lever A

C

Charge lamp

AB

AC

Air cleaner clogging alarm

SM

Meter (Speed/Tacho) +

A24

SM

Meter (Speed/Tacho) –

—

TT

T/M oil temperature alarm

WT

Engine water temperature alarm

EP

Engine oil pressure alarm

TC

Declutch lamp

A27

Air cleaner warning lamp

E5

Power supply GND

C9

BP

Brake oil pressure alarm

PH

Preheating lamp

A28

Brake pressure warning lamp

E6

Power supply GND

C10

CE

MCU error (failure alarm)

WL

Work lamp

A29

Neutral indicator lamp

E7

Power supply GND

C11

+

+24 V power supply

W

Central alarm lamp

A30

—

E8

Power supply GND

ES

Secondary steering

GND

GND (–)

A31

—

E9

+5 V output

SS

FR switch, S/S switch indication lamp

E10

Tacho-graph E/G speed

EG2

Engine warning lamp

A33

—

E11

Power supply +24 V

C14

—

D16

Odometer selection

EG1

Engine protection lamp

H

High-beam lamp

A34

E/G droop selection 2

E12

Power supply +24 V

C15

—

D17

Shift hold switch

EG3

Engine stop lamp

L

Turn signal (left) lamp

B1

—

E13

Communication CAN H1

C16

D18

S/S shift selection switch

FR

Reversal fan indication lamp

R

Turn signal (right) lamp

B2

—

E14

E/G speed sensor 2 (not used)

C17

D19

S/S shift switch F

B3

Pressure intensifying solenoid valve

E15

E/G speed sensor 1

C18

R solenoid valve

E16

Machine speed sensor

C19

—

D21

Declutch switch

E17

Power supply

C20

—

D22

Kickout set up

—

D23

—

— —

—

A32

WTM

Engine water temperature gauge (sensor)

GND

Hour meter (–)

B4

TTM

T/M oil temperature gauge (sensor)

HM

Hour meter (+)

B5

(+)

Instrument panel illumination

—

FM

+

—

C13

B6

Reversal fan solenoid valve

E18

Communication CAN L1

C21

B7

S/S solenoid valve L

E19

S/S potentiometer

C22

Spare digital input (S/N 9001~9100)

Hydraulic oil level switch

Spare (S/N 9101~)

D14

Downshift button

D15

Declutch set up

E/G oil pressure switch — Spare analog input

Efficient loading system switch

A1

Efficient loading system solenoid valve

B8

E/G idle selection

E20

Communication CAN L0

C23

E/G mode selection switch

A2

2nd speed solenoid valve

B9

Buzzer

E21

T/M oil temperature gauge

C24

Pressure intensifying switch

Fuel gauge (sensor)

A3

Secondary steering motor relay

B10

Lower kickout relay

E22

Brake oil pressure sensor 2

C25

Reversal fan (manual) switch

—

A4

Ride control solenoid valve

B11

Lift kickout relay

E23

Hydraulic oil temperature sensor

C26

Boom angle sensor

—

A5

3rd speed solenoid valve

B12

MCU fault relay

E24

Alternator

—

A6

Hour meter

B13

F solenoid valve

E25

Communication RXD1

C27

Secondary steering oil pressure sensor

—

A7

Lock-up solenoid valve

B14

Brake solenoid valve

E26

Tacho-graph machine speed

C28

—

E27

Declutch sensor (brake oil pressure sensor)

C29

A8

4th speed solenoid valve

B15

E/G droop selection 1

A9

E/G torque selection

B16

Communication RINI

+ 24 V power supply

A10

Back-up lamp

B17

Mode control

E28

Spare analog input

—

A11

B18

Neutral relay

E29

Communication CAN H0

—

A12

B19

Brake lamp

E30

Brake oil pressure sensor 1

—

A13

E31

T/M oil temperature sensor

—

— Steering oil pressure warning lamp —

B20

A14

Central warning lamp

B21

A15

E/G coolant temperature warning lamp

B22

N

Neutral

–

GND (–)

A16

T/M oil temperature warning lamp

1

1st speed indication

A17

D solenoid valve

2

2nd speed indication

A18

1st speed solenoid valve

3

3rd speed indication

A19

E/G oil pressure warning lamp

4

4th speed indication

A20

Auto brake indicator lamp

P

Parking brake lamp

A21

Auto shift indicator lamp

— —

C30

C31 C32

— Recall switch (S/N 9001~9100) Spare (S/N 9101~) Lower kickout switch (S/N 9001~9100) Auto/Full auto selection (S/N 9101~) Spare digital input

E32

Air temperature probe

C33

Ride control switch

Communication DOUT1

E33

Communication (RESET)

C34

Auto fan reversal switch

B23

Communication FEW

E34

E/G coolant temperature gauge

D1

Parking switch

B24

Meter output (Speed/Tacho)

Efficient loading system oil pressure sensor

D2

A/M selection

D3

Shift lever 2

E/G coolant temperature sensor (S/N 9001~9100) B25 E/G water temperature sensor (For inspection) (S/N 9101~)

C1

F34 change point selection (S/N 9101~)

Lower kickout set-up

—

GND (–)

D13

Reset switch (S/N 9001~9100)

—

— GND

MCU

S/S indicator lamp

C12

Spare digital input

C2

Specification change 1

D4

Shift lever R

C3

Specification change 2

D5

Shift lever 3

C4

Spare digital input

D6

—

D20

D24

—

— Armrest switch Tire diameter selection (S/N 9001~9100)

D25 F23 change point selection (S/N 9101~) D26

S/S shift switch R

80ZV-2 EU 92-24 92 Drawing & Diagrams Electrical Wiring Diagram (S/N 9351~) INSTRUMENT PANEL (A5) +

INSTRUMENT PANEL (A6)

MCU

+24V power supply

SS

F/R switch

A19

E/G oil pressure warning lamp

BATT

BATT

DD

Ride control

A20

Auto brake indicator lamp

GND

GND(-)

FR

Reversal fan

A21

Auto shift indicator lamp

1st speed indication

EG4

1

—

A22

—

C3

Specification change 2

D8

E/G speed sensor selection

C4

Spare digital input

D9

Meter selection

B26

Communication TXD1

C5

T/M oil temperature switch (not used)

D10

Shift lever 1

E1

S/S solenoid valve R

C6

Air cleaner clogging switch

D11

Shift lever F

C7

E/G coolant temperature switch (not used)

D12

Shift lever A

D13

F34 change point selection

2nd speed indication

EG1

—

A23

E2

Fan speed control solenoid valve

3rd speed indication

EG2

Engine warning lamp

A24

Reversal fan indicator lamp

E3

Power supply +24 V

4

4th speed indication

EG3

Engine stop lamp

SUB2

—

BP

A25

Slip control selection

E4

Power supply +24 V

C8

—

D14

Downshift button

—

A26

—

E5

Power supply GND

C9

—

D15

Declutch set up

—

A27

E6

Power supply GND

C10

D16

Odometer selection

Brake alarm

—

MCU

E/G water temperature sensor (For inspection)

2

—

MCU

B25

3

—

—

MCU

—

Air cleaner warning lamp

Spare digital input

A28

Brake pressure warning lamp

E7

Power supply GND

C11

Hydraulic oil level switch

D17

Shift hold switch

A29

Neutral indicator lamp

E8

Power supply GND

C12

Spare

D18

S/S shift selection switch S/S shift switch F

ES

Secondary steering

EP

Engine oil pressure alarm

A30

—

E9

+5 V output

C13

Lower kickout set-up

D19

WTM

Engine water temperature gauge

WT

Engine water temperature alarm

A31

—

E10

Tacho-graph E/G speed

C14

—

D20

—

D21

Declutch switch

D22

Kickout set up

—

TT

T/C (T/M) oil temperature alarm

A32

E11

Power supply +24 V

C15

—

AC

Air cleaner clogging alarm

A33

—

E12

Power supply +24 V

C16

C

Charge lamp

— HM

Hour meter

EWL

A34

E/G droop selection 2

E13

Communication CAN H1

C17

—

B1

—

E14

E/G speed sensor 2 (not used)

C18

—

E/G oil pressure switch — Spare analog input

— Armrest switch

SUB1

B2

—

E15

E/G speed sensor 1

C19

—

D25

F23 change point selection

TTM

T/C (T/M) oil temperature gauge

B3

Pressure intensifying solenoid valve

E16

Machine speed sensor

C20

—

D26

S/S shift switch R

—

FM

Fuel gauge

B4

R solenoid valve

E17

Power supply

C21

—

E18

Communication CAN L1

C22

Efficient loading system switch

E19

S/S potentiometer

C23

E/G mode selection switch

— —

P

Parking brake lamp

SM

Speed meter

INSTRUMENT PANEL (A6) Controller failure alarm —

—

MCU

B5 B6

— Reversal fan solenoid valve

B7

S/S solenoid valve L

E20

Communication CAN L0

C24

Pressure intensifying switch

B8

E/G idle selection

E21

T/M oil temperature gauge

C25

Reversal fan (manual) switch

2nd speed solenoid valve

B9

Buzzer

E22

Brake oil pressure sensor 2

C26

Boom angle sensor

Secondary steering motor relay

B10

Lower kickout relay

E23

Hydraulic oil temperature sensor

A4

Ride control solenoid valve

B11

Lift kickout relay

E24

Alternator

C27

Secondary steering oil pressure sensor

A5

3rd speed solenoid valve

B12

MCU fault relay

E25

Communication RXD1

C28

—

E26

Tacho-graph machine speed

C29

Declutch sensor (brake oil pressure sensor)

C30

Spare

C31

Auto/Full auto selection

A1

Efficient loading system solenoid valve

A2 A3

R

Turn signal (Right) lamp

A6

Hour meter

B13

F solenoid valve

WL

Work lamp

A7

Lock-up solenoid valve

B14

Brake solenoid valve

H

High-beam lamp

A8

4th speed solenoid valve

B15

E/G droop selection 1

(+)

Instrument panel illumination

A9

E/G torque selection

B16

Communication RINI

E28

Spare analog input

C32

Spare digital input

A10

Back-up lamp

B17

Mode control

E29

Communication CAN H0

C33

Ride control switch

B18

Neutral relay

E30

Brake oil pressure sensor 1

C34

Auto fan reversal switch

B19

Brake lamp

E31

T/M oil temperature sensor

D1

Parking switch

—

—

E27

—

A

AUTO lamp

A11

L

Turn signal (Left) lamp

A12

N

Neutral indication

A13

—

B20

—

E32

Air temperature probe

D2

A/M selection

W

Central alarm lamp

A14

Central warning lamp

B21

—

E33

Communication (RESET)

D3

Shift lever 2

—

E34

E/G coolant temperature gauge

D4

Shift lever R

C1

Efficient loading system oil pressure sensor

D5

Shift lever 3

D6

—

C2

Specification change 1

D7

—

AB

D24

—

CANL

TF

D23

—

CANH

CE

S/S indicator lamp

—

Steering oil pressure warning lamp

A15

E/G coolant temperature warning lamp

B22

Communication DOUT1

TC

Declutch lamp

A16

T/M oil temperature warning lamp

B23

Communication FEW

PH

Preheat lamp

A17

D solenoid valve

B24

Meter output (Speed/Tacho)

A18

1st speed solenoid valve

—

80ZV-2 EU 92-25 92 Drawing & Diagrams Electrical Wiring Diagram (CAB)

Electrical Wiring Diagram (CAB)

'

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80ZV-2 EU 92-26 92 Drawing & Diagrams Electrical Wiring Diagram (CAB)

ROPS CAB S/N 0101~0280

Working lamp (front)

Rotary warning lamp (spare) (A3) GND Speaker (option) (A4) Rotary warning lamp (spare) (A3) Working lamp (rear) (A5) (A2) (B3)

(A6)

(Option) Room lamp

Speaker

(B2)

Wiper motor (rear)

Speaker (B4) Cigar socket Wiper S/W (rear)(A9) Wiper S/W (front)(A8) (A7)

(A1)

(A9) (A8)

Car radio (C5) Wiper motor (front)

(B1)

Relay wiper intermittent Working lamp (front) (B6)

(B5)

MODM

Speaker (option) (C1~C3)

(B9) (B7) CAN (Resistor)

To floor board

(C4) Rotary warning lamp (option)

(B8) 80-90ZV2 EU ROPS

K90V2E92015

80ZV-2 EU 92-27 92 Drawing & Diagrams Electrical Wiring Diagram (CAB)

ROPS CAB S/N 0281~0346

ROPS CAB S/N 0347~ Working lamp (front)

Working lamp (front)

Rotary warning lamp (spare) (A3) GND Speaker (option) (A4) Rotary warning lamp (spare) (A3) Working lamp (rear) (A5)

Rotary warning lamp (spare) (A3) GND Speaker (option) (A4) Rotary warning lamp (spare) (A3) Working lamp (rear) (A5) (B3)

(S/N 0296~)

(A6)

(B3)

(A6)

(A2)

(A2) Room lamp

Speaker

Room lamp

Speaker (B2)

Wiper motor (rear)

Wiper motor (rear)

(B2)

Speaker (A1)

(B4)

(B4) Speaker Cigar socket

Cigar socket

Wiper S/W (rear)(A9) Wiper S/W (front)(A8)

(S/N 0296~)

Wiper S/W (rear)(A9) Wiper S/W (front)(A8) (A7)

(A9)

(A7)

(A1)

MODM

(A9) (A8)

(A8)

(C5)

(B9) CAN (Resistor)

Car radio

Relay wiper intermittent

Wiper motor (front)

(B1) Relay wiper intermittent

Wiper motor (front)

Working lamp (front)

(B8) Working lamp (front) (B6)

(B6) (B5)

(B5) MODM

Car radio (C5) Speaker (option)

Speaker (option) (C1~C3)

(B7)

(C1~C3)

(B1)

(C4)

(C4) To floor board

(B7)

Rotary warning lamp (option)

To floor board

Rotary warning lamp (option)

(B9) CAN (Resistor) (B8) 80-90ZV2 EU ROPS

K90V2E92016

80ZV-2 EU 92-28 92 Drawing & Diagrams Electrical Connection Diagram (1/2) (S/N 9001~9100)

Electrical Connection Diagram (1/2) (S/N 9001~9100) (L) (005-b)

STARTER S/W

(005) L2

F5

PREHEAT OFF ON START

(L) (005-a)

30A F10

G (010) Lx4 (005-A~005-D) E

ACC’ (086) W

(900) [W5]

30A

12V

1

BATTERY RELAY

23A

LG (122)

70A

STARTER

LY (121) YO (232)

S/S SHIFT S/W F MAGNETIC (702) S/W [BW5]

[R5] (701)

(013) (Lg)

F13

(705) (WG)

70A

(707) WL1.25

B

LB (230)

ARMREST S/W

LG (122)

SHIFT UP S/W

LY (121)

SHIFT DOWN S/W

R

ALTERNATOR M

100

DOWNSHIFT S/W

20

M PREHEAT LAMP (720) (BG)

15

(012) BW

YSb (125)

SECONDARY DECLUTCH SET-UP STEERING PUMP SLIP CONTROL S/W

LP (168) (GW) (210) BrG (255)

LIFT KICKOUT SET-UP AIR HEATER

BW (271)

LOWER KICKOUT SET-UP LOWER KICKOUT S/W

15

Lg (222)

REVERSAL FAN S/W

HEATER RELAY

ACC’

E

LgY (223) (Y) (105)

RECALL S/W

(R) (106)

RESET S/W

TO PILOT LAMP

LLg (165) GO (164) GyW (200) GL (265) (GyW) (260)

F13

E (013) (Lg) YO (176)

EP

E/G OIL PRESS. S/W

DECLUTCH S/W ON

5A

29 20A

13

5A

28 10A

E

(163) (SbW)

OFF ON

LgL (182)

AIR CLEANER CLOGGING S/W

DECLUTCH

(005-b) (L)

OFF

Gy (750) BrY (181)

HYD. OIL LEVEL S/W

(LgY) (167)

14

D12 D05 D03

B13 B04

D10 D19 D26

L (273)

NEUTRAL RELAY

X

MCU FAILURE RELAY

KO

LIFT KICKOUT RELAY

BS

LOWER KICKOUT RELAY

A30 V (100)

S/S POTENTIOMETER

G (234)

YGy (242)

SECONDARY STEERING MOTOR RELAY COIL

M

LR (146)

F SOLENOID VALVE

LBr (148)

R SOLENOID VALVE

(141) LY

1ST SPEED SOLENOID VALVE

(142) LG

D18

A05

D24

2ND SPEED SOLENOID VALVE

(LgR) (166)

BRAKE OIL PRESS. SENSOR 1

SbY (171)

BRAKE OIL PRESS. SENSOR 2

SbY (172)

SECONDARY STEERING OIL PRESS. SENSOR

SbR (240)

EFFICIENT LOADING SYSTEM OIL PRESS. SENSOR

GyB (266)

3RD SPEED SOLENOID VALVE

GyG (754) GyL (180)

T/M OIL TEMP. SENSOR

(G) (415)

AIR TEMP. PROBE

(144) LW

4TH SPEED SOLENOID VALVE

D06

GyO (220)

HYD. OIL TEMP. SENSOR

BY (114)

(LW) D07

LP (149)

B14 D17 A07

Y (160)

WR (170)

E/G SPEED SENSOR

ECM (41)

LLg (140)

W (161) Y (159)

D15 A04

LgL (261)

D22 C13

A01 B06 E01

C25 C34 C30

B07 E02

GB (267)

EFFICIENT LOADING SYSTEM SELECTION SOL. VALVE

LgL (225)

REVERSAL FAN SOL. VALVE

(236) BR

S/S SOLENOID VALVE R

1A (237) BL (226) LgB

1A

S/S SOLENOID VALVE L

1A

D21 D01 C23

A21 A29

C22

A14

C33

A28

C16

A19 A15

C11 C06

A16 A27 A12

(LgR) (130) (GR) (135) (GyB) (103) (LgY) (173) (Gy) (749) (GyG) (753) (GyL) (190) (LgW) (192) (O) (241)

PL (108) PG (109) PB (110)

REVERSAL FAN INDICATOR LAMP

(LgB) (224) LgBr (104)

S/S INDICATOR LAMP BUZZER

BZ

(YB) (401)

E/G COOLANT TEMP. GAUGE

E27 E21

(BrW) (402)

T/M OIL TEMP. GAUGE

E30 B24

E22 C27

(WL) (400)

METER OUTPUT (SPEEDOMETER/TACHOMETER)

(420) OSb (+)

(-)

(421) OB (+)

(-)

TACHOGRAPH E/G SPEED

C01 E26

B25

TACHOGRAPH GROUND SPEED

E31 A06

E32

B08

E23

A09

E07

YSb (403) SbR (208) SbP (202)

HOUR METER DRIVE AI

E/G IDLE SELECTION

TC

E/G TORQUE SELECTION

SbW (203)

E16

A34 SbLg (204)

E15

A25

(GW) (212)

E/G DROOP SELECTION 1 E/G DROOP SELECTION 2

E08

B19

C02

(LB) (138) (RG) (331)

SLIP CONTROL SELECTION

ECM (3) E

TO BACK-UP LAMP TO BRAKE LAMP

C03 D02

(RIN1)B16

D16

(DOUT1)B22

GL (810) RS232C

GR (811)

D25 D08

(CANH0)E29

D09

(CANL0)E20

S2H S2L

CAN

S2S E

(221) LgB

C12

B09 E34

A10 P (107)

OPT OPT A/M SELECTION ODOMETER SELECTION TIRE DIA. SELECTION SPEED SENSOR SELECTION METER SELECTION

SLIP CONTROL INDICATOR LAMP

(RL) (235)

C26

E

RIDE CONTROL SOLENOID VALVE

D23

A24

(OSb) (211)

E19

B15

D SOLENOID VALVE GROUND SPEED SENSOR

D14

A32

E09(+5V)

E10

E/G COOLANT TEMP. SENSOR

(143) LO (LO)

A08

BrR (251)

DECLUTCH SENSOR

(LY) A02

C31

AUTO FAN REVERSAL S/W

30 20A

BrB (258)

NR

E

A17 (YL) (124)

SHIFT HOLD S/W

PARKING SOL (162) LgG

LgW (101)

BOOM ANGLE SENSOR

F5

E

5A

B10

(SbP)(145)

(LG) YV (231)

S/S SHIFT SELECTION S/W

(707) WL

CHARGE LAMP 20

YW (233)

S/S SHIFT S/W R

VOLTAGE RELAY WG (705)

RL1.25 (703)

15

B11

D04

A18

NR

CAB

D11

B C

[R5] x 6 (910 ~ 915)

MACHINE

B18

A03 LW (120) LO (123)

(013) (Lg)

B

E12 E04 E11 E03

SHIFT LEVER

F N R

WV (700)

5A

5A

F13

F14

F12

15A

(014) G1.25

LR (126) LBr (128)

(708) WP

(063) WR1.25

E24

B12

ECM (39)

5A

(064) G1.25

(062) BW

WL (707)

BATTERY (015) (065) WR1.25 F15 WR

R1 BR B AC R2 C

E05 E06 E17

12V

100

(060) (901) W [W5]

(012) BW

TO PARKING S/W

ACC’

B BR ACC R1 R2 C

FAN SPEED CONTROL SOL.VALVE

MAIN MCU

E

F13 (013) (Lg)

AUTO SHIFT INDICATOR LAMP NEUTRAL INDICATOR LAMP CENTRAL WARNING LAMP BRAKE OIL PRESS. WARNING LAMP E/G OIL PRESS. WARNING LAMP E/G COOLANT TEMP. WARNING LAMP T/M OIL TEMP. WARNING LAMP AIR CLEANER WARNING LAMP STEERING OIL PRESS. WARNING LAMP

F5

PARKING S/W

FUEL EFFICIENT MODE S/W

12 15A

27

5A

11 10A

26

5A

10 15A

25 20A

9

15A

24 10A

8

15A

23 10A

7

10A

22

6

15A

21 15A

5

30A

20 10A

4

15A

19 10A

3

10A

18

5A

2

15A

17

5A

ECM

1

20A

16

5A

36 30A

EFFICIENT LOADING SYSTEM S/W

This page illustrates the transmission is in neutral and key switch is in OFF position.

RIDE CONTROL S/W

3A

X

MCU FAILURE FUEL LEVEL GAUGE

(LgW) (102)

(404) (YBr) (LgSb) (112)

WARNING BUZZER

BZ

E

70ZV2-85ZV2-09708-05563 EU 1/2 70V2E92021

80ZV-2 EU 92-29 92 Drawing & Diagrams Electrical Connection Diagram (2/2) (S/N 9001~9100)

Electrical Connection Diagram (2/2) (S/N 9001~9100) ACC'

E

1.25

R (001)

RB (301)

LT

RY (302)

Br (003)

BrW (250)

(036) [G3]

F36

BUCKET LEVELER

10A

30A

EL

BrB (257)

LH

FOR OPT LAMP

BrR (272)

FOR OPT LAMP

E

39 43

REMOTE THROTTLE GR (742)

F7

OY (007)

C

10A

LICENSE LAMP (OPT)

(015) WR

F15

FLOAT

BS

FOR OPT LAMP

RB (303)

ACC'

32

THROTTLE OPENING SENSOR

ACC'

BrW (733)

22

OR (019)

M

HU EL

F6

RG (006)

LEFT HEADLIGHT (H)

M

FRONT WORKING LIGHT

5A F16

R (002)

R WIPER

REAR WORKING LIGHT REAR WORKING LIGHT

LB (138)

RL (330)

(521) RLg

BACK-UP LAMP

F20

CAB REAR WORKING LIGHT

E 31

(GL) (213)

DATA LINK CONNECTOR

3

ACC'

F22 5A

RG (331)

RIGHT BRAKE LAMP

E

CAB REAR WORKING LIGHT F26 (RL)

O (020)

(511)GyB (512)WR

G (010)

F10

BM

(510)Gy

(RB) (300) (NIGHT ILLUMINATION)

CD

NIGHT ILLUMINATION

ROOM LAMP

RIGHT TURN SIGNAL PL

G

S2H S2L

CAN

BLOW-OFF THERMISTOR(THF) (BY)

CANL0

WATER TEMP. SENSOR(THW) (Y) E

LEFT REAR TURN SIGNAL

18

LEFT TURN SIGNAL PL

27

(PL)

E

20

9 24

12

25

13

10 36

14

26

15

11 35

1 23 22

(329) GW

HORN RELAY

(BR) (BrW) (WY)

A/M SERVO MOTOR

M

(WR)

MAM

(OL) (GO)

RIGHT VENT SELECTION SERVO MOTOR

M

(Sb)

MV1

(WG) (LgY)

LEFT VENT SELECTION SERVO MOTOR

M

(BrB)

MV2

(WP) (VW)

DEF SELECTION SERVO MOTOR

M

(YB)

MV3

(BG) (PB)

INSIDE/OUTSIDE AIR SELECTION SERVO MOTOR

M

(V)

MRF SPHL

HORN

(328) (GL)

(PL)

3 16

INSOLATION SENSOR(SS)

(323) BP

2 21

34

(BrR)

CAB ACC'

5

OUTSIDE AIR SENSOR(THAM)

RESISTOR (326) (RBr)

(RB)

INSIDE AIR SENSOR(THI) (P)

GND

CANH0

S2S

B E L

(BrY)

(GW)

LEFT FRONT TURN SIGNAL

(327) RBr

FLASHER UNIT (HAZARD)

KEY

RIGHT FRONT TURN SIGNAL RIGHT REAR TURN SIGNAL

27

(BR)

MODM

3

19

(513)WB

FLASHER UNIT (WINKER) (324) (RO)

(LO)

EC

RADIO

15A

(320) P COMBINATION (325) S/W (321) RO RO TR (322) TB RBr TL (010)

28

6

5A (WBr) (022)

LEFT BRAKE LAMP

B

A

CAB WORKING LIGHT

(004) F4 R

15A

(GW) (212)

F G

13

CAB WORKING LIGHT

(520) RGy

TO REAR WORKING LIGHT

BACK-UP LAMP

TO MCU (B19)

F10

Sb (205)

E

(Y0) (748)

OG (016)

10A

B

TC

WIPER S/W

TO CAB REAR

BACK-UP ALARM

W (060)

SbY (209)

D

(YL) (747)

10 20

RLg(206) AI

B C

S2S

37 34

(060) W

S2L

47 BL (741)

OW (017)

TO FRONT WORKING LIGHT

RGy (520) WORKING LIGHT

B E L

46

ECM

RGy (312)

REAR WORKING LIGHT S/W

ACC'

25

S2H

5A

15A

TO MCU (A10)

24

DEC

(A25)

TO CAB

B PG (739) PW (740)

B S1 S2 WASH

PL

INC

GR (508)

WORKING LIGHT PL F17

(m)

CAN

S2S

RESISTOR

2

INC/DEC S/W

M (507) GY

WASHER MOTOR (506)

E

RLg (521) WORKING LIGHT

1.25

OL (018)

5A

FRONT WORKING LIGHT

S2L BrG (738)

WIPER MOTOR

F18

LEFT HEADLIGHT (L)

FRONT WORKING LIGHT S/W F2

M

RIGHT HEADLIGHT (H)

(E15)

S2H

DIAGNOSTIC S/W

5 3 INTER2 MITTENT 6 WIPER 4 RELAY

PB

(161) W

41 11

IDLE

1

WASHER MOTOR (500)

HIGH BEAM PL

RLg (311)

42

1

GyW (737)

LW (505)

(504) LY

RIGHT HEADLIGHT (L)

15A

E/G oil press.

EP

(752) GyR

23

GyY (736)

F WIPER

L (503)

(501) Y W (502) WIPER S/W S2 S3 WASH B Sint S1

TO RADIO

(310) (RGy)

(751) GyR

IDLE SW OFF IDLE

10A

1.25

F13

9

WIPER MOTOR

F19

RW (308)

(013) (Lg)

E

INSTRUMENT PANEL LIGHTING

LH

WARNING

49

YV (734)

(306) (305) UL RY RY

45

THROTTLE PEDAL

BLg (735)

(307) (RY)

(731) (BrB)

E

TAIL LAMP

RB (300)

STOP

(732) MAINTENANCE (BrW)

26

BG (744)

(730) (BrR)

44

21

GY (743)

AIR-SUS. COMPRESSOR

TAIL LAMP

COMBINATION HL S/W

2

J2

FOR OPT LAMP

(304) RW

1

3

BOOM KICKOUT

KO

LT

UL

4

B

LT

20A LH

F3

COMBINATION S/W

(086) [W3]

AIRCON UNIT

F1

E

J3

B

E

ACC'

CONVERTER

ACC'

HORN S/W

24V

F22

(WBr) (022)

5A

TO RADIO/ROOM LAMP TO MCU (E17)

F10

E

12V

CAB

4

E ACM

(WBr)(022)

(LgR) (BL) SPCD (LgW)

OW (017)

This page illustrates the transmission is in neutral and key switch is in OFF position.

CH

RY1.25

(010) G

F29

R2

20A ACC'

8

RY2 RY1.25

RG

10A

G2

3

2

4

BLOWER MOTOR

1 BLC

G1.25

ECC

YR

COMPRESSOR CLUTCH

EC

5A F28

M

BM

E F27

MB

1.25

1.25

RB

RW CD

MCD

M

1.25

Y

RCD

CONDENSER MOTOR CH

ACC'

E

70ZV2-85ZV2-09708-05563 EU 2/2 70V2E92022

80ZV-2 EU 92-30 92 Drawing & Diagrams Electrical Connection Diagram (1/2) (S/N 9101~9200)

Electrical Connection Diagram (1/2) (S/N 9101~9200) (L) (005-b)

STARTER S/W

(005) L2

F5

PREHEAT OFF ON START

(L) (005-a)

30A F10

G (010) Lx4 (005-A~005-D) E

ACC’ (086) W

(900) [W5]

30A

12V

1

BATTERY RELAY

23A

LG (122)

70A

STARTER

LY (121) YO (232)

S/S SHIFT S/W F MAGNETIC (702) S/W [BW5]

[R5] (701)

(013) (Lg)

F13

(705) (WG)

70A

(707) WL1.25

B

LB (230)

ARMREST S/W

LG (122)

SHIFT UP S/W

LY (121)

SHIFT DOWN S/W

R

ALTERNATOR M

100

DOWNSHIFT S/W

20

15

(012) BW

PREHEAT LAMP

SECONDARY DECLUTCH SET-UP STEERING PUMP SLIP CONTROL S/W

AIR HEATER

LOWER KICKOUT SET-UP

M

(720) (BG)

YSb (125) LP (168) (GW) (210) BrG (255)

LIFT KICKOUT SET-UP

15

BW (271)

Lg (222)

REVERSAL FAN S/W

HEATER RELAY

ACC’

E

LgY (223) (Y) (105)

SPARE

(R) (106)

SPARE

TO PILOT LAMP

LLg (165) GO (164) GyW (200) GL (265) (GyW) (260)

F13

E (013) (Lg) YO (176)

EP

E/G OIL PRESS. S/W

DECLUTCH S/W ON

5A

29 20A

13

5A

28 10A

E

(163) (SbW)

OFF ON

LgL (182)

AIR CLEANER CLOGGING S/W

DECLUTCH

(005-b) (L)

OFF

Gy (750) BrY (181)

HYD. OIL LEVEL S/W

(LgY) (167)

14

L (273)

NEUTRAL RELAY

X

MCU FAILURE RELAY

KO

LIFT KICKOUT RELAY

BS

LOWER KICKOUT RELAY

D12 D05 D03

B13 B04

D10

YGy (242)

A30 V (100)

S/S POTENTIOMETER

G (234)

R SOLENOID VALVE

(141) LY

D19 D26

F SOLENOID VALVE

LBr (148)

1ST SPEED SOLENOID VALVE

(LY) A02

(142) LG

D18

A05

2ND SPEED SOLENOID VALVE

3RD SPEED SOLENOID VALVE

(LO) A08

(LgR) (166)

BRAKE OIL PRESS. SENSOR 1

SbY (171)

BRAKE OIL PRESS. SENSOR 2

SbY (172)

SECONDARY STEERING OIL PRESS. SENSOR

SbR (240)

EFFICIENT LOADING SYSTEM OIL PRESS. SENSOR

GyB (266) GyG (754) GyL (180)

T/M OIL TEMP. SENSOR

(G) (415)

AIR TEMP. PROBE

(144) LW

4TH SPEED SOLENOID VALVE

D06

GyO (220)

HYD. OIL TEMP. SENSOR

BY (114)

(LW) D07

LP (149)

B14 D17 A07

Y (160)

WR (170)

E/G SPEED SENSOR

ECM (41)

LLg (140)

W (161) Y (159)

D15 A04

LgL (261)

D22 C13

A01 B06

GB (267)

EFFICIENT LOADING SYSTEM SELECTION SOL. VALVE

LgL (225)

REVERSAL FAN SOL. VALVE

C25 C34 C30

E01 131.357 B07 E02

S/S SOLENOID VALVE R

1A

(237) BL (226) LgB

1A

S/S SOLENOID VALVE L (221) LgB

1A C12 D21 D01 C23

A21 A29

C22

A14

C33

A28

C16

A19 A15

C11 C06

A16 A27 A12

(LgR) (130) (GR) (135) (GyB) (103) (LgY) (173) (Gy) (749) (GyG) (753) (GyL) (190) (LgW) (192) (O) (241)

FAN SPEED CONTROL SOL.VALVE F13 (013) (Lg)

P (107) PL (108) PW(111) PG (109) VG (157) VY (158) PB (110)

REVERSAL FAN INDICATOR LAMP

(LgB) (224) LgBr (104)

S/S INDICATOR LAMP BUZZER

BZ

(YB) (401)

E/G COOLANT TEMP. GAUGE

E27 E21

(BrW) (402)

T/M OIL TEMP. GAUGE

E30 B24

E22 C27

(WL) (400)

METER OUTPUT (SPEEDOMETER/TACHOMETER)

(420) OSb (+)

(-)

(421) OB (+)

(-)

TACHOGRAPH E/G SPEED

C01 E26

B25

TACHOGRAPH GROUND SPEED

E31 A06

E32

B08

E23

A09

E07

YSb (403) SbR (208) SbP (202)

HOUR METER DRIVE AI

E/G IDLE SELECTION

TC

E/G TORQUE SELECTION

SbW (203)

E16

A34 SbLg (204)

E15

A25

(GW) (212)

E/G DROOP SELECTION 1 E/G DROOP SELECTION 2

B19

(LB) (138) (RG) (331)

SLIP CONTROL SELECTION

ECM (3)

E08

E

TO BACK-UP LAMP TO BRAKE LAMP

C02 C03

(RIN1)B16

C31

(DOUT1)B22

GL (810)

D25

(CANH0)E29

D13

(CANL0)E20

RS232C

GR (811)

D02

S2H S2L

CAN

S2S

D16 D08

E

D09 E

AUTO SHIFT INDICATOR LAMP

B09 E34

E

DESTINATION SWITCH 1 DESTINATION SWITCH 2 AUTO/FULL AUTO SELECTION A/M SELECTION F23 CHANGE POINT SELECTION F34 CHANGE POINT SELECTION ODOMETER SELECTION SPEED SENSOR SELECTION METER SELECTION

SLIP CONTROL INDICATOR LAMP

(RL) (235)

C26

A10

RIDE CONTROL SOLENOID VALVE

D23

A24

(OSb) (211)

E19

B15

D SOLENOID VALVE GROUND SPEED SENSOR

D14

A32

E09(+5V)

E10

E/G COOLANT TEMP. SENSOR

(143) LO

D24

BrR (251)

DECLUTCH SENSOR SECONDARY STEERING MOTOR RELAY COIL

M

LR (146)

(236) BR

AUTO FAN REVERSAL S/W

30 20A

BrB (258)

NR

E

A17 (YL) (124)

SHIFT HOLD S/W

PARKING SOL (162) LgG

LgW (101)

BOOM ANGLE SENSOR

F5

E

5A

B10

(SbP)(145)

(LG) YV (231)

S/S SHIFT SELECTION S/W

(707) WL

CHARGE LAMP 20

YW (233)

S/S SHIFT S/W R

VOLTAGE RELAY WG (705)

RL1.25 (703)

15

B11

D04

A18

NR

CAB

D11

B C

[R5] x 6 (910 ~ 915)

MACHINE

B18

A03 LW (120) LO (123)

(013) (Lg)

B

E12 E04 E11 E03

SHIFT LEVER

F N R

WV (700)

5A

5A

F13

F14

F12

15A

(014) G1.25

LR (126) LBr (128)

(708) WP

(063) WR1.25

E24

B12

ECM (39)

5A

(064) G1.25

(062) BW

WL (707)

BATTERY (015) (065) WR1.25 F15 WR

R1 BR B AC R2 C

E05 E06 E17

12V

100

(060) (901) W [W5]

(012) BW

TO PARKING S/W

ACC’

B BR ACC R1 R2 C

MAIN MCU

NEUTRAL INDICATOR LAMP CENTRAL WARNING LAMP BRAKE OIL PRESS. WARNING LAMP E/G OIL PRESS. WARNING LAMP E/G COOLANT TEMP. WARNING LAMP T/M OIL TEMP. WARNING LAMP AIR CLEANER WARNING LAMP STEERING OIL PRESS. WARNING LAMP

F5

PARKING S/W

FUEL EFFICIENT MODE S/W

12 15A

27

5A

11 10A

26

5A

10 15A

25 20A

9

15A

24 10A

8

15A

23 10A

7

10A

22

6

15A

21 15A

5

30A

20 10A

4

15A

19 10A

3

10A

18

5A

2

15A

17

5A

ECM

1

20A

16

5A

36 30A

EFFICIENT LOADING SYSTEM S/W

This page illustrates the transmission is in neutral and key switch is in OFF position.

RIDE CONTROL S/W

3A

X

MCU FAILURE FUEL LEVEL GAUGE

(LgW) (102)

(404) (YBr) (LgSb) (112)

WARNING BUZZER

BZ

E

70ZV2-85ZV2-09708-06140 EU 1/2 70V2E92028

80ZV-2 EU 92-31 92 Drawing & Diagrams Electrical Connection Diagram (2/2) (S/N 9101~9200)

Electrical Connection Diagram (2/2) (S/N 9101~9200) ACC'

E

1.25

R (001)

RB (301)

LT

RY (302)

Br (003)

BrW (250)

(036) [G3]

F36

BUCKET LEVELER

10A

30A

EL

BrB (257)

LH

FOR OPT LAMP

BrR (272)

FOR OPT LAMP

E

39 43

REMOTE THROTTLE GR (742)

F7

OY (007)

C

10A

LICENSE LAMP (OPT)

(015) WR

F15

FLOAT

BS

FOR OPT LAMP

RB (303)

ACC'

32

THROTTLE OPENING SENSOR

ACC'

BrW (733)

22

OR (019)

M

HU EL

F6

RG (006)

LEFT HEADLIGHT (H)

M

FRONT WORKING LIGHT

5A F16

R (002)

R WIPER

REAR WORKING LIGHT REAR WORKING LIGHT

LB (138)

RL (330)

(521) RLg

BACK-UP LAMP

F20

CAB REAR WORKING LIGHT

E 31

(GL) (213)

DATA LINK CONNECTOR

3

ACC'

F22 5A

RG (331)

RIGHT BRAKE LAMP

E

CAB REAR WORKING LIGHT F26 (RL)

O (020)

(511)GyB (512)WR

G (010)

F10

BM

(510)Gy

(RB) (300) (NIGHT ILLUMINATION)

CD

NIGHT ILLUMINATION

ROOM LAMP

RIGHT TURN SIGNAL PL

G

S2H S2L

CAN

BLOW-OFF THERMISTOR(THF) (BY)

CANL0

WATER TEMP. SENSOR(THW) (Y) E

LEFT REAR TURN SIGNAL

18

LEFT TURN SIGNAL PL

27

(PL)

E

20

9 24

12

25

13

10 36

14

26

15

11 35

1 23 22

(329) GW

HORN RELAY

(BR) (BrW) (WY)

A/M SERVO MOTOR

M

(WR)

MAM

(OL) (GO)

RIGHT VENT SELECTION SERVO MOTOR

M

(Sb)

MV1

(WG) (LgY)

LEFT VENT SELECTION SERVO MOTOR

M

(BrB)

MV2

(WP) (VW)

DEF SELECTION SERVO MOTOR

M

(YB)

MV3

(BG) (PB)

INSIDE/OUTSIDE AIR SELECTION SERVO MOTOR

M

(V)

MRF SPHL

HORN

(328) (GL)

(PL)

3 16

INSOLATION SENSOR(SS)

(323) BP

2 21

34

(BrR)

CAB ACC'

5

OUTSIDE AIR SENSOR(THAM)

RESISTOR (326) (RBr)

(RB)

INSIDE AIR SENSOR(THI) (P)

GND

CANH0

S2S

B E L

(BrY)

(GW)

LEFT FRONT TURN SIGNAL

(327) RBr

FLASHER UNIT (HAZARD)

KEY

RIGHT FRONT TURN SIGNAL RIGHT REAR TURN SIGNAL

27

(BR)

MODM

3

19

(513)WB

FLASHER UNIT (WINKER) (324) (RO)

(LO)

EC

RADIO

15A

(320) P COMBINATION (325) S/W (321) RO RO TR (322) TB RBr TL (010)

28

6

5A (WBr) (022)

LEFT BRAKE LAMP

B

A

CAB WORKING LIGHT

(004) F4 R

15A

(GW) (212)

F G

13

CAB WORKING LIGHT

(520) RGy

TO REAR WORKING LIGHT

BACK-UP LAMP

TO MCU (B19)

F10

Sb (205)

E

(Y0) (748)

OG (016)

10A

B

TC

WIPER S/W

TO CAB REAR

BACK-UP ALARM

W (060)

SbY (209)

D

(YL) (747)

10 20

RLg(206) AI

B C

S2S

37 34

(060) W

S2L

47 BL (741)

OW (017)

TO FRONT WORKING LIGHT

RGy (520) WORKING LIGHT

B E L

46

ECM

RGy (312)

REAR WORKING LIGHT S/W

ACC'

25

S2H

5A

15A

TO MCU (A10)

24

DEC

(A25)

TO CAB

B PG (739) PW (740)

B S1 S2 WASH

PL

INC

GR (508)

WORKING LIGHT PL F17

(m)

CAN

S2S

RESISTOR

2

INC/DEC S/W

M (507) GY

WASHER MOTOR (506)

E

RLg (521) WORKING LIGHT

1.25

OL (018)

5A

FRONT WORKING LIGHT

S2L BrG (738)

WIPER MOTOR

F18

LEFT HEADLIGHT (L)

FRONT WORKING LIGHT S/W F2

M

RIGHT HEADLIGHT (H)

(E15)

S2H

DIAGNOSTIC S/W

5 3 INTER2 MITTENT 6 WIPER 4 RELAY

PB

(161) W

41 11

IDLE

1

WASHER MOTOR (500)

HIGH BEAM PL

RLg (311)

42

1

GyW (737)

LW (505)

(504) LY

RIGHT HEADLIGHT (L)

15A

E/G oil press.

EP

(752) GyR

23

GyY (736)

F WIPER

L (503)

(501) Y W (502) WIPER S/W S2 S3 WASH B Sint S1

TO RADIO

(310) (RGy)

(751) GyR

IDLE SW OFF IDLE

10A

1.25

F13

9

WIPER MOTOR

F19

RW (308)

(013) (Lg)

E

INSTRUMENT PANEL LIGHTING

LH

WARNING

49

YV (734)

(306) (305) UL RY RY

45

THROTTLE PEDAL

BLg (735)

(307) (RY)

(731) (BrB)

E

TAIL LAMP

RB (300)

STOP

(732) MAINTENANCE (BrW)

26

BG (744)

(730) (BrR)

44

21

GY (743)

AIR-SUS. COMPRESSOR

TAIL LAMP

COMBINATION HL S/W

2

J2

FOR OPT LAMP

(304) RW

1

3

BOOM KICKOUT

KO

LT

UL

4

B

LT

20A LH

F3

COMBINATION S/W

(086) [W3]

AIRCON UNIT

F1

E

J3

B

E

ACC'

CONVERTER

ACC'

HORN S/W

24V

F22

(WBr) (022)

5A

TO RADIO/ROOM LAMP TO MCU (E17)

F10

E

12V

CAB

4

E ACM

(WBr)(022)

(LgR) (BL) SPCD (LgW)

OW (017)

This page illustrates the transmission is in neutral and key switch is in OFF position.

CH

RY1.25

(010) G

F29

R2

20A ACC'

8

RY2 RY1.25

RG

10A

G2

3

2

4

BLOWER MOTOR

1 BLC

G1.25

ECC

YR

COMPRESSOR CLUTCH

EC

5A F28

M

BM

E F27

MB

1.25

1.25

RB

RW CD

MCD

M

1.25

Y

RCD

CONDENSER MOTOR CH

ACC'

E

70ZV2-85ZV2-09708-06140 EU 2/2 70V2E92022a

80ZV-2 EU 92-32 92 Drawing & Diagrams Electrical Connection Diagram (1/2) (S/N 9201~9350)

Electrical Connection Diagram (1/2) (S/N 9201~9350) ACC'

STARTER S/W B

BR ACC R1 R2

(086) W

C

PREHEAT OFF ON

(900) [W 5]

30A

12V

(060) (901) W [W 5 ]

START

F5

(065) WR1.25 F15 5A

G (010)

F10

Lx4 (005-A~005-D)

ACC'

WV (700)

E05

E06

E04

E17

WL (707)

LR (126)

STARTER

BATTERY RELAY

LBr (128) F N R

B

C

100

MAGNETIC S/W (702)

1

VOLTAGE RELAY

[R 5 ] (701)

[BW 5]

RL1.25 (703)

WG (705)

2 3 A

LW (120) LO (123) LG (122)

NR

LY (121) F13

(013) (Lg)

(705) (WG)

(EU:STANDARD)

(707) WL

F/R S/W

WL1.25

YO (232) YW (233)

R B

I 20

LY (121)

SHIFT DOWN S/W

PREHEAT LAMP

S/S SHIFT SELECTION S/W

(720) (BG)

YV (231) LB (230)

(YL) (124) YSb (125)

SHIFT HOLD S/W

LP (168)

DECLUTCH SET-UP

M

(EU:STANDARD)

SLIP CONTROL S/W

SECONDARY STEERING PUMP

LIFT KICKOUT SET-UP

(GW) (210) BrG (255) BW (271)

LOWER KICKOUT SET-UP

ACC'

E

TO PILOT LAMP, BACK-UP LAMP

REVERSAL FAN S/W

Lg (222)

AUTO FAN REVERSAL S/W

LgY (223)

(R) (106)

NEW ECO MODE SELECTION

P (107) PL (108)

SPECIFICATION SWITCH 2

E

F13 (013) (Lg) YO (176) (LgY) (167)

ON

PW (111)

AUTO/FULL AUTO SELECTION A/M SELECTION

PG (109) VG (157)

F23 CHANGE POINT SELECTION F34 CHANGE POINT SELECTION ODOMETER SELECTION

VY (158) PB (110)

SPEED SENSOR SELECTION METER SELECTION

DECLUTCH

DECLUTCH S/W

(162) PARKING SOL LgG

OFF ON

LLg (165)

(005-b) (L)

30

20A

5A

29

20A

13

5A

28

10A

12

15A

27

5A

11

10A

26

5A

10

15A

25

20A

9

15A

24

10A

8

15A

23

10A

7

10A

22

3A

15A

21

15A

5

30A

20

10A

4

15A

19

10A

3

10A

18

5A

2

15A

17

5A

1

20A

16

5A

GL (265)

F5

(GyW) (260) EP

E/G OIL PRESS S/W

Gy (750) BrY (181)

HYD. OIL LEVEL S/W

LgL (182)

AIR CLEANER CLOGGING S/W

EU 70ZV-2 OPT

LIFT KICKOUT RELAY

BS

LOWER KICKOUT RELAY

B04 A18

(EU:STANDARD)

SECONDARY STEERING MOTOR RELAY COIL

M

(146) LR

F SOLENOID VALVE

(148) LBr

R SOLENOID VALVE

(141) LY

1ST SPEED SOLENOID VALVE

D19

A02

(142) LG

2nd SPEED SOLENOID VALVE

D26

D06

A05

(143) LO

3rd SPEED SOLENOID VALVE B09

D07

LgBr (104)

BUZZER RELAY

BZ

(LO) A08

(144) LW

E34

4th SPEED SOLENOID VALVE

(YB) (401)

E/G COOLANT TEMP. GAUGE

D18 (LW) D24

D14

B14

D17

A07

D15

A04

E21

LP (149)

D SOLENOID VALVE

WR (170)

V (100)

B24

(UNUSED)

LLg (140)

E09(+5V)

S/S POTENTIOMETER

G (234)

(UNUSED)

D23

A01

D22 B06

BrR (251)

RIDE CONTROL SOLENOID VALVE EFFICIENT LOADING SYSTEM SELECTION SOLENOID VALVE

GB (267) LgL (225)

E01

(LgR) (166)

EU 70ZV-2 OPT

BRAKE OIL PRESS. SENSOR 1

REVERSAL FAN SOLENOID VALVE

C34

E02

(226) LgB

(221) LgB

FAN SPEED CONTROL SOLENOID VALVE

1A

C02 C03

(013) (Lg)

C31 D02 D25 D13 D16

D21 D01

A29 A14 A28 A19 A15 A16 A27 A12

C23

A20

C22 C33

A30

C16

A32

C11

A24

EFFICIENT LOADING SYSTEM OIL PRESS. SENSOR

GyB (266)

(EU:STANDARD)

SECONDARY STEERING PRESS. SENSOR

SbR (240)

(LgR) (130) (GR) (135) (GyB) (103) (LgY) (173) (Gy) (749) (GyG) (753) (GyL) (190) (LgW) (192) (O) (241) (GY) (169) (OSb) (211) (RL) (235) (LgB) (224)

AUTO SHIFT INDICATOR LAMP NEUTRAL INDICATOR LAMP CENTRAL WARNING LAMP BRAKE OIL PRESS. WARNING LAMP E/G OIL PRESS. WARNING LAMP E/G COOLANT TEMP. WARNING LAMP T/M OIL TEMP. WARNING LAMP AIR CLEANER WARNING LAMP

E/G COOLANT TEMP. SENSOR (FOR INSPECTION) T/M OIL TEMP. SENSOR

GyG (754) GyL (180) (G) (415)

SLIP CONTROL INDICATOR LAMP REVERSAL FAN INDICATOR LAMP S/S INDICATOR LAMP

GyO (220)

HYD. OIL TEMP. SENSOR

BY (114)

GROUND SPEED SENSOR

ECM(41)

W (161) Y (160)

E/G SPEED SENSOR

Y (159)

STEERING OIL PRESS. WARNING LAMP AUTO BRAKE INDICATOR LAMP (UNUSED) MCU PROGRAM REWRITE

E27 E26

24kl

TACHOGRAPH E/G SPEED

+5V FEW RESET RXD TXD MD2 GND

(100) V

A06 B08

C01

C27

B15 A34

B25 E31

24kl

TACHOGRAPH GROUND SPEED

A25

YSb (403) SbR (208) SbP (202) SbW (203)

HOUR METER DRIVE E/G IDLE SELECTION

AI

E/G TORQUE SELECTION

TC F5

E/G DROOP SELECTION 1 E/G DROOP SELECTION 2 (UNUSED)

ECM(3)

TRACTION CONTROL SELECTION

DC

SbLg (204) (GW) (212)

E32 A10

E23 E07

B19

(LB) (138) RL (245)

BACK-UP LAMP RELAY

RR

BRAKE RELAY

BR

E

E15 E16 B19

(70ZV2 S/N ~9205, 80ZV2 S/N ~9206,

(RG) (331)

TO BRAKE LAMP 85ZV2 S/N ~9214)

(RIN1) B16 B23 (OUT_FEW) E33 (OUT_RES) E25 (RXD0) B26 (TXD0) B17 (OUT_MD2)

(DOUT1) B22 (CANH0) E29 (CANL0) E20

GL (810) RS232C

GR (811) S2H S2L S2H S2L

E

(70ZV2 S/N 9206~, 80ZV2 S/N 9207~, 85ZV2 S/N 9215~)

E08

(E09) YB (115) YG (116) YL (117) YO (118) YBr (119)

(421) OB

13kl

A09

OUTSIDE AIR TEMP. SENSOR

F13 A21

EU 70ZV-2 OPT

S/S SOLENOID VALVE L 1A

C12

(420) OL

13kl

SbY (172) E22

S/S SOLENOID VALVE R 1A

(237) BL

E10

C26

SbY (171) E30

BRAKE OIL PRESS. SENSOR 2

(236) BR

METER OUTPUT (SPEEDOMETER)

DECLUTCH SENSOR

C13

C25

T/M OIL TEMP. GAUGE

(400) (WL)

E19

BOOM ANGLE SENSOR LgL (261)

(BrW) (402)

MAIN MCU

CAN

S2S

C06

EFFICIENT LOADING SYSTEM S/W

(LgW) (102)

(LgSb) (112)

WARNING BUZZER

This page illustrates the transmission is in neutral and key switch is in OFF position.

E

RIDE CONTROL S/W X

MCU FAILURE 6

GyW (200)

PARKING S/W

FUEL EFFICIENT MODE S/W H

MCU FAILURE RELAY

KO

D10

D09

(163) (SbW)

OFF

5A

D03

D08

GO (164)

14

D05

YGy (242)

C30

SPECIFICATION SWITCH 1

15

B13 D12

B07

NEW DECLUTCH SELECTION NEW ECO: Connection OLD ECO: Open

CAB

A03

A17

DOWNSHIFT S/W HEATER RELAY

M

NEUTRAL RELAY

X

OPT

15

100

L (273)

F5

ARMREST S/W

AIR HEATER

(012) BW

B10

NR

(LG) LG (122)

SHIFT UP S/W

E

ALTERNATOR

15

D04

LgW (101) BrB (258)

R

20

70A

B11

(SbP) (145)

(LY) F

CHARGE LAMP (707)

MACHINE

B18

D11

SHIFT LEVER

70A

(013) (Lg)

[R5 ]x6 (910 915)

B

E24

E/G DROOP SELECTION 1

E12 E11

B12 5A

F13

(014) G1.25

5A

(063) WR1.25

15A

F12 (012) BW

(064) G1.25 F14

E03 (062) BW

E

TO PARKING S/W

(L) (005-a)

E

(708) WP

(015) WR

(005) L2

30A

BATTERY

ECM(39)

R1 BR B AC R2 C

(L) (005-b)

12V

100

BZ

: shows OPT.

FUEL LEVEL GAUGE (404) (YBr)

ECM 36

30A

E

70-85ZV2-09708-06431 1/2

K80V292006

80ZV-2 EU 92-33 92 Drawing & Diagrams Electrical Connection Diagram (2/2) (S/N 9201~9350)

Electrical Connection Diagram (2/2) (S/N 9201~9350) ACC'

ACC'

E

E F3

F1

COMBINATION S/W

1.25

R (001)

LT

RB (301)

BrB (257)

Br (003)

KO

10A

BOOM KICKOUT

LT

20A

EL LH

RY (302)

BrR (272)

LH

FLOAT

B

BS

LICENSE LAMP

(086) [W 3 ]

FOR OPT LAMP

BrW (250)

30A

4

1

3

2

(015) WR

F15

39 43

REMOTE THROTTLE GR (742) GY (743)

F7

OY (007)

O (020)

KEY S2H

(307) (RY)

HIGH BEAM PL

(306) RY

RIGHT HEADLIGHT (H)

(310) (RGy)

CAB WORKING LIGHT CAB WORKING LIGHT CAB REAR WORKING LIGHT CAB REAR WORKING LIGHT

RGy (520)

INC/DEC S/W INC

REAR WORKING LIGHT REAR WORKING LIGHT

OR (019)

PW (740)

DEC

RR

10A

(70ZV2 S/N ~9205, 80ZV2 S/N ~9206, 85ZV2 S/N ~9214)

(501) Y W (502)

9 23

RG (331)

(B19)

BACK-UP LAMP (500) WASHER PB

1

WIPER S/W

BL (741)

70ZV2 : Open 80ZV2 : Connection 85ZV2 EXP : Open EU : Connection

3

INTER-

(A25)

(GW)(212)

(GL) (213)

27

25 12 10

INSIDE AIR SENSOR (TH I) (161) W

(751) GyR

36

13

26

BLOW-OFF THERMISTOR (TH F )

(E15)

(BY)

14 11

WATER TEMP. SENSOR (TH W) (Y)

E/G OIL PRESS. EP

34

15

35

OUTSIDE AIR SENSOR (TH AM)

(752) GyR

(PL)

1

3

23 16

22

M MAM

(OL) (GO)

MV1

(WG) (LgY)

MV2

(WP) (VW)

MV3

(BG) (PB)

INSIDE/OUTSIDE AIR SELECTION SERVO MOTOR

M

(V)

MRF

8

(LgR) (BL)

ACM

SPCD (LgW)

S2S

2

DEF SELECTION SERVO MOTOR

M

(YB)

SP HL 4

S2H CAN

LEFT VENT SELECTION SERVO MOTOR

M

(BrB)

INSOLATION SENSOR (SS)

11

RIGHT VENT SELECTION SERVO MOTOR

M

(Sb)

CH

RY1.25 (060) W

24 25

46

34

10

S2H

S2H

S2L

S2L

S2S

S2S

(YL) (747)

F29

C D

F28 10A

DATA LINK CONNECTOR

2

BLOWER MOTOR

1

G 1.25

RY 1.25

EC C

COMPRESSOR CLUTCH

EC 1.25

1.25

RB

RW CD

MCD

M

1.25

Y

R CD

CONDENSER MOTOR CH

A

E

3 4

BLC YR

RG

G2

M

BM

5A

E

G

13

31

F27

RY 2

R2

20A

B

F

(Y0) (748) (Y0

MB

ACC'

E

19

4

3

ECM

WIPER MOTOR

M (507)GY

MOTOR

R WIPER GR (508)

B S1 S2 WASH

M

FLASHER UNIT (WINKER)

WIPER S/W F16

(324) (RO)

RIGHT TURN SIGNAL PL

OG (016)

5A FOR EXP SPECIFICATION

(325) RO

RIGHT FRONT TURN SIGNAL

(327) RBr

F17

RIGHT REAR TURN SIGNAL

5A

LEFT FRONT TURN SIGNAL

F22

LEFT REAR TURN SIGNAL

OW (017)

(326)(RBr)

(510) Gy

(WBr) (022)

3A

NIGHT ILLUMINATION LEFT TURN SIGNAL PL

G (010)

F10

RADIO

(511) GyB (512) WR

(RB) (300)

(513) WB

B E L (323) BP FOR EU SPECIFICATION

(329) GW

F22

This page illustrates the transmission is in neutral and key switch is in OFF position.

3A

12V

(WBr) (022)

24V

(328)(GL)

: shows OPT.

DC-DC CONVERTER

HORN

HORN RELAY

24

A/M SERVO MOTOR

(WY) (WR)

4 RELAY

(506) WASHER PL

E

20

(BrW)

YW (505) 5

OL (018)

5A

(70ZV2 S/N 9206~, 80ZV2 S/N 9207~, 85ZV2 S/N 9215~)

SbR (216)

2 21

(PL) (BR)

WIPER

M F18

Sb (205)

3 27

5

1

20 SbY (209)

SbW (207) DC

2 MITTENT 6

MOTOR

RIGHT BRAKE LAMP LEFT BRAKE LAMP

49

37

F WIPER

S2 S3 B WASH S1 Sint

BACK-UP ALARM

FLASHER UNIT (HAZARD)

L

(504) LY

15A

(RB)

(GW) 45

47

TC

M (503)

TO REAR CAB WORKING LIGHT

RL(330)

(320) P COMBINATION S/W (321) RO TR (322) TB RBr TL (010) G

18

28

9

WIPER MOTOR F19

BACK-UP LAMP

B E L

(BrY)

(BR)

B PG (739)

(m)

RLg (206) AI

BR

NIGHT ILLUMINATION

F13

S2L

TO CAB WORKING LIGHT

RGy (312)

(004) R

WARNING

RESISTOR

R (002)

15A

(731) (BrB)

(013) (Lg)

22

1.25

RGy (520)

B

32

ROOM LAMP

RLg (521)

TO REAR WORKING LIGHT

FRONT WORKING LIGHT

TO MCU

STOP

DIAGNOSTIC S/W

TO FRONT WORKING LIGHT

FRONT WORKING LIGHT

REAR WORKING LIGHT S/W

W (060)

IDLE

BrG (738)

WORKING LIGHT PL

RLg(521)

F10

RESISTOR

G (010)

LEFT HEADLIGHT (L)

RLg (311)

F13

(730) (BrR)

26

42 GyY (736)

GyW (737)

RIGHT HEADLIGHT (L)

FRONT WORKING LIGHT S/W

ACC'

IDLE S/W OFF IDLE

CANL0

S2S

F10

(013) (Lg)

CD

(BrR)

S2L

LEFT HEADLIGHT (H)

15A

44

GND

S2H CAN

(308) RW

F4

YV (734)

CANH0

S2L

LH

F2

21

41 BrW (733)

MODM

HU

(305) UL RY

RG (006)

THROTTLE OPENING SENSOR

CIGARETTE LIGHTER

10A

EL COMBINATION S/W HL

F6

BG (744)

BLg (735)

15A

19

(P) F20

1.25

AIR-SUS COMPRESSER

C

10A

(LO)

THROTTLE PEDAL

TO RADIO/AIRCON UL

BM EC

TAIL LAMP

(304) RW

6

5A

E

TAIL LAMP

(RB) (300)

F26 (RL)

J2

MACHINE WIDTH LAMP

INSTRUMENT PANEL LIGHTING

E

ACC'

B

MACHINE WIDTH LAMP

RB (303)

(036) [G 3]

F36

BUCKET LEVELER

FOR OPT LAMP

E

J3

LT

AIRCON UNIT

B

HORN S/W

OW (017)

TO RADIO/ROOM LAMP TO MCU

F10

(010) G

E

(E17)

E

ACC'

E

CAB

70-85ZV2-09708-06431 2/2

K80V292007

80ZV-2 EU 92-34 92 Drawing & Diagrams Electrical Connection Diagram (1/2) (S/N 9351~)

Electrical Connection Diagram (1/2) (S/N 9351~)

( & 2

7 # /

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( 1& 2 1& 2 ( &

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5#/ 3 # # B 7 % 3

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5 // / #/ 5 // / #/

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5 5 # !5#% /$/ 3 5 // / #/

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7 % 7 % #! / !

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% @ / 5 #

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% ! / 5 # % ! / 5 # # / ! / 5 # / 5 #

3 $

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3 5# 3

3 5 3 % %

7 % 7 % / !

$ $% ( $ $ $ '

"

% /

% / 7 / / 7 /

#

/ /

3 / ! 3

This page illustrates the transmission is in neutral and key switch is in OFF position.

3

(

/75 7 ! / &

5#% / &

( /-&

?;< :A,

$ "

# / / & # & ! 7 / 5 #

$ (

/ # / &

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3

"

( &

9

4 ( 4 4

& 2

/75

/ / &

(

80ZV-2 EU 92-35 92 Drawing & Diagrams Electrical Connection Diagram (2/2) (S/N 9351~)

Electrical Connection Diagram (2/2) (S/N 9351~)

!

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80ZV-2 EU 92-36 92 Drawing & Diagrams Electrical Wiring Diagram (Cabin Air Conditioner)

Electrical Wiring Diagram (Cabin Air Conditioner) Control panel

Illumination power supply

24V(BR')

Fuse box 26

25

24

23

22

21

20

19

18

17

8

7

6

5

4

3

2

1

36

35

34

33

32

31

30

29

28

27

16

15

14

13

12

11

10

9

F26

RB A401 RL B408

1

RG B409

2

RB B417

3

R B418

4

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

B BR 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

RL RB LgR PL BrW BG A612 A401 A507 A101 A504 A505 A508

8

1

F27 5A F28

1

A2

10A

A3

F29

Insolation sensor (SS)

BR Y A509 A611

20A

1

2

1

2

B LgW B410 D104 1

2

1

2

(Black)

(Black)

(Black)

B5

B6

B7

A9

A4 1

Sb GO WR B304 B303 B302

LgY BrB RB A220 A210 A305

RB BrB LgY A801 B312 B311

3

1

BL BR PL LgR WP A308 A211 A303 A304 A311

A5

A6

1

1

P VW YB WY PB V A313 A218 A219 A207 A206 A205

WY V PB YB VW P B320 B319 B318 B317 B316 B314 1

A8

1

Y R RB RW A704 A703 B101 B102

B4

5

GW BY BrY LO Y RL B310 B309 B308 B307 A901 B315

1

Sb GO WR WP A404 A405 A406 A506

GW LO BrY BY B503 C601 C501 C903 B603 LgY BrB LgR WY V P RL VW YB PB C107 C106 D103 D201 C901 C203 C202 C407 C406 B807

B

BG BL B A505 A510 B103

BR RG RL YR PL WG OL BrW B A702 A701 B202 A508 A502 A503 A504 A509 A501 9

A6

10

WP WR GO Sb C201 B806 B907 B906

WY V YB PB 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

6

A7

A5

1 LO GW BY BrY A607 A608 A609 A610

B3

WP LgR PL BR BL B301 B313 B406 A902 B411 B402 B WG OL BrW BG B401 B405 B404 B403 B412

OL WG BG BrW B A301 A302 A309 A310 A212 5

10 3

B D101 1

1

BL BG C702 C405

Y RW RB R B704 B502 B504 C904

BR

PL

B801 B901 C103 C205

B702 B703 C701

BrW OL WG B805 B905 C105

C403 C502 C602 D202

YR B602

RL

B4

RG B604

Def selection servo motor (MV3) 9

B501 B601 D102

B803 B903 C101 C204 C401

B3

6

M

Air mixing servo motor (MAM)

Vent selection servo motor (MV1)

Front vent selection servo motor (MV2)

Inside/outside air selection servo motor (MRF) 7

6

5

4

WP VW YB C203 C202 C201

M

M

Connector between floor and rear

3

2

1

PL C204

BR C205

7

M

1

M

C3 3

1

Rear harness

C307 C306 C305 WP VW YB

Electric blower condenser

M

1

1 1 3

2

B B410

2

6

5

WY WR BrW B320 B302 B403

4

3

PL B406

7

RW B416

2

1

7

BR B402

6

5

4

3

GO Sb OL B303 B304 B404 1

2

PL B406

1

7

BR B402

7

6

5

4

3

LgY BrB WG B311 B312 B405

2

BR B402

B9

6

5

PB V BG B318 B319 B412

VW YB WP B316 B317 B301

1

3

B8

2

7

BR PL B402 B406

PL B406

7

1

C303 C301 PL BR

1

B1

Y B415

3

7

4

3

2

1

BR B402

PL B406

7

1

1

C1

C4

C2

High/low pressure SW SP HL

1

Inside air sensor (THI)

Compressor clutch (ECC)

Blower main relay (RLBM)

BLC

Water temperature sensor (THW)

2

Blow-off thermistor (THF)

Blower motor (MB)

SP CD 4

3

M

1

A1

1

A4

1 4

B2

3 2

YR

G B RY BL C801 C802 B411 B410

2

2

WR GO Sb A204 A208 A209

YR B407

BrR PL A316 A303

C7 BR GW B402 B309

BR BY B402 B308 1

2

C5

C6

C8

RL B408 B B401

1

2 G C704 D302

LgW B701

RY RL D301 B315

RY C703 1

2

LgR B313

R LO B418 B310

1

4

C9

D1

G C801

BR B402

RY C902

P B314 1

1

D2

D3

95ZVE72020

80ZV-2 EU 92-37 92 Drawing & Diagrams Electrical Circuit Diagram (Cabin Air Conditioner)

Electrical Circuit Diagram (Cabin Air Conditioner) SW K 1 1

10A

5A

13 FU B

FU A

20A

5

8

12

5

8

12

5A LIGHT SW SIGNAL

2

M RF

M V3

3

9 2RY 9 1.25RY

9 2RY

D1

MB

6

M

M CD

16

16

1.25RY

19

M FRE

7

M

RL BM

REC

6

SP CD

RL CD

Vz

RL EC

2

2

24

25 15 26 22

27

28 15 29 22

225W M V 3A

M

10

80W

1.25G

4

10

3 1

2 +B 6

2G 2G

10 4

Pt

2

DEF

2

GND

RL BM

FOOT

RL EC

RL CD

39

Vz

FU EC

Pt

FU CD

GND

1

1

13

19

16

19

18

24

39 5

M V 3B

25 35

34

SV 3

M RFA

26

28

29

22

23

11

S RF

M RFB

27

1

9 BLC B 3

RL CH BLC F

BAT

BLC

2 11

01

AC M

11 8

01

28 G

4

4 R CD

7

7 RL CH

14

12

13

3

16

01

14

17

18

20

22 B P

21

0.5B

1

01

15

14

17

18

20

TH AM

EC C

D2

TH W

TH I

27 15

4 23

21 30

GS

21

20

2

31 M AMB

24

32

33 M V 1B

S AM

M AMA

25

9

34

36 36

35 M V 1A

S V1

26

10

37 M V 2A

38 M V 2B

S V2

S SD

TH F

40W

Vz

Pt

37 15 38 22 GND

36

FACE

34 22 35 15

SHUT

33

GND

31 22 32 15

Pt

30

Vz

23

FOOT

15

FACE

15

Pt

15

Vz

15

03

Mhot

02

Mcool

01

GND

22 01

0.5B

SP HL

02

01

01 0.5B

M

M

0.5B

03

M AM

ACM

Air conditioner control amplifier

M AM

Air mixing servo motor

RL CH

Condenser HI relay

BAT

Battery

MB

Blower motor

RL EC

Compressor clutch relay

BLC

BLC (blower linear controller)

M CD

Condenser motor

S SD

Solar insolation sensor

D1

Diode 1

M RF

Inside/outside air servo motor

SPCD

Condenser speed change pressure switch

D2

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

M V1

M V2

Dotted lines indicate the wiring on the machine side.

Frost prevention thermistor

95ZVE72019

80ZV-2 EU 92-38 92 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 (86ºF)

18 (65ºF)

High load (under burning sun in spring or summer)

18.5 (65ºF) ~ 31.5 (90ºF)

Normal

30 (86ºF) ~0

High load

X

Automatic control

Normal

X

Frost cut

X

X

X

X

High pressure cut

X

X

X

Low pressure cut

X

X

High pressure error

X

<0

Normal

X

32 (90ºF)

Before engine is warmed Water temperature < 25ºC

X

Before/after engine is warmed Water temperature > 55ºC

X

35 (95ºF) ~0

18.5 (65ºF) ~ 31.5 (90ºF)

X

Automatic control

Set value

X

Mode just before OFF is displayed.

Nothing is displayed.

X 

Blow-off

Blower motor

BLC

Compressor (clutch)

Set value

or X

(Hi or Lo)

Automatic control

Blower manual

HI ~ Lo

X

OFF

X

FACE

X

X

X

X

OFF High air blow

(Lo)

High pressure < 1,226 kPa (12.5 kgf/cm2) (178 psi)

X

X

Evaporator frost prevention control

X

X

X

Condenser clogging, etc.

X

X

X

X

Gas leak, etc.

X

X

X

X

X

High/low pressure cut, etc.

X

X

X

X

X

Outside air < 0  Fixed to "foot" and compressor disabled

X

X

X

X

X

Prevention of cold air blow at low temperature

X

X

X

X

X

Set value: 32  High air blow

X

X

or X

X

X

X

Set value

X

(Hi or Lo) X

X

X

X

X

X

or X

FACE /FOOT

X

X

or X

FOOT

X

X

or X

FOOT /DEF

X

X

or X

DEF

X

X

or X

Automatic control

or X

or X

X

or X

X

Mode manual

Inside/ outside air manual

Outside air

X

Inside air

X

ON

X

(Hi or Lo)

Automatic control

(Hi or Lo) (Hi or Lo) (Hi or Lo) (Hi or Lo) (Hi or Lo) (Hi or Lo) (Hi or Lo)

A/C manual 

OFF

X

Set value: 18  High air blow High pressure > 1,520 kPa (15.5 kgf/cm2) (220 psi)

Hi ～ Lo OFF

Remarks

(Hi) X

X

Condenser motor

Outside air > 30  Fixed to "face" (Hi or Lo) Set value: 18  High air blow

or X

High air blow

X

Air mixing

Major functional parts Inside/ outside air

X

X

X

X

X

80ZV-2 EU 92-39 92 Drawing & Diagrams Electrical Equipment Layout

Electrical Equipment Layout Front chassis

Bucket leveler (L1)

Left turn signal

Head lamp (K0)

Head lamp (K3)

Right turn signal

Ground

Ground

Width lamp (opt) (S/N 9040~) Horn Boom angle sensor (L3)

(L2) (K7)

(K1/K2)

(K6) Front chassis ground (S/N 9102~) For ride control (option)(L4) To rear chassis

To rear chassis

To rear chassis

LH

RH

Top view (K1/K2) Green& Red

Green& Black

Black

Black

Red& Light green

Red& Black

(LH) Red& Brown (RH) Red& Orange

Detail of Front Lamp Wiring

Detail around Center Pin (S/N 9214~)

80ZV2-03256-00054 EU 80V2E92011a

80ZV-2 EU 92-40 92 Drawing & Diagrams Electrical Equipment Layout Front chassis

Combination lamp

Not used Head lamp (K5) Working lamp

(K3) To rear chassis (K1)

(K4)

(K2) Ride control (option) (L4)

(K6) (L2)

Bucket leveler (L1) Working lamp

Width lamp (option) Head lamp

Boom angle sensor (L3)

S/N 9040~

(K9) Combination lamp (K0)

Horn

(K8)

K80V2E92001a

80ZV-2 EU 92-41 92 Drawing & Diagrams Electrical Equipment Layout Rear chassis (S/N 9001~9101) (1/2) Efficient loading system solenoid valve (L5)

Fuel level sensor (J8)

(H3~H6)

To front

(H1)

To front

Hydraulic oil level switch (M4)

Efficient loading system oil pressure sensor (L6)

(H3~H6)

Floor harness To floor harness

(H1)

To floor harness

A-A

To floor ground To floor (H2)

A-A

(S/N ~9040)

Hydraulic oil temperature sensor (L7)

(S/N 9041~)

Floor harness A

To washer motor

A

Air conditioner condenser (L9)

Starter

Engine ground

(H7) Transmission solenoid valve (J1~J7)

Parking brake solenoid (M2)

Transmission oil temperature sensor (M5)

Ground

To floor

Washer motor (M8)

(H7)

Speed sensor (automatic gear) (M9)

Brake oil pressure sensor (M2/M3)

Ground

Air cleaner (L0)

ECM (P7) (50 poles)

Engine water temperature sensor (M6)

Air heater

ECM (P8) (4 poles)

Alternator ground Rear chassis ground

Rear chassis ground to engine body

Rear chassis ground battery ground

Fan speed control sol. valve (P1)

Reversal fan solenoid valve Alternator (M7)

Air conditioner compressor (P2)

To rear grill

LH

Voltage relay (S/N ~9038)

To combination lamp

To combination lamp To starter

Top view

RH

To fusible link

To rear chassis harness To battery To air heater

Engine relay wiring (screen board)

Engine relay wiring (beside starter)

80ZV2-03257-00136 EU 1/2

80V2E92012a

80ZV-2 EU 92-42 92 Drawing & Diagrams Electrical Equipment Layout Rear chassis (S/N 9001~9101) (2/2) Screen board 20 Red

BK & White

(Red tape) Fusible link (N1)

Fusible link (N2)

(S/N ~9038)

White & Green

85 Red

Starter

BK BK

15 BK Heater relay (N6)

2

White&Blue

To ground E G

White&Pink ( + Mark)

R

B

1

3

Voltage relay (N8)

B

4

White & Blue

Magnetic switch (N7)

( + Mark)

(S/N ~9008)

To ground 70A 30A

BK

70A 70A

15 BK BK & Green

5 BK & White

Battery relay (N3) Air heater

White & Green

Fuse (ECM) 5 White

5 White 20 BK

( + Mark)

White & Violet

5 Red x 6 2 Red

(P6)

5 White

100 Red ( + Mark)

Red & Blue 5 Red

BK

(N0)

2 poles (N5)

20

To rear chassis harness

Alternator wiring (S/N 9001~9039)

Alternator wiring (S/N 9040)

4 poles (N9) G

Diode unit (N4)

B

( + Mark) 20

R

To rear chassis harness

To rear chassis harness

To rear chassis harness

To rear chassis harness

B

( + Mark) 20 20

R

I 20

White&Blue White&Pink

White&Pink

Engine relay unit wiring

Rear working lamp

G

I

White&Blue To battery (+)

To rear chassis harness

To ground

Alternator wiring (S/N 9041~9042)

To rear chassis harness

To ground

Alternator wiring (S/N 9043~)

Rear working lamp

To back buzzer

4 85 Red F

1 5 Red R

3

85 BK

2

5 BK & White

To battery relay

Engine ground + Mark: Connected to red cable Mark: Connected to black cable To rear chassis harness

Radiator guard wiring

Rear working lamp connection

To rear chassis harness

Transmission solenoid wiring

Starter motor wiring 80ZV2-03257-00136 EU 2/2

80V2E92013

80ZV-2 EU 92-43 92 Drawing & Diagrams Electrical Equipment Layout Rear chassis (S/N 9101~) (1/2) To floor harness

Fuel level sensor (J8)

Efficient loading system solenoid valve (L5)

(S/N 9105~)

Hydraulic oil level switch (M4)

Efficient loading system oil pressure sensor (L6) To front

(H1)

To front Floor harness

To floor ground To floor

(H2)

Hydraulic oil temperature sensor (L7)

Speed sensor (automatic gear) (M9)

Floor harness Washer motor (M8)

To washer motor To floor

Air conditioner condenser (L9)

A

(H7)

A

Transmission oil temperature sensor (M5)

Ground Engine ground (S/N 9206~)

Parking brake solenonid (M1)

(H7) Transmission solenoid valve (J1~J7)

Brake oil pressure sensor (M2/M3)

Ground

Air cleaner (L0) Starter

ECM (P7) (50 poles)

Engine ground (S/N ~9205)

Air heater

Fan speed control solenoid valve (P1)

Reversal fan solenoid valve (opt)

Alternator ground Rear chassis ground

ECM (P8) (4 poles)

Alternator (M7)

Rear chassis ground battery ground

Rear chassis ground to engine body

Air conditioner compressor (P2)

To rear grill

LH

To combination lamp

To combination lamp

RH Top view

80ZV2-03257-01352 EU 1/2

K80V2E92012

80ZV-2 EU 92-44 92 Drawing & Diagrams Electrical Equipment Layout Rear chassis (S/N 9101~) (2/2) Screen board 20 Red 85 Red BK & White

(Red tape) Fusible link (N1)

Fusible link (N2)

Starter G

15 BK Heater relay (N6)

Magnetic switch (N7)

B

( + Mark) 20

R

White&Blue 70A 30A

BK

70A 70A

15 BK BK & Green

5 BK & White

Battery relay (N3) Air heater

5 White

5 White 20 BK

( + Mark)

White & Violet

5 Red x 6 2 Red

(P6)

5 White

100 Red ( + Mark)

5 Red

20 85 BK

White&Pink Red & Blue White & Green

Fuse (ECM)

85 Red

I

5 Red

To ground

To rear chassis harness

5 BK & White

To battery relay

To rear chassis harness

Engine ground

Starter motor wiring

Alternator wiring

BK

(N0)

2 poles (N5)

4 poles (N9)

Diode unit (N4) 4

To battery (+)

To rear chassis harness

To rear chassis harness

To rear chassis harness

F

Engine relay unit wiring

R 3

Rear working lamp

1

2

Rear working lamp

Transmission solenoid wiring To back buzzer

Magnetic switch

Fuse (ECM)(N0)

Fusible link To battery relay (N5/N9)

To fusible link To battery + Mark: Connected to red cable Mark: Connected to black cable To rear chassis harness

Radiator guard wiring

Rear working lamp connection (S/N ~9205)

Rear working lamp connection (S/N 9206~)

To air heater To rear chassis harness

Engine relay wiring (screen board)

To rear chassis harness

Engine relay wiring (beside starter) 80ZV2-03257-01352 EU 2/2

K80V2E92013

80ZV-2 EU 92-45 92 Drawing & Diagrams Electrical Equipment Layout Rear chassis (S/N 9040~9042) Alternator

(S/N 9001~9100)

(S/N 9043~) Alternator

(S/N 9101~)

(S/N ~9039) Alternator

(S/N 9040~)

To floor board

(S/N 9001~9008)

Starter motor (P0)

(S/N 9001~9038) Voltage relay (N8)

To engine

Alternator (M7)

(P0)

Cooling fan turn control solenoid

Starter motor

Magnetic S/W (N7)

To engine

Fusible link (N1/N2)

Fuse unit (N0)

(S/N 9001 ~9008) Magnetic S/W

Battery relay (N3)

Air cleaner (L0)

(L0)

Air cleaner

A/C condenser (L9)

(N5)

(N7) (N3) Battery relay

A/C condenser (L9)

Heater relay (N6)

Fuse unit

(N0)

(N2)

(N9)

Fusible link

(H3~H6)

(N1)

Diode unit

To floor board

(H3~H6)

(N6)

To floor board

(N4)

Diode unit

Heater relay

(N4) ELS oil pressure sensor (L6) (L5)

ELS solenoid (option) (L5)

To engine E/G water temperature sensor

(P6)

(L6) ELS oil pressure sensor

To engine

(L8)

ELS solenoid (option)

(M6)

(K1/K2)

To front chassis To front chassis (H7)

(H1)

(M5)

To floor board To floor board T/M oil temperature sensor (M5) Fuel level sensor (J8)

T/M oil temperature sensor

(J8)

Fuel level sensor K80V2E92010

80ZV-2 EU 92-46 92 Drawing & Diagrams Electrical Equipment Layout Rear chassis

Working lamp

T/M solenoid valve (J1~J7)

(H2)

Air compressor

To floor board Working lamp (R2) (S/N 9009~) (P2)

Back-up alarm

Cooling fan turn control solenoid

Combination lamp

(R4) License lamp

ECM (P7)

Air heater

(S/N 9009~)

(R3)

(P1) (R6)

ECM (P8)

Parking brake solenoid (M1) Resistor (P9)

Brake oil main press. S/W (M2/M3)

Rear chassis (RH)

Battery Combination lamp

(H1)

To floor board (R1)

(R7)

(P5/M0)

Washer motor (M8)

(S/N 9001~9008) (M4)

Hydraulic oil level switch Hydraulic oil temperature sensor (L7)

Speed sensor (for auto-shift) (M9)

Battery K80V2E92011

80ZV-2 EU 92-47 92 Drawing & Diagrams Electrical Equipment Layout Floor board

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80ZV-2 EU 92-48 92 Drawing & Diagrams Electrical Equipment Layout Control box (S/N 9001~9100) 70ZV-2: S/N 9034~ 80ZV-2: S/N 9039~ 85ZV-2: S/N 9043~

70ZV-2: S/N 9001~9033 80ZV-2: S/N 9001~9038 85ZV-2: S/N 9001~9042 To declutch set-up switch Lift kickout / lower kickout set-up switch

4 poles black connector

Declutch set-up switch To declutch set-up switch Lift kickout / lower kickout set-up switch

Remote kickout / lower kickout set-up switch

To floor harness

4 poles blue connector

4 poles white connector Flasher unit

6 poles white connector

Circuit protector (E3/E4)

Fuse unit (V4) Datalink connector (T4)

Fuse box (cab) Fuse box (main) 4 poles black connector Declutch set-up switch (T6) Remote kickout / lower kickout set-up switch (T7)

Buzzer (G6)

6 poles white connector Not used

Buzzer (G6)

4 poles white connector (T1) RS232C

4 poles white connector (T1) RS232C

3 poles white connector (T2) Diagnostic switch connection

3 poles white connector (T2) Diagnostic switch connection

MCU 2 poles blue connector (S2) Speedometer dividing ratio selection

Fuse box (cab) Fuse box (main)

Fuse unit (V4)

Switch wiring in control box Declutch set-up switch (T6) Remote kickout / lower kickout set-up switch (T7)

4 poles black connector Back signal (OPT)

MCU

Front

2 poles white connector (S3) Odometer selection

Front

2 poles white connector (S3) Odometer selection 2 poles black connector (S4) A/M selection

2 poles black connector (S4) A/M selection 3 poles blue connector (S1) Option

(Ground)

4 poles black connector

4 poles blue connector

(Red tape)

3 poles blue connector (S1) Option

(Ground) 4 poles blue connector Voltage relay

Starter switch (E1/E2) Fuse box

To downshift button (G1)

4 poles white connector Flasher unit

Data link connector (T4) To pilot valve (G2~G4)

6 poles white connector

Relay connection 4 poles white connector (G0) Diagnostic increment / decrement switch

Shift hold switch (G9)(opt)

Air-sus. (T5)

Power (option) directed to battery

(70ZV2: S/N 9034~) (80ZV2: S/N 9039~) (85ZV2: S/N 9043~)

Air conditioner unit (H9/H0) 70ZV2-85ZV2-03255-00340 EU 2/2

K85V2E92015

80ZV-2 EU 92-49 92 Drawing & Diagrams Electrical Equipment Layout Control box (S/N 9101~) To declutch set-up switch Lift kickout / lower kickout set-up switch 4 poles black connector Back signal (OPT)

4 poles black connector

4 poles blue connector Fuse unit (V4) Datalink connector (T4)

(Red tape)

Fuse box (cab) Fuse box (main)

4 poles blue connector Voltage relay

Buzzer (G6) 2 poles black connector (W3) E/G water temp. sensor (for inspection)

Declutch set-up switch (T6) Remote kickout / lower kickout set-up switch (T7)

Declutch set-up switch

Fuse unit (V3)

6 poles white connector (T3) (not used)

4 poles white connector Flasher unit

Remote kickout / lower kickout set-up switch

6 poles white connector

4 poles white connector (T1) RS232C

Relay connection (S/N ~9200)

3 poles white connector (T2) New ECO mode selection (S/N 9201~)

4 poles black connector (for brake relay) (70ZV2: S/N 9206~)(80ZV2: S/N 9207~) (85ZV2: S/N 9215~)

To floor harness

MCU 2 poles blue connector (W7) Auto/Full Auto selection

Front

Back signal (OPT)

2 poles green connector (W8) F23 change point selection 2 poles brown connector (W9) F34 change point selection 2 poles white connector (S3) Odometer selection 2 poles black connector (S4) A/M selection

3 poles blue connector (S1) Option

4 poles black connector

4 poles blue connector

(Ground)

Switch wiring in control box (Red tape)

Starter switch (E1/E2) Fuse box

4 poles blue connector Voltage relay To downshift button (G1) 4 poles white connector Flasher unit

Data link connector (T4) To pilot valve (G2~G4)

6 poles white connector 4 poles white connector (G0) Diagnostic increment / decrement switch

Shift hold switch (G9)(opt)

Air-sus. (T5)

Power (option) directed to battery

Relay connection (S/N 9201~)

Air conditioner unit (H9/H0) 70ZV2-85ZV2-03255-01810 EU 2/2

K85V2E92016

80ZV-2 EU 92-50 92 Drawing & Diagrams Electrical Equipment Layout Floor board

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80ZV-2 EU 92-51 92 Drawing & Diagrams Electrical Equipment Layout Floor board

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80ZV-2 EU 92-52 92 Drawing & Diagrams Electrical Equipment Layout (K-Lever)

Electrical Equipment Layout (K-Lever) Horn switch

1

Joy stick K-Lever switch

Fuse unit

2 1 3

4

8

1

5

6

2

3

Horn switch

Horn relay

F

2 4

L

1 2 3 4

Br

B

W

R

R

B R

(Black)

B

F

R

L

V

U

805 806 P P 809 810 P P

YV B

Downshift button

D

1A

3 7

Armrest switch

(Black)

W

800 P B

R

803 P

B

L

808 P

B

B B

804 P

3

R R G L

D

Y

W

808 P 802 807 P P

801 P

G L R R

YV B

G G GW GL

E0 B

2

YV 12

Standard harness

B

7

807 B R 801 P P 810 809 804 803 802 800 P P P P P P 1

B

806 P

SOL. B

805 P

B

SOL. A

Standard harness

Standard harness

6

1

Solenoid valve

1 6

BL BR G V

YO LB

YW

L BY

B

7

12

E0 Connector SPPC(L)

SPPC(R)

Horn switch Bucket control lever

Standard harness Solenoid valve

To K-Lever K-Lever switch

Hoist control lever

A-A (Fuse unit)

K-Lever Horn relay SOL.B(L) Connect 806 wire

E0 connector for F/R switch opt. or K-Lever connector

Downshift button

4

3

A

Horn relay

A

R R G L

Solenoid valve To horn switch To downshift button Ground SOL.A(R) Connect 805 wire

2

1

2 G L R R G G GW GL

Standard floor harness

To K-Lever

B-detail 1 1 K-Lever Solenoid valve

Control box detail Wire color: black, red, pink Armrest angle switch

Lever (potentiometer)

K-Lever detail

To solenoid valve

1. Cable assembly 2. Cable assembly 3. Cable assembly 4. Fuse unit Note Refer to the electrical connection diagram page 92-28 for the K-Lever electrical connection diagram.

1

For adjusting the speed of the K-Lever, refer to the K-Lever section on "MODM Parameter Setting Monitor" page 62-89.

To control box

80-90ZV2_03030-30032A 80V2U92021

80ZV-2 EU 92-53 92 Drawing & Diagrams Outline of MODM (Machine Operation Diagnostic Module) Operation

Outline of MODM (Machine Operation Diagnostic Module) Operation [

[ ] button

] button

(Press)

(Press) Machine fault log

Input/Output monitor Press and hold Press and hold

Press and hold Press and hold Engine fault log

Replacement monitor

Input signal Display window

[

(step back)] button

[

Fault log monitor

(step forward)] button

(Press)

Unit conversion Information monitor

Current output

Press and hold Language select.

Output signal (Press)

(Press)

(Press)

Outside air temperature

Specification setting monitor

Parameter setting monitor

Electric current output (FAN SOL)

Engine oil filter

Machine speed and engine speed

Fuel filter

Engine coolant temperature

Coolant filter

T/M oil temperature

T/C line filter

Hydraulic oil temperature

Hydraulic oil return filter

Odometer

Engine oil

Cycle

T/C and T/M oil

Hydraulic sys. press.

Axle gear oil

Voltage

Hydraulic oil

Hour meter

Group 2

Calendar

Output 6 group

Brake main pressure 2

Input 7 group

Replacement monitor screen

Information monitor screen

Specification setting monitor screen

Parameter setting monitor screen

Output signal screen

Current output screen

Input signal screen

Password input

Deceleration 1

Press and hold

Press and hold

All reset

Deceleration 2

Ride control 1

Output 1 group

Brake pedal pressure

Input 1 group

Ride control 2

Output 2 group

Steering pressure

Input 2 group

Boom angle

Group 1

Brake main pressure 1

80V2U92006

80ZV-2 EU 92-54 92 Drawing & Diagrams Outline of MODM (Machine Operation Diagnostic Module) Operation

& % %' & ( ) * ! *

# !

' + (S/N 9001~9101, 9103, 9104 only)

. ! + !

(

0 1 .

0 1 . # !

+ , -+

/

! 2 -

!

! " ! #

$%

' +

. ! +

!

80ZV-2 EU 92-55 92 Drawing & Diagrams Outline of MODM (Machine Operation Diagnostic Module) Operation

Information Monitor Hour Meter

Outside Temprature (Information Menu Initial Screen) 3 sec

Unit Conversion

Language Selection 2 sec Change No Change Active Error

Machine Speed / Engine Speed Unit Conversion

Active Error Odometer Press any button Replacing Time Comming

Cycle

Engine Coolant Temprature

Reset

Unit Conversion

Replace Pop Up

Reset Press any button

Hydraulic System Oil Pressure

Transmission Oil Temprature

Unit Conversion (Pressure)

Unit Conversion

Specification Setting Monitor

Reset

Voltage

Hydraulic Oil Temprature Unit Conversion

Replace Monitor

Reset

Press any button:

Hour Meter

Odometer / Trip Meter Unit Conversion

(

Reset

Cycle

,

,

or

)

Reset

Outside Temperature

80V2U92008

80ZV-2 EU 92-56 92 Drawing & Diagrams Outline of MODM (Machine Operation Diagnostic Module) Operation

Replacement Monitor Hydraulic Oil

Enigin Oil Filter Cartrige (Replace Monitor Initial Screen)

Engine Oil

Transmission & Torque Converter Oil

2 sec

2 sec Timer Reset

Timer Reset 2 sec Change No Change Fuel Filter

2 sec

2 sec Change No Change

2 sec Change No Change

Press any button

Timer Reset

2 sec Change No Change

Information Monitor

2 sec Change No Change

2 sec Engine Oil Filter

Timer Reset 2 sec Change No Change Hydraulic Return Filter

Replace Pop Up

2 sec

Hydraulic Oil Timer Reset

Transmission & Oil Filter

Press any button

Timer Reset

2 sec Change No Change 2 sec

Active Error

Replacing Time Comming

2 sec

Axle Gear Oil Timer Reset

Coolant Filter

Active Error

2 sec

Fault Log Monitor

Timer Reset Press any button:

Timer Reset

(

,

,

or

)

2 sec Change No Change Engine Oil

2 sec Timer Reset 2 sec Change No Change

Transmission & Torque Conveter Oil

80V2U92009

80ZV-2 EU 92-57 92 Drawing & Diagrams Outline of MODM (Machine Operation Diagnostic Module) Operation

Fault Log Monitor 2 sec Engine Fault Log

Machine Fault Log 2 sec

Active Fault Engine Fault Log Maximum

Machine Fault Log Maximum

Machine Fault Log 1 (Initial Screen for Machine Fault Log)

Engine Fault Log 1 (Initial Screen for Engine Fault Log)

2 sec

Active Fault Press any button Replacing Time Comming (Timer 0)

Clear Fault Log Replace Pop Up

2 seconds or more: Return after clear Return without clear Machine Fault Log 2

2 sec

Press any button Engine Fault Log 2

Clear Fault Log Replace Monitor

2 seconds or more: Return after clear Return without clear Machine Fault Log 3

2 sec

Engine Fault Log 3 Clear Fault Log Input/Output Monitor

2 seconds or more: Return after clear Return without clear Clear Fault Log Press any button (

Maximum Machine Fault Log

2 sec

,

,

or

)

Maximum Engine Fault Log Clear Fault Log

2 seconds or more: Return after clear Return without clear

Machine Fault Log 1

Engine Fault Log 1

Note When pressing the [ ] button to clear a fault code, password entry is required on the 80ZV-2 S/N 9201 and thereafter.

80V2U92010

80ZV-2 EU 92-58 92 Drawing & Diagrams Outline of MODM (Machine Operation Diagnostic Module) Operation

Input/Output Monitor 2 sec

2 sec Other Output

Input Signal 2 sec

Analogue Input 2 sec

Output Signal

2 sec Other Output

2 sec

2 sec

DI Port 7

DI Port 1 (Initial Screen for I/O Monitor)

2 sec

2 sec

Input Signal 2 sec

Active Error

DO Port 6

Brake main press 2

Active Error Press any button

Brake Pedal Output Oil Pressure

Fan Control Sol. Valve

DO Port 1

Replacing Time Comming Replace Pop Up Press any button Steering Oil Pressure

DI Port 2

DO Port 2

Fault Log Monitor

DI Port 3

Boom Angle

DO Port 3

Parameter Setting Monitor

Brake Main Pressure 1 Press any button (

Brake Main Pressure 2

DI Port 7

DI Port 1

Input Signal Screen

Brake Pedal Pressure

Input Sensor Screen

,

,

or

)

DO Port 6

DO Port 1

Output Signal Screen

Cooling Fan Current Output

80V2U92011

80ZV-2 EU 92-59 92 Drawing & Diagrams Outline of MODM (Machine Operation Diagnostic Module) Operation

Parameter Setting Monitor Power Control (Vni) Setting 2

Calendar

Deceleration Pervention Setting 1 (Initial Screen for Parameter Setting)

2 sec

Lower Kick Out Input/Output Monitor

Parameter Setting 2 sec Change No Change Deceleration Prevention Setting 2

2 sec

Lift Kick Out Specification Selection Monitor

Parameter Setting 2 sec Change No Change Ride Control Setting 1

2 sec

2 sec

Calendar Parameter Setting

Parameter Setting 2 sec Change No Change

2 sec Change No Change Ride Control Setting 2

2 sec Deceleration Prevention Setting 1

Parameter Setting 2 sec Change No Change Speed Meter Divide Setting 1

Parameter Setting

2 sec Parameter Setting 2 sec Change No Change

- SPEED METER DIV2 - TRACTION CONTROL F1 - TACHOGRAPH DIV1 - TRACTION CONTROL DSsc - TACHOGRAPH DIV2 - TRACTION CONTROL Isc - SECONDARY STEERING ON - TRACTION CONTROL ti - SECONDARY STEERING OFF - TRACTION CONTROL SCv - K-LEVER V1 - TRACTION CONTROL SCeg - K-LEVER V2 - TRACTION CONTROL SCi - K-LEVER Vmax - TRACTION CONTROL SCt - K-LEVER i1 - T/M CUT OFF IS - K-LEVER i2 - 2 STAGE DSon - K-LEVER imax - POWER CONTROL TWni

The cursor flashes in a 1-second cycle. (lights for 0.5 second and lights off for 0.5 second). The cursor moves rightward. (upper right

lower left

lower right

upper left)

The cursor skips (digits/column) which can not be changed. Adding 1 to the value where the cursor is (0

1

2

9

0)

Subtraciting 1 to the value where the cursor is. (9

8

7

0

9)

Power Control (Vni) Setting 2

80V2U92012a

80ZV-2 EU 92-60 92 Drawing & Diagrams Outline of MODM (Machine Operation Diagnostic Module) Operation

Specification Setting Monitor (1/2) Program No. (Initial Screen for Specification)

Password Input The cursor moves rightward. (upper right

lower left

lower right

upper left).

The cursor moves leftward. (upper left

Password

lower right

lower left

upper right).

Adding 1 to the value where the cursor is. (

1

2

9

0)

To confirm the change, press this button for 2 seconds or more. Password OK 2 sec

Press and hold

Press and hold

Kick down

F/R Shift

- Auto brake - Engine speed - Engine curve - Cooling fan - T/C oil temp. switch - E/G coolant temp. switch - E/G coolant temp. sensor - E/G oil press. switch - E/G oil press. sensor - Brake press. diff. switch

- Shift hold - Ride control - Secondary steering - K-Lever - Hydraulic press. increase - Traction control - Tachograph - Efficient loading sys. (ELS) - Lower kickout - Lift kickout

Brake oil level

Wheel type

All reset

Group 1

Group 2

Specification setting monitor screen

Group 2

Group 1

80V2U92013a

80ZV-2 EU 92-61 92 Drawing & Diagrams Outline of MODM (Machine Operation Diagnostic Module) Operation

Specification Setting Monitor (2/2) Program No. (Initial Screen for Specification)

Password Input The cursor moves rightward. (upper right

lower left

lower right

upper left).

The cursor moves leftward. (upper left

Password

lower right

lower left

upper right).

Adding 1 to the value where the cursor is. (

1

2

9

0)

To confirm the change, press this button for 2 seconds or more. Password OK 2 sec

All Setting Reset

All Setting Reset Press and hold

2 sec Change No Change Press and Press and hold hold Group 1 of Specification setting monitor screen

Press and hold

Parameter Setting Monitor

Group 2 of Specification setting monitor screen Specification Selection Press and hold

Specification item 24 2 sec

Specification Item 2

Specification item 23 2 sec

Specification Item 1 Specification Selection

2 sec Change No Change

2 sec

Specification Item 4

Specification Selection

Specification Selection

2 sec Change No Change - Ride control - Secondary steering - K-Lever - Hyd. press. increase

Specification Item 15

2 sec

- E/G coolant temp. switch - E/G coolant temp. sensor - E/G oil pressure switch - E/G oil pressure sensor

Specification Item 22 Specification Selection

Specification Item 24

2 sec Change No Change 2 sec

2 sec Specification Selection

Specification Item 23

Specification Selection

2 sec Change No Change 2 sec

All Setting Reset

Specification Selection

2 sec Change No Change Specification item 2

The cursor flashes in a 1 second cycle.

2 sec Change No Change - Engine speed - Engine curve - Cooling fan - T/C oil temp. switch

- Traction control - Tachograph - Efficient loading sys. (ELS) - Lower kickout

Not returning to password screen

2 sec Change No Change Press and hold

2 sec

Specification Item 3

Information Monitor

Specification Selection

2 sec Change No Change Specification item 1 80V2U92014a

80ZV-2 EU 92-62 92 Drawing & Diagrams MODM: Input/Output Monitor - Input/Output Signal Correspondence Table

MODM: Input/Output Monitor - Input/Output Signal Correspondence Table 0

1

2

3

4

5

6

7

INPUT 1

Shift lever F

Shift lever R

Shift lever 1

Shift lever 2

Shift lever 3

Shift lever A

Shift-up

Shift-down

INPUT 2

Transmission pressure switch

Kick-down

Declutch switch

Declutch setup

Parking switch

Engine speed sensor selection (ECM output/sensor output)

A/M selection (automatic/manual)

Meter selection (speedometer/ tachometer)

INPUT 3

Speedometer dividing ratio selection (large size tire/small size tire)

F/R switch F

F/R switch R

Spare input

F/R switch selection ON/OFF switch

Stick steering (K-Lever) arm rest switch

Shift hold switch

Traction control switch

INPUT 4

Engine mode selection (economical/normal)

Spare input

Pressure increase switch

Ride control switch

Kickout setup

Odometer selection (only forward/forward and backward)

Efficient loading system (ELS) switch

Lower kickout switch

INPUT 5

Lower kickout setup

Spare input

Clear fault log

Alternator neutral point voltage

Spare input

Opt 1

Hydraulic oil level switch

INPUT 6

Brake differential pressure switch

Brake oil level switch

Engine oil pressure switch

Engine coolant temperature switch

Transmission oil temperature switch

Transmission oil filter switch

Air cleaner clogging switch

Radiator water level switch

INPUT 7

Fuel level 3/4

Fuel level 1/2

Fuel level 1/4

Fuel level 1/8

Fuel level F

Reversal fan

Auto fan reversal

Error log recall

0

1

2

3

4

5

6

Opt 2

7

OUTPUT 1

1st speed solenoid valve

2nd speed solenoid valve

3rd speed solenoid valve

4th speed solenoid valve

F solenoid valve

R solenoid valve

H solenoid valve

Brake solenoid valve

OUTPUT 2

D solenoid valve

LU solenoid valve

Ride control solenoid valve

Efficient loading system (ELS) selection solenoid valve

Alternate idle relay

Pressure increase solenoid valve

Reversal fan solenoid valve

Brake lamp

OUTPUT 3

Selection switch indicator lamp

Reversal fan indicator lamp

Brake oil pressure warning lamp

Engine oil pressure warning lamp

Engine coolant temperature warning lamp

Transmission oil temperature warning lamp

Transmission oil filter warning lamp

Air cleaner warning lamp

OUTPUT 4

Back lamp

Secondary steering motor relay

Hour meter driving

Engine curve selection 1 (torque)

Neutral relay

MCU failure relay

Kickout coil

Lower kickout relay

OUTPUT 5

Slip control indicator lamp

Auto shift indicator lamp

Neural indicator lamp

Auto brake indicator lamp

Central warning lamp

Radiator water level warning lamp

Steering oil pressure warning lamp

Fuel level F

OUTPUT 6

Fuel level 3/4

Fuel level 1/2

Fuel level 1/4

Fuel level E

Slip control selection

Engine curve selection 3 (ISC)

Engine curve selection 1 (droop)

Buzzer

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