Kawasaki WHEEL LOADER 95ZV-2 SHOP MANUAL 93215-00481 - PDF DOWNLOAD by www.heydownloads.com

95ZV-2

93215-00481

SHOP MANUAL General Information Function & Structure

Printed in Japan (K) ( ヨーロッパ用 )

93215-00481

March 2011

SHOP MANUAL WHEEL LOADER

95ZV-2 General Information Standard Measurement Values for Performance Check Function & Structure Check & Adjustment Powered by CUMMINS QSX-15 Engine Serial No. 97C5-9001 and up

93215-00481 March 2011

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 95ZV-2 General Information .................................................................................................................................. 00-1 How to Use Manual ........................................................................................................................................... 00-2 Safety precautions ...................................................................................................................................... 00-2 Symbols ...................................................................................................................................................... 00-3 Outline ............................................................................................................................................................... 00-4 Layout of main components ........................................................................................................................ 00-4 Inspection and maintenance table .............................................................................................................. 00-6 Recommended lubricants ........................................................................................................................... 00-9 Coolant ..................................................................................................................................................... 00-10 Lubrication chart ........................................................................................................................................00-11 Weight of main components ..................................................................................................................... 00-12 Bolt tightening torque ................................................................................................................................ 00-13 Hose band tightening torque ..................................................................................................................... 00-17 Liquid gasket and screw lock agent .......................................................................................................... 00-18 Cautions regarding welding repair service ................................................................................................ 00-20

95ZV-2 Measurement for Performance Check ..................................................................................................... 03-1 Cautions on Safety ............................................................................................................................................ 03-2 Standard Measurement Values for Performance Check ................................................................................... 03-3

95ZV-2 Function & Structure Chassis Group ........................................................................................................ 12-1 Front Chassis .................................................................................................................................................... 12-2 Loading linkage ........................................................................................................................................... 12-2 Loading linkage pin ..................................................................................................................................... 12-4 Rear Chassis .................................................................................................................................................... 12-5 Fuel tank ..................................................................................................................................................... 12-5 Floor board mount ....................................................................................................................................... 12-6 Center Pin ......................................................................................................................................................... 12-7 Upper center pin ......................................................................................................................................... 12-7 Lower center pin ......................................................................................................................................... 12-7 Dust seal ..................................................................................................................................................... 12-8

95ZV-2 Check & Adjustment Chassis Group ........................................................................................................ 13-1 Linkage Pin ....................................................................................................................................................... 13-2 Liner ............................................................................................................................................................ 13-2

Center Pin ......................................................................................................................................................... 13-5 Adjusting shim ............................................................................................................................................. 13-5 Grease nipple installation direction ............................................................................................................. 13-5 Installing bearing outer ring ......................................................................................................................... 13-5

95ZV-2 Function & Structure Power Group ........................................................................................................... 22-1 Power Line ........................................................................................................................................................ 22-2 Engine / Transmission ....................................................................................................................................... 22-4 Engine / transmission mount ....................................................................................................................... 22-4 Radiator (S/N 9001~9150) ................................................................................................................................ 22-5 Radiator (S/N 9151~) ........................................................................................................................................ 22-6 Propeller Shaft .................................................................................................................................................. 22-8 Second propeller shaft assembly ................................................................................................................ 22-9 Third propeller shaft assembly .................................................................................................................. 22-10 Axle Assembly ................................................................................................................................................. 22-11 Axle Support .................................................................................................................................................... 22-12 Torque Proportioning Type Differential Gear (TPD) ........................................................................................ 22-14 Function of T.P.D ....................................................................................................................................... 22-17 Operation of T.P.D ..................................................................................................................................... 22-18 Limited Slip Differential (LSD) (option) ............................................................................................................ 22-19 LSD structure ............................................................................................................................................ 22-19 LSD function .............................................................................................................................................. 22-23 LSD operation ........................................................................................................................................... 22-23

95ZV-2 Check & Adjustment Power Group ........................................................................................................... 23-1 Engine ............................................................................................................................................................... 23-2 Measuring engine speed ............................................................................................................................. 23-2 Measuring engine oil pressure .................................................................................................................... 23-2 Propeller Shaft .................................................................................................................................................. 23-3 Propeller shaft phase .................................................................................................................................. 23-3 Second propeller shaft alignment ................................................................................................................ 23-3 Propeller shaft tightening torque ................................................................................................................. 23-4 Axle ................................................................................................................................................................... 23-5 Axle nut tightening procedure ..................................................................................................................... 23-5 Differential gear adjustment procedure ....................................................................................................... 23-6

95ZV-2 Function & Structure Torque Converter and Transmission Group ........................................................... 32-1 Torque Converter .............................................................................................................................................. 32-2 Torque converter structure .......................................................................................................................... 32-2 Power flow path .......................................................................................................................................... 32-2 Torque multiplication ................................................................................................................................... 32-2 Torque Converter (Lock-up) (Option) ................................................................................................................ 32-3 Lock-up clutch structure .............................................................................................................................. 32-4 Lock-up clutch function (only forward) ........................................................................................................ 32-4 Torque Converter Gear Pump ........................................................................................................................... 32-6 Gear pump specifications ........................................................................................................................... 32-6 Gear pump specifications ........................................................................................................................... 32-7 Transmission ..................................................................................................................................................... 32-8 Clutch combination ..................................................................................................................................... 32-8 Planetary gear ............................................................................................................................................. 32-8 Shift lever position ....................................................................................................................................... 32-8 Downshift button operation ......................................................................................................................... 32-8 Gear train and number of teeth ................................................................................................................... 32-9 Clutch Pack ..................................................................................................................................................... 32-12 Power Flow Path in the Transmission ............................................................................................................. 32-13 Forward 1st speed power flow path .......................................................................................................... 32-13 Forward 2nd speed power flow path ......................................................................................................... 32-14 Forward 3rd speed power flow path .......................................................................................................... 32-14 Forward 4th speed power flow path .......................................................................................................... 32-15 Reverse 1st speed power flow path .......................................................................................................... 32-16 Reverse 2nd speed power flow path ......................................................................................................... 32-16 Reverse 3rd speed power flow path ......................................................................................................... 32-17 Hydraulic System Diagram ............................................................................................................................. 32-18 Hydraulic Circuit Diagram ............................................................................................................................... 32-20 Oil Flow ........................................................................................................................................................... 32-22 Oil flow in the torque converter line ........................................................................................................... 32-22 Oil flow to the clutch .................................................................................................................................. 32-22 T/C and T/M Oil Circulation ............................................................................................................................. 32-23

Modulator Valve Unit ....................................................................................................................................... 32-25 Interior schematic (simple explanation) ..................................................................................................... 32-27 Modulator valve function ........................................................................................................................... 32-28 Modulator valve operation ......................................................................................................................... 32-30 Control Valve Assembly .................................................................................................................................. 32-32 Check valve ............................................................................................................................................... 32-34 Clutch solenoid valve assembly ................................................................................................................ 32-35 Clutch valve assembly .............................................................................................................................. 32-39

95ZV-2 Check & Adjustment Torque Converter and Transmission Group ........................................................... 33-1 Clutch Oil Pressure and Time Lag .................................................................................................................... 33-2 Measuring clutch oil pressure ..................................................................................................................... 33-2 Measuring clutch time lag ........................................................................................................................... 33-4

95ZV-2 Function & Structure Hydraulic Group ...................................................................................................... 42-1 Flushing Hydraulic Circuit ................................................................................................................................. 42-2 Purpose of flushing ..................................................................................................................................... 42-2 Cautions on Hydraulic Parts Replacement ....................................................................................................... 42-3 Hydraulic Circuit Symbols ................................................................................................................................. 42-4 Hydraulic lines ............................................................................................................................................. 42-4 Pumps & motors .......................................................................................................................................... 42-4 Cylinders ..................................................................................................................................................... 42-4 Operation methods ...................................................................................................................................... 42-5 Pressure control valve ................................................................................................................................. 42-5 Flow control valve ....................................................................................................................................... 42-5 Directional control valve .............................................................................................................................. 42-6 Check valve ................................................................................................................................................. 42-6 Miscellaneous hydraulic symbols ................................................................................................................ 42-7 Hydraulic System Operation ............................................................................................................................. 42-8 Hydraulic system operation outline ............................................................................................................. 42-8 Layout of Hydraulic Units ................................................................................................................................ 42-10

Hydraulic Tank .................................................................................................................................................42-11 Hydraulic Tank (S/N 9001~9300) ...............................................................................................................42-11 Hydraulic Tank (S/N 9301~) ...................................................................................................................... 42-13 Hydraulic tank specifications ..................................................................................................................... 42-15 Hydraulic oil level check ............................................................................................................................ 42-16 Hydraulic Pump ............................................................................................................................................... 42-17 Loading and pilot and brake pump/Steering pump ................................................................................... 42-17 Loading and pilot and brake pump/Steering pump specifications ............................................................. 42-17 Hydraulic pump principle ........................................................................................................................... 42-18 Hydraulic pump wear plate ....................................................................................................................... 42-19 Hydraulic pump bushing lubrication .......................................................................................................... 42-19 Hydraulic Cylinder ........................................................................................................................................... 42-20 Boom cylinder ........................................................................................................................................... 42-20 Bucket cylinder .......................................................................................................................................... 42-20 Steering cylinder ....................................................................................................................................... 42-21 Hydraulic cylinder specifications ............................................................................................................... 42-22 Loading System .............................................................................................................................................. 42-23 Reducing Valve (for Pilot Pressure) ................................................................................................................ 42-24 Pilot valve (S/N 9001~9250) ........................................................................................................................... 42-25 Pilot valve (S/N 9251~9255) ........................................................................................................................... 42-30 Pilot valve (S/N 9256~) ................................................................................................................................... 42-35 Multiple Control Valve (KML35A/2T003B) ....................................................................................................... 42-40 Multiple control valve specifications .......................................................................................................... 42-41 Multiple control valve main relief valve ..................................................................................................... 42-42 Multiple control valve overload relief valve (with make-up function) ......................................................... 42-44 Multiple control valve make-up valve ........................................................................................................ 42-45 Multiple control valve bucket spool ........................................................................................................... 42-46 Multiple control valve boom spool ............................................................................................................. 42-48 Adapter (Orifice) .............................................................................................................................................. 42-51 Ride Control (OPT) ......................................................................................................................................... 42-52 Ride control hydraulic circuit ..................................................................................................................... 42-52 Ride control operation ............................................................................................................................... 42-53 Ride control valve assembly (Reducing valve circuit) ............................................................................... 42-55 Ride control valve assembly (Accumulator circuit) ................................................................................... 42-58 Accumulator (for ride control) .................................................................................................................... 42-61

Steering System .............................................................................................................................................. 42-62 Orbitrol® ........................................................................................................................................................... 42-63 Orbitrol® structure ..................................................................................................................................... 42-63 Orbitrol® specifications .............................................................................................................................. 42-64 Orbitrol® operation .................................................................................................................................... 42-65 Orbitrol® feed-back mechanism operation ................................................................................................ 42-67 Steering speed and flow rate control ......................................................................................................... 42-68 Hydraulic pump oil amount and steering force .......................................................................................... 42-68 Orbit rotor operation principle .................................................................................................................... 42-69 Steering Valve (KVS32-A4.0/20) ..................................................................................................................... 42-70 Steering valve operation ........................................................................................................................... 42-72 Steering spool variable throttle .................................................................................................................. 42-74 Steering valve flow control spool ............................................................................................................... 42-75 Steering valve main relief valve ................................................................................................................ 42-76 Steering valve overload relief valve .......................................................................................................... 42-78 Steering pilot circuit and its operation ....................................................................................................... 42-80 Stop Valve ....................................................................................................................................................... 42-82 Stop valve function .................................................................................................................................... 42-83 Stop valve operation ................................................................................................................................. 42-83 Reducing Valve (for Orbitrol®) ......................................................................................................................... 42-84 Steering Line Filter .......................................................................................................................................... 42-85 K-Lever (OPT) ................................................................................................................................................. 42-86 Hydraulic circuit ......................................................................................................................................... 42-86 Hydraulic line diagram ............................................................................................................................... 42-87 Hydraulic line ............................................................................................................................................. 42-88 Solenoid valve mount ................................................................................................................................ 42-89 Solenoid valve assembly (1/2) .................................................................................................................. 42-90 Solenoid valve assembly (2/2) .................................................................................................................. 42-91 Efficient Loading System ................................................................................................................................. 42-92 Efficient loading system outline ................................................................................................................. 42-92 Mounting of the ELS valve ........................................................................................................................ 42-93 Mounting of the variable kickout sensor .................................................................................................... 42-94 Efficient loading system operation ............................................................................................................ 42-95 Fan Motor System ........................................................................................................................................... 42-96 Mounting of fan motor ............................................................................................................................... 42-96

Fan Motor Line ................................................................................................................................................ 42-97 Hydraulic circuit (fan motor normal rotation) ............................................................................................. 42-99 Proportional relief valve (S/N 9001~9150) .............................................................................................. 42-101 Proportional relief valve (S/N 9151~) ...................................................................................................... 42-103 Fan motor ................................................................................................................................................ 42-105 Reversing Fan Motor Line (OPT) .................................................................................................................. 42-108 Reversing fan motor function .................................................................................................................. 42-108 Hydraulic circuit (Reverse rotation) ..........................................................................................................42-112 Secondary Steering ........................................................................................................................................42-113 Secondary steering operation ..................................................................................................................42-113 Secondary steering motor and pump .......................................................................................................42-115

95ZV-2 Check & Adjustment Hydraulic Group .................................................................................................................................................... 43-1 Loading/Steering Circuit Relief Valve/Ride Control Circuit Reducing Valve (OPT) ........................................... 43-2 Loading circuit relief valve setting pressures .............................................................................................. 43-2 Ride control circuit reducing valve setting pressures (OPT) ....................................................................... 43-7 Steering circuit relief valve setting pressures .............................................................................................. 43-9 Hydraulic Cylinder ........................................................................................................................................... 43-14 Cylinder natural drift .................................................................................................................................. 43-14 Stop Valve ....................................................................................................................................................... 43-17 Stop valve adjustment procedure ............................................................................................................. 43-17

95ZV-2 Function & Structure Brake Group ........................................................................................................... 52-1 Brake System Outline ....................................................................................................................................... 52-2 Service brake .............................................................................................................................................. 52-2 Parking brake .............................................................................................................................................. 52-2 Adjustment of axle internal pressure ........................................................................................................... 52-2 Brake Units Layout ............................................................................................................................................ 52-3 Unloader Valve .................................................................................................................................................. 52-4 Unloader valve operation ............................................................................................................................ 52-6 Valve Unit .......................................................................................................................................................... 52-7 Accumulator ...................................................................................................................................................... 52-9

Brake Valve ..................................................................................................................................................... 52-10 Brake valve performance chart ................................................................................................................. 52-11 Brake valve outline .................................................................................................................................... 52-12 Service Brake .................................................................................................................................................. 52-14 Service brake operation ............................................................................................................................ 52-14 Service brake friction plate ........................................................................................................................ 52-15 Service brake steel plate ........................................................................................................................... 52-16 Service brake piston .................................................................................................................................. 52-17 Service brake pedal stroke adjusting mechanism (S/N 9001~9014) ........................................................ 52-18 Brake circuit air bleeding procedure .......................................................................................................... 52-20 Parking Brake .................................................................................................................................................. 52-22 Parking brake operation ............................................................................................................................ 52-25 Parking brake friction plate ........................................................................................................................ 52-27 Parking brake steel plate ........................................................................................................................... 52-27 Parking brake solenoid valve .................................................................................................................... 52-28 Parking Brake Manual Release ....................................................................................................................... 52-29 Brake Circuit Check Valve ............................................................................................................................... 52-31 Auto Brake ...................................................................................................................................................... 52-32 Auto brake circuit ...................................................................................................................................... 52-32 Auto brake operation set value ................................................................................................................. 52-32 Solenoid valve (for Autobrake circuit) ....................................................................................................... 52-33 Pressure Sensor (for stop lamp and declutch) ................................................................................................ 52-34 Pressure sensor (for declutch) .................................................................................................................. 52-34 Pressure sensor (for stop lamp) ................................................................................................................ 52-34

95ZV-2 Check & Adjustment Brake Group ............................................................................................................ 53-1 Brake Circuit Oil Pressure ................................................................................................................................. 53-2 Unloader valve setting pressure .................................................................................................................. 53-2 Brake valve oil pressure .............................................................................................................................. 53-4 Service Brake .................................................................................................................................................... 53-6 Service brake performance check ............................................................................................................... 53-6 Service brake friction plate wear measurement .......................................................................................... 53-7 Cautions on installing brake discs ............................................................................................................... 53-9 Parking Brake .................................................................................................................................................. 53-10 Parking brake performance check ............................................................................................................ 53-10

95ZV-2 Function & Structure Electrical Group ...................................................................................................... 62-1 How to Use Electrical Wiring Diagram .............................................................................................................. 62-2 Utilisation des schémas des câblages électriques (FRANÇAIS) ...................................................................... 62-3 Verwendung des elektrischen Schaltplans (DEUTSCH) ................................................................................... 62-4 Modalità di utilizzo dello schema dei collegamenti elettrici (ITALIANO) ............................................................ 62-5 Cómo utilizar un Diagrama de Alambrado Eléctrico (ESPAÑOL) ..................................................................... 62-6 Como Utilizar o Diagrama de Ligações Eléctricas (PORTUGUÊS) .................................................................. 62-7 Electrical Cable Color Codes ............................................................................................................................ 62-8 Electrical Circuit Symbols ................................................................................................................................. 62-9 Sensor Mount .................................................................................................................................................. 62-10 Fuse .................................................................................................................................................................62-11 Fuse box ....................................................................................................................................................62-11 Fusible link ................................................................................................................................................ 62-13 Engine Start Circuit ......................................................................................................................................... 62-14 Engine start circuit diagram ...................................................................................................................... 62-14 Neutral starter ........................................................................................................................................... 62-15 Starter switch ............................................................................................................................................ 62-16 Battery relay .............................................................................................................................................. 62-17 Alternator I terminal wire ........................................................................................................................... 62-18 Diode unit .................................................................................................................................................. 62-18 Neutral relay .............................................................................................................................................. 62-19 Magnetic switch ........................................................................................................................................ 62-20 Voltage relay ............................................................................................................................................. 62-21 Power Generating/Charging Circuit ................................................................................................................ 62-22 Alternator .................................................................................................................................................. 62-22 ECM (Engine Controller) ................................................................................................................................. 62-23 Function of ECM ....................................................................................................................................... 62-23 Connection diagram .................................................................................................................................. 62-23 Monitor lamp test ...................................................................................................................................... 62-24 Failure diagnosis ....................................................................................................................................... 62-25 Quantum fault code information ................................................................................................................ 62-28 Accelerator pedal ...................................................................................................................................... 62-34 Transmission Control Circuit and Monitor Circuit ............................................................................................ 62-37 Machine control unit (MCU) ...................................................................................................................... 62-37 Machine control unit (MCU) connection diagram ...................................................................................... 62-39

Machine control unit (MCU) function ......................................................................................................... 62-41 Adjustable declutch preset switch ............................................................................................................. 62-50 Monitoring system ..................................................................................................................................... 62-60 Operation monitor lamps ........................................................................................................................... 62-62 Instrument Panel and Switch .......................................................................................................................... 62-63 Instrument panel ....................................................................................................................................... 62-63 Instrument panel rear surface ................................................................................................................... 62-64 Gauge circuit ............................................................................................................................................. 62-65 Fuel gauge circuit ...................................................................................................................................... 62-67 MODM ............................................................................................................................................................. 62-68 MODM function ......................................................................................................................................... 62-68 Monitor Changeover .................................................................................................................................. 62-68 Information Monitor ................................................................................................................................... 62-71 Replacement Monitor ................................................................................................................................ 62-75 Fault Log Monitor ...................................................................................................................................... 62-81 Input/Output Monitor ................................................................................................................................. 62-88 Parameter Setting Monitor ........................................................................................................................ 62-92 Specification Setting Monitor ................................................................................................................... 62-101 Electrical Detent Circuit ................................................................................................................................. 62-107 Bucket leveler .......................................................................................................................................... 62-107 Detent solenoid ....................................................................................................................................... 62-108 Lift kickout & lower kickout ...................................................................................................................... 62-109 Sensor assy .............................................................................................................................................62-111 Detent solenoid ....................................................................................................................................... 62-113 Preset height adjustment ........................................................................................................................ 62-113 Diode ............................................................................................................................................................. 62-114 Diode check method ............................................................................................................................... 62-115 Caution for diode check method ............................................................................................................. 62-115 Surge voltage and surge suppression diodes ......................................................................................... 62-117

95ZV-2 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

95ZV-2 Check & Adjustment Operator Station Group .......................................................................................... 73-1 Air Conditioner .................................................................................................................................................. 73-2 Adjustment of lubricating oil quantity when components of air conditioner are replaced ............................ 73-2 Adjustment of air gap (between hub and rotor) in compressor magnetic clutch ......................................... 73-5 Compressor V-belt adjustment .................................................................................................................... 73-6 Parts to be replaced periodically ................................................................................................................. 73-7

95ZV-2 Drawing & Diagrams ................................................................................................................................ 92-1 Axle Assembly .................................................................................................................................................. 92-2 Torque Converter and Transmission ................................................................................................................. 92-3 Hydraulic & Brake Circuit (S/N 9001~9250) ...................................................................................................... 92-4 Hydraulic & Brake Circuit (S/N 9251~) .............................................................................................................. 92-5 Brake Circuit ..................................................................................................................................................... 92-6 Electrical Wiring Diagram (1/3) (S/N 9001~9048) ............................................................................................. 92-7 Electrical Wiring Diagram (2/3) (S/N 9001~9048) ............................................................................................. 92-8 Electrical Wiring Diagram (3/3) (S/N 9001~9048) ............................................................................................. 92-9 Electrical Wiring Diagram (1/3) (S/N 9049~9250) ........................................................................................... 92-10 Electrical Wiring Diagram (2/3) (S/N 9049~9250) ............................................................................................92-11 Electrical Wiring Diagram (3/3) (S/N 9049~9250) ........................................................................................... 92-12

Electrical Wiring Diagram (1/3) (S/N 9251~) ................................................................................................... 92-13 Electrical Wiring Diagram (2/3) (S/N 9251~) ................................................................................................... 92-14 Electrical Wiring Diagram (3/3) (S/N 9251~) ................................................................................................... 92-15 Electrical Wiring Diagram ................................................................................................................................ 92-16 Way of looking at connectors .................................................................................................................... 92-16 Electrical wiring diagram abbreviation chart .................................................................................................... 92-18 Electrical Wiring Diagram (CAB) ..................................................................................................................... 92-19 Electrical Connection Diagram (1/2) (S/N 9001~9250) ................................................................................... 92-22 Electrical Connection Diagram (2/2) (S/N 9001~9250) ................................................................................... 92-23 Electrical Connection Diagram (1/2) (S/N 9251~) ........................................................................................... 92-24 Electrical Connection Diagram (2/2) (S/N 9251~) ........................................................................................... 92-25 Electrical Wiring Diagram (Cabin Air Conditioner) .......................................................................................... 92-26 Electrical Circuit Diagram (Cabin Air Conditioner) .......................................................................................... 92-27 Equipment Operation Table (Cabin Air Conditioner) ....................................................................................... 92-28 Electrical Equipment Layout ............................................................................................................................ 92-29 Electrical Equipment Layout (K-Lever) ............................................................................................................ 92-40 Outline of MODM (Machine Operation Diagnostic Module) Operation ........................................................... 92-41 MODM: Input/Output Monitor - Input/Output Signal Correspondence Table ................................................... 92-50

00-1 95ZV-2 General Information

95ZV-2 General Information How to Use Manual ................................................. 00-2 Outline ..................................................................... 00-4

00-2 95ZV-2 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.

00-3 95ZV-2 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 92-18. 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

00-4 95ZV-2 General Information Outline

Outline Layout of main components 3

21 5

3 6

18 11 4 16

17 (S/N 9001 ~ 9150)

19 95V2E00002

00-5 95ZV-2 General Information Outline

(S/N 9151~)

19 K95V2U00001

1. Engine assembly (Cummins QSX-15) 2. Transmission/Torque converter assy 3. Hydraulic pump 4. Multiple (loader) control valve 5. Steering valve 6. Pilot valve (for loading) 7. Transmission control valve 8. Air cleaner 9. ELS valve 10. Muffler 11. Radiator 12. Front axle assembly 13. Rear axle assembly 14. 2nd propeller shaft 15. 3rd propeller shaft 16. Hydraulic oil cooler (air-to-oil type) 17. T/C oil cooler 18. Air charge cooler 19. Fuel cooler 20. Parking brake 21. Combination valve 22. Fan motor

00-6 95ZV-2 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

250

500

1000

1500

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

Inspect Automatic Belt Tensioner Pulley Replace Fuel Tank Breather Replace Fuel Filter Cartridge Replace Coolant Filter Cartridge (One year or 1500 hours whichever comes first.)

One year or 1500 hours

Clean Fuel Tank Check and Adjust Valve Lash Clearance Check Vibration Damper Check Engine Compression Pressure Check Injection Pressure Clean Crankcase Breather Tube Clean or Replace Air Cleaner Element Clean Radiator / Air cooler / Hydraulic oil cooler / Fuel cooler Fins Clean or Replace Air Cleaner Element Replace Coolant

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

2000

When Required

00-7 95ZV-2 General Information Outline : First time replacement or cleaning only Operating hours Section

Item for check 10

250

500

1000

1500

Check Transmission Oil Level Transmission & Torque Converter

Replace Transmission Oil Filter Cartridge Replace Transmission Oil Clean or Replace Transmission Breather Check Tire for Damage, Air and Tread Depth Greasing (Axle support) Check Tire Air Pressure Check Differential Gear Oil Check Planetary Gear Oil Greasing (Pillow block bearing unit)

Axle system

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

Every 12000 hours

Greasing (3rd Propeller Shaft)

Every 12000 hours

Check Steering Wheel Operation Steering system Greasing (Steering Cylinder) Clean Filter for Orbitrol® Check Service Brake Operation Check Parking Brake Operation Check Parking Brake Gear Oil Brake system

Replace Parking Brake Gear Oil Check Service Brake Disk Wear Check Brake Accumulator Clean Filter for Brake Line Check Hydraulic Oil Level Greasing Replace Hydraulic Oil Return Filter Replace Hydraulic Oil, Clean Filter

Loading system

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

2000

When Required

00-8 95ZV-2 General Information Outline : First time replacement or cleaning only Operating hours Section

Item for check 10

250

500

1000

1500

Adjust and Check Rear View Mirrors ROPS (Roll Over Protective Structure) Cab Check Seat Belt Restraint Greasing (Center Pin) Chassis Check Ride Control Accumulator (option) Replace Seat Belt and Tether Check Windshield Washer Fluid Check Bucket Stopper Check Monitor Panel Operation Check Horn Operation Electrical system

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

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

Walk-Around Inspection

Every 3 years or 6000 hours

2000

When Required

00-9 95ZV-2 General Information Outline

Recommended lubricants Refill capacity (Approximate)

Kind of Oil

Engine

49.2 liter

Engine oil (CH4 or CI4)

Transmission

70 liter

Engine oil (CD) or ATF

Hydraulic tank

∗1

∗3

150 liter

Hydraulic oil

Differential & Planetary

Front: 100 liter Rear: 100 liter

Engine oil (CD)

Parking brake

3 liter

Fuel tank

465 liter

Ambient Temperature (ºC) -30

-20

-10

Change Interval (Hours)

SAE10W-30

∗2

SAE15W-40

500

SAE10W

1,000

ATF ISO VG32 ISO VG46

Engine oil SAE40 or SAE50

2,000

ASTM D975 No.1

Diesel fuel

ASTM D975 No.2

daily

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

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

Transmission

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

Hydraulic System

Use industrial-type hydraulic oils which are certified by suppliers having anti-wear, anti-foam, anti-rust and anti-oxidation additive properties for heavy duty use. Use of the wrong viscosity of oil can cause improper operation of hydraulic functions or premature pump failure. ∗3. In a case that fire-resistant fluid is used in the hydraulic circuit, replace hydraulic pumps every 6,000 hrs operation. Warning: When operating in cold ambient temperatures (0 ºF/15 ºC or colder) ISO VG32 or equivalent hydraulic oil use is recommended. When changing over to cold climate hydraulic oil (i.e. from thicker ISO VG46 to thinner ISO VG32), brake system bleeding at each wheel hub will be required to remove thicker oil and prevent delayed reaction of brake application and release.

Differential & 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.

00-10 95ZV-2 General Information Outline

Diesel Fuel

Requirements for diesel fuel

Specifications

Grade No. 1-D

Grade No. 2-D

Flash Point ºC.

min.

Water and Sediment % vol.

max.

0.05

Distillation Temperature ºC. 90% vol. recovered

max.

288

338

min.

1.3

1.9

max.

2.4

4.1

Kinematic Viscosity mm2/s at 40ºC Ash % mass

max.

0.01

Sulfur % mass

max.

0.50

Cetane Number

min.

Carbon residue on 10% distillation residue % mass

max.

0.15

0.35

Coolant Coolant specification

Recommended mixture of antifreeze

The machine is originally filled with Long Life Coolant (non-Amin type ethylene glycol) which need not be replaced for the first two years or 3,000 hours.

(S/N 9001~9150) Expected minimum ambient temperature

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

-20ºC (-4ºF)

-15ºC (5ºF)

Pure Water

Do not use Amin type Long Life Coolant in cooling system. It may cause a corrosion against radiator or heater core.

(liter) (gal)

54.0 (14.3)

59.8 (15.8)

65.5 (17.3)

71.3 (18.8)

77.0 (20.3)

Antifreeze

(liter) (gal)

61.0 (16.1)

55.2 (14.6)

49.5 (13.1)

43.7 (11.6)

38.0 (10.1)

If standard antifreeze (not Long Life Coolant) is used for the replacement, it should be replaced every six months.

(S/N 9151~) -35ºC -30ºC -25ºC (-31ºF) (-22ºF) (-13ºF)

-20ºC (-4ºF)

-15ºC (5ºF)

Mixture Ratio (%)

Expected minimum ambient temperature Pure Water

(liter) (gal)

47.0 (12.4)

52.0 (13.7)

57.0 (15.0)

62.0 (16.4)

67.0 (17.7)

Antifreeze

(liter) (gal)

53.0 (14.0)

48.0 (12.7)

43.0 (11.4)

38.0 (10.0)

33.0 (8.7)

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.

00-11 95ZV-2 General Information Outline

Lubrication chart 2ND PROPELLER SHAFT

DIFF & GEAR BOX

DIFF

HYDRAULIC TANK

TRANSMISSION

EVERY 12000Hr

EVERY 2000Hr

DIFF

DIFF & GEAR BOX

EVERY 1000Hr ENGINE OIL PAN

LINK SYSTEM

EVERY 500Hr

PILLOW UNIT GO

EVERY 250Hr

EVERY 50Hr

G TO

G STEERING CYL.

BUCKET

EVERY DAY

G AXLE SUPPORT

CENTER PIN

2ND PROPELLER SHAFT

3RD PROPELLER SHAFT 95ZV2-44794-23580 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

00-12 95ZV-2 General Information Outline

Weight of main components

Part name

Approx. weight (kg)

Approx. weight (lb)

Bucket

2,750

6,050

Item Unit name

Boom

2,130

4,690

"Z" -Lever

275/pc

605/pc

Link (Bucket to Lever)

60/pc

130/pc

175

385

Screen board Engine room

Chassis

Roof

100

Radiator guard

195

430

Access panel

35/pc

80/pc

275

605

Excluding oil

Fuel tank

230

510

Excluding fuel

Floor board

285

630

Cab (ROPS)

600

1,320

Left side

155

With handrail

Right side

110

With handrail

Front chassis

2,400

5,280

Rear chassis

2,550

5,610

Counter weight

1,920

4,230

Engine

1,600

3,520

Other

Excluding oil

Radiator assembly

570

1,260

Excluding water and oil

Transmission

1,570

3,460

Excluding oil

Second propeller shaft

200

Third propeller shaft

Front axle assembly

2,000

4,400

Excluding tires and oil

Rear axle assembly

2,030

4,470

Excluding tires and oil (Including axle support)

Front

550

1,210

Rear

370

820

Multiple control valve

200

Differential

Hydraulic system

GSC bucket

Hydraulic tank

Deck

Power line

Remarks

Pilot valve

Steering valve

110

Orbitrol®

Gear pump

35/pc

80/pc

Double pump x 2pcs

Fan motor

110

Boom cylinder

280/pc

620/pc

Excluding oil

Bucket cylinder

135/pc

300/pc

Excluding oil

Steering cylinder

50/pc

110/pc

Excluding oil

Tire

830/pc

1,830/pc

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

Battery

50/pc

110/pc

00-13 95ZV-2 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

(F) 1.25

132

(F) 1.25

142

M10

M12

M14

M16

M18

M20

M22

M24

M27

M30

Unified thread

Bolt strength

Nominal dimension

8.8 (8T)

10.9 (11T)

142

206

(F) 1.5

152

221

216

314

(F) 1.5

226

330

299

436

(F) 1.5

324

476

417

608

(F) 1.5

451

662

559

814

(F) 1.5

598

878

721

1,030

(F) 2.0

770

1,128

1,030

1,520

(F) 2.0

1,128

1,618

1,422

2,109

(F) 2.0

1,569

2,256

1,912

2,844

M33

(F) 2.0

2,059

3,040

5/16

18 UNC

3/8

16 UNC

7/16

14 UNC

103

1/2

13 UNC

103

147

9/16

12 UNC

147

216

5/8

11 UNC

201

294

3/4

10 UNC

358

525

7/8

9 UNC

554

809

8 UNC

868

1,275

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

00-14 95ZV-2 General Information Outline

(kgf-m) Bolt size Type

Metric thread

Nominal diameter

Pitch

M10

M12

M14

M16

M18

M20

M22

M24

M27

M30

Unified thread

Bolt strength

Nominal dimension

M33

5/16

8.8 (8T)

10.9 (11T)

2.7

3.9

5.4

7.8

(F) 1.25

5.6

8.2

9.2

13.5

(F) 1.25

9.8

14.5

21.0

(F) 1.5

15.5

22.5

22.0

32.0

(F) 1.5

23.0

33.7

30.5

44.5

(F) 1.5

33.0

48.5

42.5

62.0

(F) 1.5

46.0

67.5

57.0

83.0

(F) 1.5

61.0

89.5

73.5

105.0

(F) 2.0

78.5

115.0

105.0

155.0

(F) 2.0

115.0

165.0

145.0

215.0

(F) 2.0

160.0

230.0

195.0

290.0

(F) 2.0

210.0

310.0

18 UNC

2.5

3.6

3/8

16 UNC

4.5

6.6

7/16

14 UNC

7.2

10.5

1/2

13 UNC

10.5

15.0

9/16

12 UNC

15.0

22.0

5/8

11 UNC

20.5

30.0

3/4

10 UNC

36.5

53.5

7/8

9 UNC

56.5

82.5

8 UNC

88.5

130.0

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

00-15 95ZV-2 General Information Outline

(lb-ft) Bolt size Type

Metric thread

Nominal diameter

Pitch

8.8 (8T)

10.9 (11T)

19.5

(F) 1.25

105

150

(F) 1.5

110

160

M10

M12

M14

M16

M18

M20

M22

M24

M27

M30

Unified thread

Bolt strength

Nominal dimension

160

230

(F) 1.5

165

245

220

320

(F) 1.5

235

350

305

450

(F) 1.5

330

490

410

600

(F) 1.5

440

650

530

760

(F) 2.0

565

830

760

1,120

(F) 2.0

830

1,190

1,050

1,550

(F) 2.0

1,160

1,660

1,410

2,100

M33

(F) 2.0

1,520

2,240

5/16

18 UNC

18.0

3/8

16 UNC

7/16

14 UNC

1/2

13 UNC

105

9/16

12 UNC

110

160

5/8

11 UNC

150

215

3/4

10 UNC

265

385

7/8

9 UNC

410

595

8 UNC

640

940

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

00-16 95ZV-2 General Information Outline

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

Metric thread

Bolt strength

Nominal dimension

Pitch

0.8

1.25

8.8 (8T)

M10

1.5

M12

1.75

M16

231

M20

2.5

441

M24

765 (kgf-m)

Bolt size Type

Metric thread

Bolt strength

Nominal dimension

Pitch

0.8

0.7

1.2

8.8 (8T)

1.25

2.9

M10

1.5

5.4

M12

1.75

9.6

M16

23.5

M20

2.5

45.0

M24

78.0 (lb-ft)

Bolt size Type

Metric thread

Bolt strength

Nominal dimension

Pitch

8.8 (8T)

0.8

5.0

8.6

1.25

20.9

M10

1.5

38.9

M12

1.75

69.1

M16

169.2

M20

2.5

324.0

M24

561.6

00-17 95ZV-2 General Information Outline

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

Hose band

Tightening torque (N-m)

Tightening torque (kgf-cm)

Tightening torque (lb-ft)

69002-02200

1.6

1.2

2.9

Hose band

Tightening torque (N-m)

Tightening torque (kgf-cm)

Tightening torque (lb-ft)

69002-02200

1.6

1.2

2.9

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

16.5

7.9

18.5

9.5

20.5

12.7

24.5

15.9

29.9

19.0

30.0

25.4

38.0

69002-04400

31.8

45.8

69002-05200

38.1

52.1

69002-05700

50.8

67.8

69002-07100

60.5

76.0

69002-08200

75.5

93.0

69002-09500

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

16.5

18.5

20.5

22.0

24.5

26.0

29.0

30.5

32.0

34.0

39.5

41.5

46.0

48.0

54.0

70.5

73.0

69002-02700 69002-03100

69002-02300 69002-02700

69002-03100

69002-03800

69002-04400

69002-05200 69002-05700 69002-07600

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

Fix the band avoiding the beading.

2~3 mm (1/8 in) Pipe

Hose Hose band

K50V200002

00-18 95ZV-2 General Information Outline

Liquid gasket and screw lock agent

Cautions regarding reassembly

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:

Completely remove the hardened lock agent from the screw and the threaded hole before reassembling the screw.

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.

To reassemble a 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)

00-19 95ZV-2 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

65ZV00004

65ZV00002

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.

00-20 95ZV-2 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.

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

00-21 95ZV-2 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.

00-22 95ZV-2 General Information

MEMO

03-1 95ZV-2 Measurement for Performance Check

95ZV-2 Measurement for Performance Check Cautions on Safety .................................................. 03-2 Standard Measurement Values for Performance Check ........................................................................... 03-3

03-2 95ZV-2 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.

03-3 95ZV-2 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 9001~9250)

Minimum no-load speed, Low Idle (LI)

850±50

Maximum no-load speed, High Idle (HI)

2,040±50

Maximum speed in torque converter stall mode

2,000±100

1,800±100

Maximum speed in multiple control valve relief mode

2,010±100

1,670±100

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

1,460 +150 - 100

1,250 +150 - 100

Minimum no-load speed, Low Idle (LI) Engine speed (min-1) (rpm) (S/N 9251~)

850±50

Maximum no-load speed, High Idle (HI)

2,040±50

1,800±50

Maximum speed in torque converter stall mode

2,020±100

1,800±100

Maximum speed in multiple control valve relief mode

2,010±100

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

1,530 +150 - 100

1,300 +150 - 100

Main pressure MPa (kgf/cm2) (psi) Transmission

Fuel efficient mode

Normal

Engine speed

Remarks

725 in hibernate mode

Idling (LI)

2.4±0.2 (24±2) (341±28)

Maximum (HI)

3.0±0.2 (31±2) (441±28) 1st speed

2.2±0.2 (22±2) (313±28)

Except 1st speed

2.4±0.2 (24±2) (341±28)

1st speed

2.5±0.2 (25±2) (356±28)

Except 1st speed

2.9±0.2 (30±2) (427±28)

Idling (LI)

Clutch pressure MPa (kgf/cm2) (psi) Maximum (HI) Clutch time lag (sec)

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

0.3±0.1

Before wheels move

03-4 95ZV-2 Measurement for Performance Check Standard Measurement Values for Performance Check

Standard measurement values for performance check

Item Measurement item

System

Hydraulic line

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

3 (1/8) or less

Bucket cylinder

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

Engine speed

Full steering time (sec)

Engine speed

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

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

Fuel efficient mode

Boom cylinder

Boom rising time (no load) (sec)

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

Normal

Remarks

23±3.0 -1

1,500 min (rpm)

10.5±1.0

Maximum (HI)

6.7±0.5

Idling (LI)

5.0±0.5

1,500 min-1 (rpm)

2.4±0.3

Full accelerated engine speed

2.4±0.5

Loading line main relief pressure (HI)

20.6±0.5 (210±5) (2,986±71)

Loading line overload relief pressure (LI)

23.5±0.5 (240±5) (3,413±71)

Steering line main relief pressure (HI)

20.6±0.5 (210±5) (2,986±71)

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)

910 +75 - 200

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

1,300 +100 - 50

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

750 +50 - 200

Run engine at lowest possible speed while setting

03-5 95ZV-2 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

Engine speed

Maximum (HI)

Fuel efficient mode

Normal

Remarks

Performance of service brake

Brake

Performance of parking brake

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

Slowly increase the engine speed, and check that the machine does not move at the Before brake check, be maximum engine speed. sure to disconnect the cable connector of parking brake solenoid valve.

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

Accumulator charge time (sec)

Engine speed (LI)

Number of brake pedal applications

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

Declutch engagement (cm) (in)

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

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

3.9±0.5 (40±5) (569±71) 16

at least 10 times

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

15 (6) or less

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

03-6 95ZV-2 Measurement for Performance Check

MEMO

12-1 95ZV-2 Function & Structure Chassis Group

95ZV-2 Function & Structure Chassis Group Front Chassis .......................................................... 12-2 Rear Chassis........................................................... 12-5 Center Pin ............................................................... 12-7

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

Front Chassis Loading linkage

6 95ZV12001

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

12-3 95ZV-2 Function & Structure Chassis Group Front Chassis

4,490 mm (14’8 13/16”)

Even contact both sides

45 º

40 º 270 mm Hinge pin height at (10.6 in) bucket on ground

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

Typical bucket dump stopper clearance (Contact attachment supplier for details on non-standard attachments) To increase clearance increase height of #9 To reduce clearance decrease height of #9 95V2U12002a

12-4 95ZV-2 Function & Structure Chassis Group Front Chassis

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

2. Boom - Lever

3. Boom - Boom cylinder

4. Front chassis - Boom

5. Bucket - Rod

6. Lever - Rod

7. Lever - Bucket cylinder

8. Bucket cylinder Front chassis

9. Boom cylinder Front chassis

10. Front chassis Steering cylinder

11. Steering cylinder Rear chassis

5 10

K95ZV12003

12-5 95ZV-2 Function & Structure Chassis Group Rear Chassis

Rear Chassis Fuel tank B

7 10

A-Detail

9 (S/N ~9150) 10 1

8 A

1. Fuel tank 2. Fuel level sensor 3. Fuel tank filler assembly 4. Filter 5. Drain plug 6. Inspection hole cover 7. Gasket (Rubber seal type) 8. Suction pipe 9. Pipe (for vacuum prevention) (S/N ~9150) 10. Fuel return pipe B-Detail

95V2E12001

12-6 95ZV-2 Function & Structure Chassis Group Rear Chassis

Floor board mount

Viscous mount

Floor board

2 2

95ZV12007

1. Floor board 2. Rubber cushion 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.

8 9

7 5

K95V2U12001

1. Stud bolt 2. Stud 3. Cushion rubber (S/N ~9182: HS62) (S/N 9183~: HS70) 4. Case 5. Seal plate 6. Damping plate 7. Silicone oil 8. Plain washer 9. Hexagon head bolt The floor board is supported by a viscous mount in four positions so that vibrations, impacts and sounds generated in the chassis are not transmitted to the inside of cabin.

12-7 95ZV-2 Function & Structure Chassis Group Center Pin

Center Pin Upper center pin

Lower center pin 1

4 9, 10 3 Front chassis

Front chassis

6 2 7 Rear chassis

Rear chassis 2 Upper

4 Lower

8, 10

95ZV12009

95ZV12010

Upper

Lower

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

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

12-8 95ZV-2 Function & Structure Chassis Group Center Pin

Dust seal

Center pin

Dust seal position 90ZV12007

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

13-1 95ZV-2 Check & Adjustment Chassis Group

95ZV-2 Check & Adjustment Chassis Group Linkage Pin ............................................................. 13-2 Center Pin ............................................................... 13-5

13-2 95ZV-2 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 attach a "DO NOT OPERATE!" tag on the cab. - Block the tires with chocks to prevent the tires from moving.

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

Liner

95ZV12004

Adjustment portion

Liner hole diameter (mm)

110

111

Adjustment unnecessary

13-3 95ZV-2 Check & Adjustment Chassis Group Linkage Pin

Bucket hinge pin section Boom

Bucket

Bushing

Hinge pin (#1)

Bolt

Dust seal

Shim

Seal retainer assy

Shim 95V2E13001

Adjust the clearance (*) to 1.0 mm (0.039 in) or less for hinge pin (#1).

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

R122

3. Place the shim between the bucket boss and the seal retainer assy so that the clearance between the boom boss and the seal retainer (* marked) is less than 1mm.

Tighten the bolt for the seal retainer assy. : 417 N-m (42.5 kgf-m) (307 lb-ft)

Shim 90V2E13001

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

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

13-4 95ZV-2 Check & Adjustment Chassis Group Linkage Pin

Adjustment

95ZV12005

Adjust the clearance (*) to 1.2 mm (0.047 in) or less for #2 ~ #7 between the bosses using liners. For the steering cylinder, be sure to adjust the clearance on the rear chassis side first and then on the front chassis side while checking that the cylinder is not inclined.

13-5 95ZV-2 Check & Adjustment Chassis Group Center Pin

Center Pin Adjusting shim

Grease nipple installation direction 1 4 9, 10 3

Grease nipple Front

Front chassis

5 6 7

[Upper]

[Lower]

Rear chassis 2 Upper

8, 10 95ZV12009

The clearance between the front chassis and bearing cover (3) is 0.75±0.5 mm (0.03±0.02 in) before shim adjustment.

95ZV13002

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

Installing bearing outer ring

Add shims (5) so that the clearance is 0.1±0.05 mm (0.004±0.002 in). After that, tighten bolt (9). : (8): 422 N-m (43.0 kgf-m) (311 lb-ft) (with lubrication oil) : (9): 441 N-m (45.0 kgf-m) (326 lb-ft)

Front

Rear

Center line

Split of outer bearing

95ZV13003

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

13-6 95ZV-2 Check & Adjustment Chassis Group

MEMO

22-1 95ZV-2 Function & Structure Power Group

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

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

Power Line 15

95V2U22001

(S/N 9151~)

K95V2U22001

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. Charge air cooler 14. Fuel cooler 15. Precleaner

22-3 95ZV-2 Function & Structure Power Group Power Line The power output from the engine is transmitted to the transmission through the torque converter (combined with the transmission). The speed and direction are changed according to the engagement of the transmission clutches. The power is then transmitted through the second and third propeller shafts to the differential gears of front and rear axles. Finally the power is transmitted through the axles to the planetary gears, and tires to move the machine. On the fan side of the engine, there is a radiator. The radiator incorporates engine coolant, torque converter oil cooler, charge air cooler, fuel cooler and an external air type hydraulic oil cooler. A parking brake is installed on the second propeller shaft. (S/N 9151~) The torque converter oil cooler is separately mounted on the chassis.

22-4 95ZV-2 Function & Structure Power Group Engine / Transmission

Engine / Transmission Engine / transmission mount

Bracket

Engine side

Transmission side

Bracket

Flywheel

5 1 4

3 6 7

2 1 A-Detail

B-Detail

C-Detail

1. Bushing 2. Sleeve 3. Block 4. Washer 5. Washer 6. Plate 7. Ring gear

95V2E22002

Bolts are used to connect the engine flywheel housing to the torque converter housing, and a spline ring coupling (7) is used to transmit the engine power to the torque converter. Therefore no thrust load is placed on the engine flywheel or crankshaft. Rubber cushions are used to mount the engine and the transmission on the chassis.

22-5 95ZV-2 Function & Structure Power Group Radiator (S/N 9001~9150)

Radiator (S/N 9001~9150) Charge air cooler OUT

Coolant IN

Charge air cooler IN

B 1

B 3

A C

Hydraulic oil cooler OUT

Bypass Fuel cooler IN coolant IN T/C oil Fuel cooler Hydraulic oil cooler IN cooler OUT OUT

1. Radiator assembly 2. Radiator duct 3. Stay (Bracket) 4. Charge air cooler 5. Hydraulic oil cooler

2 5

T/C oil cooler IN

Coolant OUT

6. T/C oil cooler 7. Fuel cooler 8. Plate 9. Bushing-Rubber

A-Detail

B-Detail

C-Detail K95V2U22002

The radiator incorporates the engine coolant, cooling fin, air charged cooler, and an external air type hydraulic oil cooler. For the engine coolant, air charge cooler, fuel cooler and hydraulic oil cooler, the air-cooling system is used. For the torque converter oil, the water-cooling system is used. When the coolant is cold enough, the thermostat is completely closed directing coolant from the bypass line to the torque converter oil cooler. The coolant flow cools the torque converter oil to prevent it from being overheated even when the thermostat is closed.

The fuel cooler and air charge cooler are required to meet engine emission regulations. Capacity in radiator: 70 L (18.5 gal) Cooling water 3.4 L (0.9 gal) Hydraulic oil Torque converter oil 3.0 L (0.8 gal) 2.1 L (0.6 gal) Fuel Dry weight

570 kg (1,260 lbs)

22-6 95ZV-2 Function & Structure Power Group Radiator (S/N 9151~)

Radiator (S/N 9151~) Coolant deaerating tank Coolant IN Charge air cooler IN

Charge air cooler OUT Hydraulic oil cooler IN

1 5

Coolant OUT Coolant IN Fuel cooler OUT

Fuel cooler IN

T/C oil cooler OUT

Hydraulic oil cooler OUT

Coolant IN (bypass)

T/C oil cooler IN

D-D

Coolant OUT Coolant OUT (bypass) K97V2J22001

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

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

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

When the coolant is cold enough, the thermostat is completely closed directing coolant from the bypass line to the torque converter oil cooler. The coolant flow cools the torque converter oil to prevent it from being overheated even when the thermostat is closed. The fuel cooler and air charge cooler are required to meet engine emission regulations.

22-7 95ZV-2 Function & Structure Power Group Radiator (S/N 9151~)

Radiator mount

A-Detail

B-Detail

C-Detail 95V2E22004

1. — 2. — 3. Stay (Bracket) 4. — 5. — 6. — 7. — 8. Plate 9. Bushing-Rubber Capacity in radiator: 62 L (16.5 gal) Cooling water 7 L (1.9 gal) Hydraulic oil Torque converter oil 3 L (0.8 gal) 2.1 L (0.6 gal) Fuel Dry weight

570 kg (1,260 lbs)

22-8 95ZV-2 Function & Structure Power Group Propeller Shaft

Propeller Shaft 1

95V2E22005

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.

22-9 95ZV-2 Function & Structure Power Group Propeller Shaft

Second propeller shaft assembly Front differential – Transmission

6 c

1 b

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

a 45

View Z

d Every 12000 hours greasing

5 Every 2000 hours greasing

Front differential

Transmission

c 1

Every 12000 hours greasing

a 95V2U22002

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

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

22-10 95ZV-2 Function & Structure Power Group Propeller Shaft

Third propeller shaft assembly Transmission – Rear differential

Grease nipple installation angle (a, b)

a 45

Z View Z

Rear differential side

Every 12000 hours greasing Transmission side 95V2U22003

1. Journal spider assy 2. Propeller shaft

22-11 95ZV-2 Function & Structure Power Group Axle Assembly

Axle Assembly 51

1 42

41 43 30 24

50 3

39 38

6 2 12

11 28

49 20

48 19

47 20

54 (S/N 9001 ~9014)

32 31

15 17 9

37 23 16 27 26 10

2618 16

34 5

13 14 22 40

52 36

4 53

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

35 8

37. Socket bolt 38. Spring 39. U-nut 40. Bolt 41. O-ring 42. Spacer 43. Ring 44. O-ring 45. Plug 46. Spring 47. Sleeve 48. Bushing 49. Socket bolt 50. Bolt 51. Bolt 52. Bolt 53. Socket bolt 54. Flange bolt 95ZV22010

22-12 95ZV-2 Function & Structure Power Group Axle Support

Axle Support

Grease pipe connection port (PT1/8)

Pin (Axle housing)

Rear side of axle support

9 Front

5 4 14

Front side of axle support

View A-A

8 7

Groove at bushing end

10 12

#11 Details

#10 Details

95V2U22005

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

8. Lip seal 9. Breather 10. Bushing 11. Bushing 12. Ring 13. Snap ring 14. O-ring

22-13 95ZV-2 Function & Structure Power Group Axle Support

9 (S/N 9032~) 9 (S/N ~9031)

7 6

9 (S/N ~9031) 9 (S/N 9032~)

14 2 4 10 5 7 FRONT

11 3

8 13 K95V2E22001

1. Shaft 2. Rear axle support (front) 3. Rear axle support (rear) 4. Wear ring 5. Plate 6. Plate 7. Lip seal 8. Lip seal 9. Breather (S/N 9001~9031) Fitting (S/N 9032~) 10. Bushing

11. Bushing 12. Ring 13. Snap ring 14. O-ring

22-14 95ZV-2 Function & Structure Power Group Torque Proportioning Type Differential Gear (TPD)

Torque Proportioning Type Differential Gear (TPD) Front differential gear (S/N 9001~9088)

3 36

33 35

5 6

7 8

9 10 21 25

11 12 13

20 14

16 18 19 K95V2U22005

22-15 95ZV-2 Function & Structure Power Group Torque Proportioning Type Differential Gear (TPD)

Front differential gear (S/N 9089~9250) 2

1 23 24

29 3 36 K95V2U22003

Front differential gear (S/N 9251~)

1 23

3 36

K95V2U22004

1. Nut 2. Flange yoke 3. Oil seal 4. Plug 5. Housing 6. Shim 7. Taper roller bearing 8. Spacer 9. Spiral gear set 10. Carrier assembly 11. Taper roller bearing 12. Adjusting nut

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

25. Snap ring 26. O-ring 27. O-ring 28. Gear 29. Piston assembly 30. Oil seal 31. Friction disc 32. Separation disc 33. Pin 34. Spring pin 35. Spring 36. Oil seal (Double lip) (S/N 9066~)

22-16 95ZV-2 Function & Structure Power Group Torque Proportioning Type Differential Gear (TPD)

Rear differential gear 1 2 3

26 4 24

5 6

7 8 9 10

21 25

12 13 15

14 17 16

19 20

K95V2U22006

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. Pin 18. Wear ring 19. Spider 20. Housing 21. Roller bearing 22. O-ring 23. O-ring 24. O-ring 25. Snap ring 26. Oil seal (Double lip) (S/N 9066~)

22-17 95ZV-2 Function & Structure Power Group Torque Proportioning Type Differential Gear (TPD)

Function of T.P.D

Contact between pinion and side gear

The differential gear used for the machine is the torque proportioning type. Compared with the conventional differential, the torque proportioning differential (T.P.D.) can reduce tire slippage on sandy or muddy ground.

T.P.D.

Conventional differential

Difference in gear shapes

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

Shaft center of side gear 95ZV22018

Conventional differential

Conventional differential There is little change in distance from the shaft center of the side gear. T.P.D. The contact point varies as the gear rotates. The distance between the contact point and the shaft center of the side gear also varies in the range of R1~R2.

T.P.D.

95ZV22014

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

22-18 95ZV-2 Function & Structure Power Group Torque Proportioning Type Differential Gear (TPD)

Operation of T.P.D Rotational direction

Pinion

Pinion Side gear

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

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

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

95ZV22015

The function of the T.P.D. is as follows: If the surface resistance values of the right and left wheels differ from each other, engagement position of the pinion gear with the side gears will be automatically shifted to transmit different torque to the right and left wheels. Different torque in right and left wheels prevents the tires from slipping. The number of pinion gear teeth is an odd number, and the pinion gear operate as follows. 1. When the traction of the right and left wheels are identical to each other, the pinion and side gears will be engaged as shown in figure [A]. In this case, the torque arms of both side gears are identical to each other (R1 = R2). As a result, identical driving force will be applied to both the right and left wheels. 2. If the left wheel loses traction the engagement position between the pinion and side gears will be shifted as shown in figure [B] to quickly rotate (spin) the left wheel. As a result, the torque arms of the both side gears differ from each other (R1> R2), and the driving force of the left wheel is small. As a result, tire slipping can be reduced. When the driving force of the left wheel is reduced

(slipping occurs), the driving force of the right wheel will be increased to limit the reduction in the total amount of the driving force. Assuming that the driving torque of the right wheel is TR, and that of the left wheel is TL, the relation between TR and TL can be expressed as follows: TR R ------ = ------1 TL R2 The value obtained from the above formula is referred to as the bias ratio. The limit of the bias ratio is 1.37. In other words, until the difference in the surface resistance between the right and left tires is increased to 37%, the pinion gear will be properly engaged with the shifted side gears, and driving force will be properly applied to both the side gears to prevent the tires from slipping. 3. If the surface resistance of the right wheel is reduced, the engagement position between the pinion and side gears will be shifted as shown in figure [C] above. In this case, the right and left sides are reversed compared with the above description.

22-19 95ZV-2 Function & Structure Power Group Limited Slip Differential (LSD) (option)

Limited Slip Differential (LSD) (option) LSD structure Note 1. Clutch assembly (2) is built with six plates as a unit. Do not change this combination.

Differential assembly

2. When installing clutch assembly (2), make sure of the direction of plates (surfaces with lining and surface without lining). With lining

Differential cage

Side gear

Without lining

1 2

3 4

Limited Slip Differential 1

2 3 3 2 4

95V2U22004

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

22-20 95ZV-2 Function & Structure Power Group Limited Slip Differential (LSD) (option)

Front differential gear (S/N 9001~9088)

38 26

29 33 35

5 6

8 15

9 10 21

11 12 13

20 14 20 17

16 18 19

37 K95V2U22007

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

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

27. O-ring 28. Gear 29. Piston assembly 30. Oil seal 31. Friction disc 32. Separation disc 33. Pin 34. Spring pin 35. Spring 36. Pin 37. Clutch assembly 38. Oil seal (Double lip) (S/N 9066~)

22-21 95ZV-2 Function & Structure Power Group Limited Slip Differential (LSD) (option)

Front differential gear (S/N 9089~9250)

1 23 24

29 3 38 K95V2U22008

Front differential gear (S/N 9251~)

1 23

3 38

K95V2U22009

22-22 95ZV-2 Function & Structure Power Group Limited Slip Differential (LSD) (option)

Rear differential gear 1 2 3 28

4 24

5 6

8 15 9 10

21 25

12 13 14 17

20 18

K95V2U22010

1. Nut 2. Flange yoke 3. Oil seal 4. Trunnion 5. Housing 6. Shim 7. Taper roller bearing 8. Spacer 9. Spiral gear set 10. Carrier assembly 11. Taper roller bearing 12. Adjusting nut 13. Plate 14. Wear ring

15. Side gear 16. Differential pinion 17. Pin 18. Wear ring 19. Spider 20. Housing 21. Roller bearing 22. O-ring 23. O-ring 24. O-ring 25. Snap ring 26. Pin 27. Clutch assembly 28. Oil seal (Double lip) (S/N 9066~)

22-23 95ZV-2 Function & Structure Power Group Limited Slip Differential (LSD) (option)

LSD function

LSD operation Performance comparison between LSD and TPD LSD TPD

Differential pinion

LSD Differential point 0.4 (bias ratio 2.5)

LSD clutch assembly

Torque

Differential cage

e On

Axle shaft

Side gear

Side gear moves to the left and pushes LSD clutch.

tire

in i ns sp

n ra the

0.1

erat D Op

re e ti

A n sp i

the s in

ing ra

nge

Op e TP D e rang

ge ra n

TPD Differential point 0.73 (bias ratio 1.37)

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

0.4

g ratin

0.9

Torque is transferred to the right and left tires evenly until the friction ratio between the right and left tires comes to 0.4:1. The result is that the LSD adds tractive effort.

A - Detail 95V2E22014

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.

95V2E22015

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.

22-24 95ZV-2 Function & Structure Power Group

MEMO

23-1 95ZV-2 Check & Adjustment Power Group

95ZV-2 Check & Adjustment Power Group Engine ..................................................................... 23-2 Propeller Shaft......................................................... 23-3 Axle ......................................................................... 23-5

23-2 95ZV-2 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.

Measuring engine speed Measurement instrument - Tachometer

Standard measurement value Low idle (min-1): 850±50 High idle (min-1): 2,040±50

Measurement instrument - Pressure gauge

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

Standard measurement value Engine speed

Service standard

2,040±50 min-1

0.24~0.27 MPa (2.4~2.8 kgf/cm2) (35~40 psi)

[Engine coolant temperature 50ºC (120ºF)]

(A)

97ZV23004

23-3 95ZV-2 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.

23-4 95ZV-2 Check & Adjustment Power Group Propeller Shaft

Propeller shaft tightening torque Pillow block (Center bearing)

2nd propeller shaft

Front diff. Washer

Bolt

3rd propeller shaft

Rear diff.

(S/N 9301~)

: 1. 142 N-m (14.5 kgf-m) (105 lb-ft) 2. 142 N-m (14.5 kgf-m) (105 lb-ft) 3. 142 N-m (14.5 kgf-m) (105 lb-ft) 4. 441 N-m (45.0 kgf-m) (326 lb-ft) 5. 162 N-m (16.5 kgf-m) (119 lb-ft) 6. 162 N-m (16.5 kgf-m) (119 lb-ft) 7. 162 N-m (16.5 kgf-m) (119 lb-ft) 8. 417 N-m (42.5 kgf-m) (308 lb-ft)

K95V2U23005

1. Screw lock agent (Three Bond 1327) 2. Screw lock agent (Three Bond 1327) 3. Screw lock agent (Three Bond 1327) 4. Screw lock agent (Loctite® 262) 5. — 6. — 7. — 8. Screw lock agent (Loctite® 262)

23-5 95ZV-2 Check & Adjustment Power Group Axle

Axle Axle nut tightening procedure 9

7 PT 3/8 Brake oil inlet

1 10

3 95V2E23002

1. Tighten axle nut (6) with 2,746 N-m (280 kgf-m) (2,026 lb-ft) tightening torque to install taper roller bearing (7)(8). 2. Loosen axle nut (6).

: 1. 89.7 N-m (9.15 kgf-m) (66 lb-ft) 2. 417 N-m (42.5 kgf-m) (307 lb-ft) 3. 33.3 N-m (3.40 kgf-m) (25 lb-ft) 4. 53.0 N-m (5.40 kgf-m) (39 lb-ft) 5. 86.3 N-m (8.80 kgf-m) (64 lb-ft)

3. Tighten axle nut (6) again with 2,746 N-m (280 kgfm) (2,026 lb-ft) tightening torque. #1, 2, 4, 10: Screw lock agent (Three Bond 1327) 4. Turn wheel hub (9) 2~3 turns back and forth, and measure the preload applied to section (∗ part). Preload of section (∗ part) 324~363 N (33~37 kgf) (73~81 lbf) ∗∗ ∗∗This is "breakaway" force. The force required to start the wheel turning. Note Use jig to install the floating seal to the axle assembly.

23-6 95ZV-2 Check & Adjustment Power Group Axle

Differential gear adjustment procedure Front differential (S/N 9001~9088) 1

9 6

7 (Front differential preload section)

2 (Rear differential preload section)

3 95V2E23003

: 1. 883 N-m (90.0 kgf-m) (651 lb-ft) 2. 314 N-m (32.0 kgf-m) (232 lb-ft) 3. 873 N-m (89.0 kgf-m) (644 lb-ft) 4. 52.5 N-m (5.35 kgf-m) (39 lb-ft) 5. 216 N-m (22.0 kgf-m) (159 lb-ft) 6. 86.3 N-m (8.80 kgf-m) (64 lb-ft) (Front differential only) 7. 230 N-m (23.5 kgf-m) (170 lb-ft) (Front differential only)

#2, 3, 4, 5, 7: 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)

23-7 95ZV-2 Check & Adjustment Power Group Axle

Preload adjustment

Front differential gear (S/N 9089~9250)

Measure the preload at the bolt holes of cage (2)(7). 1

Standard preload∗∗ 7

Front differential: 22~27 N (2.2~2.8 kgf) (5~6 lbf) Rear differential: 36~45 N (3.7~4.6 kgf) (8~10 lbf)

9 11

If the preload is out of the above range, replace spacer (10) to adjust the preload to the specified range. K95V2U23001

∗∗Preload is the force required to start the cage movingbreakaway force.

Front differential gear (S/N 9251~)

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

1 7

9 11

K95V2U23002

Rear differential gear

K95V2U23004

23-8 95ZV-2 Check & Adjustment Power Group Axle

Bearing installation

Oil seal installation

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

Before installing oil seal (9)(11), be sure to apply grease to the lip.

Pinion gear

Snap ring

Apply grease when assembling. 3 mm (0.118 in)

Bearing (8)

3.6 mm (0.142 in)

K85ZV23003

11 (S/N 9066~) (double lip) 9 (S/N ~9065) (single lip) K95V2U23003

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.

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

23-9 95ZV-2 Check & Adjustment Power Group Axle

Adjusting tooth contact Tooth contact

Possible cause

Adjusting method

Correct

Ring gear is too close to the drive pinion

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

Ring gear is too far from the drive pinion

Do the reverse adjusting as B.

Drive pinion is too close to the ring gear.

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

Drive pinion is too far from the ring gear.

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

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

23-10 95ZV-2 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

HEEL

4~5

Pitch line TOE

BOTTOM

10 2 Pattern B

4 TOP

4 HEEL

Pitch line

4~5

TOE BOTTOM

10 3 Pattern C

4 TOP

TOE

3 HEEL

4~5

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.

32-1 95ZV-2 Function & Structure Torque Converter and Transmission Group

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

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

Torque Converter Torque multiplication

Output

Torque ratio (t)

Input

S P

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.

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.

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)

32-3 95ZV-2 Function & Structure Torque Converter and Transmission Group Torque Converter (Lock-up) (Option)

Torque Converter (Lock-up) (Option)

T S

Oil from Lock-up solenoid valve

1 2 3

(T/M S/N PT315L01-0101~ T/M S/N PT315L04-0100)

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

K95V2U32004

1. Lock-up piston 2. Friction plate 3. Steel plate 4. Turbine shaft 5. Drive cover

32-4 95ZV-2 Function & Structure Torque Converter and Transmission Group Torque Converter (Lock-up) (Option)

Lock-up clutch structure

Lock-up clutch function (only forward)

Lock-up clutch

Output

Input Oil from Lock-up solenoid valve

T S

S Lock-up clutch P

T 5 95V2E32030

The torque converter is equipped with the lock-up device. When the lock-up clutch is engaged, the power from the engine is directly transmitted to the turbine. As a result, slip between the pump and the turbine is eliminated. This is an advantage during high speed travel and in "load and carry" operations. Less fuel is used, higher ground speed can be reached, and less heat is generated.

4 1 3

95V2E32028

While the machine is moving at the 3rd speed or the 4th speed in the automatic speed change mode, and the machine reaches the preset speed, the solenoid valve for lockup is activated by the signal from the MCU. The torque converter oil flows through the oil hole provided in the center of turbine shaft (4) and the oil hole provided in drive cover (5), then presses the lock-up piston onto the pressure plate. As a result, drive cover (5) is coupled with turbine shaft (4) to complete the lock-up status.

32-5 95ZV-2 Function & Structure Torque Converter and Transmission Group Torque Converter (Lock-up) (Option)

Automatic shift (with lock-up solenoid) Shift up Shift down

Speed

F4L F4 F3L 3 2

13.0 11.0 (8.1) (6.9)

Reverse

10.0 12.0 15.0 17.0 24.5 26.5 28.0 30.0 (6.3) (7.5) (9.4)(10.6) (15.3)(16.6) (17.5) (18.8)

Forward Speed km/h (mile/h) 95V2U32001 Automatic shift map (Normal mode)

3rd → 3rd lock-up

17.0 km/h (10.6 MPH)

4th → 4th lock-up

30.0 km/h (18.8 MPH)

4th lock-up → 4th

28.0 km/h (17.5 MPH)

3rd lock-up → 3rd

15.0 km/h (9.4 MPH)

Shift Up

Shift Down

32-6 95ZV-2 Function & Structure Torque Converter and Transmission Group Torque Converter Gear Pump

Torque Converter Gear Pump (T/M S/N PT315E01-0101~PT315E02-0195) A 6

10 2

001A

9 3 Outlet

5 11, 12 Section A-A Inlet

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

95V2E32002

Gear pump specifications Theoretical discharge

73.6 cm3/rev (4.49 in3/rev)

Maximum operation pressure

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

Maximum operation speed

2,610 min-1 (rpm)

Actual discharge

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

32-7 95ZV-2 Function & Structure Torque Converter and Transmission Group Torque Converter Gear Pump (T/M S/N PT315E02-0196~) A

001C

11 10

Outlet

9 1

Section A-A Inlet

1. Pump body 2. Pump cover 3. Drive gear 4. Driven gear 5. Bushing 6. Bushing 7. Plate 8. Seal 9. Backup ring 10. Oil seal 11. Snap ring 12. Dowel pin 13. Flange bolt

K95V2U32003

Gear pump specifications Theoretical discharge

73.6 cm3/rev (4.49 in3/rev)

Maximum operation pressure

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

Maximum operation speed

2,610 min-1 (rpm)

Actual discharge

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

32-8 95ZV-2 Function & Structure Torque Converter and Transmission Group Transmission

Transmission Clutch combination Clutch Speed range

Shift lever position 2

Position of shift lever

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

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

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

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

F2 F3 F4 N

(Either 1st or 2nd or 3rd)

R1 R2 R3

Function

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

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 engine speed and the machine speed detected.

Downshift button operation

Planetary gear

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

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

Planetary gear carrier Planetary gear

Sun gear 95V2E32021

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

32-9 95ZV-2 Function & Structure Torque Converter and Transmission Group Transmission

Gear train and number of teeth

T/C

L 82

E/G

65 67

63 80

2nd propeller shaft

3rd propeller shaft

95V2E32020

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

Clutch specifications Friction plate Name of clutch

Piston stroke (mm)

Low range clutch

5.5±0.5

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)

Reverse clutch

5.5±0.5

High range clutch

3.0±0.5

1st speed clutch

6.0±0.5

2nd speed clutch

2.0±0.5

3rd speed clutch

3.0±0.5

ø360 ø236 ø360

ø279

4±0.13 / 3.5 (Sintered)

ø159

4±0.1 / 3.4 (Sintered)

4±0.13 / 3.8 (Paper)

ø279

8 8 4

ø426

ø298

3.5±0.1 / 3.3

ø252

ø173

3.2±0.1 / 3.0

ø426

ø298

3.5±0.1 / 3.3

6 12 12 12 12 12

32-10 95ZV-2 Function & Structure Torque Converter and Transmission Group Transmission

Friction plate: mm (in) For low, reverse clutch 3.0 (0.12) 0.6 (0.02)

Detail drawing of groove 95V2E32023

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

1.2 (0.05) 360 (14.2 )

2.6 (0.10)

279 +- 00.8 (11.0 +- 00.03 )

0.1 (0.004) above

Detail drawing of groove 95V2E32024

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

2.6 (0.10)

159 +- 00.5 (6.26 +- 00.02)

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

Detail drawing of groove 95V2E32025

1. Plate 2. Facing (sintered)

32-11 95ZV-2 Function & Structure Torque Converter and Transmission Group Transmission

Steel plate: mm (in)

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

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

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

95V2E32026

0 252 +- 00.5 (9.92 +- 0.02 )

For high, 1st speed clutch

95V2E32029

32-12 95ZV-2 Function & Structure Torque Converter and Transmission Group Clutch Pack

Clutch Pack

Inlets for Inlets for reverse and 2nd and 3rd low range speed clutch oil clutch oil 24 20 21 17 16 15 11 12

Inlet of 1st speed clutch oil Inlet of high range clutch oil Inlet of lubricating and cooling oil

7 31 32 30 27 34

1. Clutch input shaft 2. High range clutch drum 3. Spider 4. High range clutch piston 5. Friction plate 6. Steel plate 7. Piston return spring 8. Reverse planetary gear carrier 9. Reverse planetary gear 10. Reverse clutch piston 11. Friction plate 12. Steel plate 13. Anchor pin 14. Piston return spring 15. Reverse ring gear 16. Low range clutch piston 17. Low range planetary gear

35 18 19

14 13

18. Low range ring gear 19. Low range sun gear 20. 3rd speed clutch piston 21. 3rd speed planetary gear 22. 3rd speed ring gear 23. 3rd speed sun gear 24. 2nd speed clutch piston 25. 2nd speed planetary gear 26. 2nd speed ring gear 27. 2nd speed sun gear 28. 1st speed clutch drum 29. 1st speed clutch piston 30. 1st speed clutch gear 31. Drop gear 32. Piston return spring 33. Clutch output shaft 34. 2nd speed planetary gear carrier 35. Low/3rd speed planetary gear carrier

95V2E32003

32-13 95ZV-2 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 21 22 18 17 1st speed clutch

Low range Inlet of low range clutch clutch oil

30 Input power

Inlet of 1st speed clutch oil

1 Output power

13 95V2E32004

When first speed forward is selected by the operator or the computer, oil is sent from the modulator valve to the low range clutch and the 1st speed clutch. When the clutch plates are pressed by the low range clutch piston, low range ring gear (18) is locked to the housing by the anchor pins (13). The torque converter rotates the low range sun gear (19) via the clutch input shaft (1). This causes low range planetary gears (17) to rotate around sun gear (19) while rotating on their own axis. This forces the carrier to rotate. Since the low range planetary carrier and 3rd speed planetary carrier are one piece, the 3rd speed planetary gears (21) also rotate around sun gear.

When the 1st speed clutch is engaged, drop gear (31), 1st speed clutch gear (30), 3rd speed ring gear (22) and 3rd speed sun gear (23), 2nd speed sun gear (27) clutch output shaft (33) form one unit. As a result, the rotation of the 3rd speed planetary gear (21) around sun gear is output as the rotation of the drop gear (31).

3rd speed planetary gear (21) (does not rotate on its own axis)

3rd speed ring gear (22) and clutch output shaft (33) form one unit Low range ring gear (18)

95ZV32007

Sun gear (19) Low range planetary gear (17) 95ZV32006

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

32-14 95ZV-2 Function & Structure Torque Converter and Transmission Group Power Flow Path in the Transmission

Forward 2nd speed power flow path

2nd speed clutch

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

Output power

95V2E32005

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

Output power

95V2E32006

32-15 95ZV-2 Function & Structure Torque Converter and Transmission Group Power Flow Path in the Transmission

Forward 4th speed power flow path 2nd speed clutch oil 2nd speed clutch

High range clutch Input power

High range clutch oil

Output power

95V2E32007

32-16 95ZV-2 Function & Structure Torque Converter and Transmission Group Power Flow Path in the Transmission

Reverse 1st speed power flow path Reverse clutch oil 1st speed clutch

Reverse clutch

Input power

1st speed clutch oil

Output power 95V2E32008

Reverse 2nd speed power flow path 2nd speed clutch oil 2nd speed clutch

Reverse clutch oil

Reverse clutch

Input power

Output power 95V2E32009

32-17 95ZV-2 Function & Structure Torque Converter and Transmission Group Power Flow Path in the Transmission

Reverse 3rd speed power flow path 3rd speed 3rd speed clutch oil clutch

Reverse clutch oil Reverse clutch Input power

Output power 95V2E32010

32-18 95ZV-2 Function & Structure Torque Converter and Transmission Group Hydraulic System Diagram

Hydraulic System Diagram

Shift lever Option 34

MCU

LU 10

5 6

H 20 L 24

16 17

36 8

2 26 21

R 22 3 18

1 19

3 4

28 29 30 33 32 31 2

1 95V2E32011

32-19 95ZV-2 Function & Structure Torque Converter and Transmission Group Hydraulic System Diagram

1. Transmission oil pan 2. Strainer 3. Torque converter gear pump 4. Line filter with bypass valve 5. Clutch pressure regulator valve 6. Modulator valve (1) 7. Relief valve 8. T/C inlet relief valve 9. Modulator valve (2) 10. Check valve (1) 11. Check valve (2) 12. Pressure sensor 13. Torque converter 14. T/C outlet relief valve 15. Oil cooler 16. High range clutch solenoid valve 17. High range clutch valve 18. Reverse clutch solenoid valve

19. Reverse clutch valve 20. Low range clutch solenoid valve 21. Low range clutch valve 22. 1st speed clutch solenoid valve 23. 1st speed clutch valve 24. 2nd speed clutch solenoid valve 25. 2nd speed clutch valve 26. 3rd speed clutch solenoid valve 27. 3rd speed clutch valve 28. High range clutch 29. Reverse clutch 30. Low range clutch 31. 1st speed clutch 32. 2nd speed clutch 33. 3rd speed clutch 34. Lock-up clutch solenoid valve (option) 35. Torque converter (with lock-up clutch) (option) 36. Check valve

32-20 95ZV-2 Function & Structure Torque Converter and Transmission Group Hydraulic Circuit Diagram

Hydraulic Circuit Diagram Neutral position Modulator valve unit

3.0

GA 0.9 6K

13 11

31 23

1st

30K 7 6

GT PR

29 19

R PH

28 17

21 P L

Note All orifice measurements ( ø) are in mm.

Clutch valve assembly

2nd

P P3

33 27

3rd

Clutch valve assembly

3 2

Clutch solenoid valve assembly

(PF1/4)

Clutch solenoid valve assembly

Modulator valve unit

Lock-up clutch solenoid valve assembly (option)

95V2E32012

32-21 95ZV-2 Function & Structure Torque Converter and Transmission Group Hydraulic Circuit Diagram

Note The orifice in the clutch valve 19 and 21 is to reduce shock at clutch engagement.

32-22 95ZV-2 Function & Structure Torque Converter and Transmission Group Oil Flow

Oil Flow Oil flow in the torque converter line From torque converter charge pump to torque converter Oil from the torque converter gear pump (3) passes through line filter (4) and enters the modulator valve unit. Since only a small amount of oil flows to the clutch circuit, most of the oil flows to clutch pressure regulator valve (5), forces it open, and passes into the torque converter circuit. If the torque converter's inlet pressure exceeds 0.9 MPa (9 kgf/cm2) (128 psi), it forces torque converter inlet relief valve (8) to open, allowing the oil to escape to the oil pan.

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

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

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

32-23 95ZV-2 Function & Structure Torque Converter and Transmission Group T/C and T/M Oil Circulation

T/C and T/M Oil Circulation (S/N 9001~9150)

Radiator

Torque converter oil cooler

Check valve

Clutch solenoid valve assembly Modulator valve unit

Clutch valve assembly Pilot line

Lock-up clutch solenoid valve assembly (option)

Transmission oil filter

Transmission

95V2E32022

32-24 95ZV-2 Function & Structure Torque Converter and Transmission Group T/C and T/M Oil Circulation

(S/N 9151~) Torque converter oil cooler

Clutch solenoid valve assembly Modulator valve unit

Pilot line

Clutch valve assembly Lock-up clutch solenoid valve assembly (option)

Transmission oil filter

Transmission

95V2E32031

32-25 95ZV-2 Function & Structure Torque Converter and Transmission Group Modulator Valve Unit

Modulator Valve Unit (T/M S/N PT315E01-0101~0282) D

ø 3.0 orifice

ø 0.9 orifice

6 9 9 GT

GB 7 F

C 5

F-F

View A

Numbers below also correspond to page 32-20. 1. — 2. — 3. — 4. — 5. Clutch pressure regulator valve 6. Modulator valve (1) 7. Relief valve (2.9 MPa (30 kgf/cm2) (427 psi)) 8. T/C inlet relief valve (0.9 MPa (9 kgf/cm2) (128 psi)) 9. Modulator valve (2) (D Solenoid valve) 10. Check valve 1 (0.6 MPa (6 kgf/cm2) (85 psi)) 11. Check valve 2 (0.4 MPa (4 kgf/cm2) (57 psi))

10 C-C

8 D-D K95V2E32001

32-26 95ZV-2 Function & Structure Torque Converter and Transmission Group Modulator Valve Unit (T/M S/N PT315E01-0283~)

ø 3.0 orifice

ø 0.9 orifice

6 9 9 GT F

GB 7 F

C F-F 5

View A

10 C-C

8 D-D K95V2E32002

32-27 95ZV-2 Function & Structure Torque Converter and Transmission Group Modulator Valve Unit

Interior schematic (simple explanation) To clutch solenoid valve

10 9 0.6 Mpa (85 psi)

0.4 Mpa (57 psi)

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

Drain

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

Drain

From pump

9 GA

To transmission clutch

To torque converter

GB 8

30K

7 6

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

From pump 95V2E32014

32-28 95ZV-2 Function & Structure Torque Converter and Transmission Group Modulator Valve Unit When changing direction or speed, the modulation mechanism works to reduce the time required for clutch engagement (time lag), to prevent the shock at clutch engagement, to improve the work efficiency and durability of the power system, and to ensure operator's comfort.

Modulator valve function Modulator valve 1 To clutch solenoid valve

The modulation mechanism controls the clutch oil pressure rising time as follows: Modulator valve 2

An electrical signal from the MCU controls the modulation operation. For information on the MCU refer to section "Electrical Group".

6 kgf/cm2 4 kgf/cm2

Clutch pressure regulator valve

Modulator valve 1

Port P

F f To torque converter

9 kgf/cm2

From pump

Drain

30 kgf/cm2

Drain

95V2E32015

The modulator valve 1 is a solenoid-operated proportional pressure reducing valve. Downward magnetic force (F) acts on the top of the spool in proportion to the amount of current applied to the coil. The bottom of the spool is acted upon by the upward hydraulic force (f). When this upward force (f) and magnetic force (F) are in balance, the spool is stationary, which generates the specified pressure at port P. The hydraulic force adjusted by modulator valve 1 acts on the right end of the clutch pressure regulator valve, and so the hydraulic force from the pump to the clutch is also controlled by modulator valve 1. In other words, when the control pressure from the modulator valve 1 is low, oil from the pump easily moves the clutch pressure regulator valve to the right end and relieves the oil to the torque converter or, above 0.9 MPa (9 kgf/cm2) (128 psi) to the drain port, reducing clutch oil pressure.

32-29 95ZV-2 Function & Structure Torque Converter and Transmission Group Modulator Valve Unit

As mentioned above, the clutch oil pressure is controlled depending on the size of current applied to the coil of modulator valve 1. Even at a minimum value of current, however, the clutch oil pressure is too high for smooth clutch engagement due to the resistance of flow across the clutch pressure regulator valve. The modulator valve 2 is used to reduce the clutch oil pressure to appropriate pressure for clutch engagement. When the modulator valve 2 is energized, the spool moves to the left and the oil in the clutch circuit is drained through the ø 0.9 orifice. The oil from the pump forces open the 0.6 MPa (6 kgf/cm2) (85 psi) and 0.4 MPa (4 kgf/cm2) (57 psi) check valve and flows to the clutch. The pressure drop due to the check valve allows a lower minimum clutch oil pressure maintained. This lower pressure allows some clutch slippage for smooth clutch engagement.

Pressure sensor The shock and the time lag when engaging the clutch vary by the clutch oil pressure rising time after the completion of the oil charging into the clutch piston chamber. In the case that the clutch oil pressure rising time is early, it causes a large shock. If it is late, it causes a large time lag. As the modulator valve 2 is ON during the oil is charging into the clutch piston chamber, oil flows to the clutch piston chamber through the check valve 0.6 MPa (6 kgf/ cm2) (85 psi) and 0.4 MPa (4 kgf/cm2) (57 psi). Oil stops flowing through the check valve at the completion of the oil charging into the clutch piston chamber. As a result, since there is no oil pressure drop in the line to the clutch piston chamber, the clutch oil pressure rises up to the lowest holding pressure regulated by the modulator valve 1. The pressure sensor detects this pressure and transfers the signal to the MCU. The MCU decides the completion of the oil charging into the clutch piston chamber and transfers the signal to the modulator valve 1 to increase the clutch pressure.

Clutch oil pressure control at the time of engine starting

Clutch oil pressure

Modulator valve 2 (D Solenoid valve)

Starter SW Engine ON start Specified pressure 3 sec

Time 95ZV32010

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

32-30 95ZV-2 Function & Structure Torque Converter and Transmission Group Modulator Valve Unit

Modulator valve operation

Initial oil charging (t1) into the clutch piston chamber

Modulation chart (Neutral→1st forward)

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

ON Low range clutch OFF solenoid valve ON

1st speed clutch solenoid valve

Modulator valve 1

Oil filling completed

Current (mA)

The 1st speed clutch solenoid valve remains energized. After a given time, the control current to the modulator valve 1 is reduced. At the same time, the modulator valve 2 is energized and the main clutch oil pressure is sharply reduced, concluding the initial oil charging into the chamber.

about 400 mA

about 170 mA 0

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

Modulator valve 2 OFF

OFF

Main pressure

Low pressure holding (t2)

Pressure MPa (kgf/cm2)

To reduce clutch engagement shock, it is necessary to engage the clutch while allowing some slippage of it. To do this, the current to modulator valve 1 is held low for a given time. During this time, the clutch piston moves while compressing the piston return spring.

Low range clutch pressure Pressure MPa (kgf/cm2)

This low pressure holding time depends on the speed of the engine: longer with lower engine speed, shorter with higher speed. Modulator 2 is kept energized allowing some oil to escape to drain.

When shifted

Shift completed

95V2E32019

Initial charging time

Changes with combination of clutches

0~0.12 sec

Low pressure holding time

Changes with engine speed

Less than 0.5 sec

Pressure rise time

Changes with combination of clutches

0.3~0.7 sec

Restoration time

Changes with combination of clutches

0.5~1.3 sec

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

speed 2.3~2.7 MPa (24~28 kgf/cm ) (341~398 psi) P3 1st Except 1st speed 2.7~3.1 MPa (28~32 kgf/cm2) (398~455 psi)

- E/G high idle

This time is also controlled by MCU.

Pressure rise (t3) When the clutch piston comes into contact with the clutch plate and the clutch plates start to transmit power, the control current to modulator valve 1 is gradually raised. This causes the clutch oil pressure to also gradually rise, and the clutch completes engagement while some slippage occurs. This rise time is also controlled by MCU.

32-31 95ZV-2 Function & Structure Torque Converter and Transmission Group Modulator Valve Unit

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

32-32 95ZV-2 Function & Structure Torque Converter and Transmission Group Control Valve Assembly

Control Valve Assembly T/M S/N: PT315E01-0101~PT315E02-0100 PT315L01-0101~PT315L02-0100 (Lock-up) Valve location Main pressure gauge port

Pilot line

Check valve

1 2

95V2E32016

1. Clutch solenoid valve assembly 2. Clutch valve assembly 3. Lock-up clutch solenoid valve assembly (option)

32-33 95ZV-2 Function & Structure Torque Converter and Transmission Group Control Valve Assembly T/M S/N: PT315E02-0101~ PT315L02-0101~ (Lock-up) Valve location Pilot line

Main pressure gauge port

1 2

K95V2U32001

1. Clutch solenoid valve assembly 2. Clutch valve assembly 3. Lock-up clutch solenoid valve assembly (option)

32-34 95ZV-2 Function & Structure Torque Converter and Transmission Group Control Valve Assembly

Check valve The check valve is designed to maintain the pressure in the clutch valve circuit, from the pump to the clutch valves, 0.3 MPa (3.0 kgf/cm2) (43 psi) or more. If the pressure falls too low during the shift modulation the clutch valve spool may return to the original position, as a result, the clutch valves would move to the OFF position and the clutches would release momentarily. The check valve prevents this.

32-35 95ZV-2 Function & Structure Torque Converter and Transmission Group Control Valve Assembly

Clutch solenoid valve assembly T/M S/N: PT315E01-0101~PT315E02-0221 PT315L01-0101~PT315L03-0100 (Lock-up) 2 PH

6 P3

3rd

A PR

P1~PH

1st

T H

2nd

R P P

A-A

P1 1st T PR R T P3 3rd T P2 2nd T PL L T PH H T P

Hydraulic Diagram 95V2E32017

1. High range clutch solenoid valve 2. Low range clutch solenoid valve 3. Reverse clutch solenoid valve 4. 1st speed clutch solenoid valve 5. 2nd speed clutch solenoid valve 6. 3rd speed clutch solenoid valve

32-36 95ZV-2 Function & Structure Torque Converter and Transmission Group Control Valve Assembly T/M S/N: PT315E04-0101~ PT315L03-0101~ (Lock-up) 2 PH

6 P3

A PR

L 3rd

P1~PH

1st

T H

2nd P

A-A

P1 1st T PR R T P3 3rd T P2 2nd T PL L T PH H T P

Hydraulic Diagram K95V2E32002

32-37 95ZV-2 Function & Structure Torque Converter and Transmission Group Control Valve Assembly

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

5 4 Modulator valve

2 6

A Transmission C oil pan

B Clutch valve

3 80ZVE32026

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

32-38 95ZV-2 Function & Structure Torque Converter and Transmission Group Control Valve Assembly After power-on (Clutch engaged status)

Modulator valve

A Transmission C oil pan

B Clutch valve

80ZVE32027

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

32-39 95ZV-2 Function & Structure Torque Converter and Transmission Group Control Valve Assembly

Clutch valve assembly

From clutch solenoid valve (PH, P2, P3, P1)

From clutch solenoid valve (PL, PR)

Orifice

B-B

A-A

4 T1

T PM P1

PC T1

T PM PR

PC T1

T PM P3

PC T1

T PM P2

PC T1

T PM PL

PC T1

T PM PH

Hydraulic Diagram 95V2E32018

1. High range clutch valve 2. Low range clutch valve 3. Reverse clutch valve 4. 1st speed clutch valve 5. 2nd speed clutch valve 6. 3rd speed clutch valve

32-40 95ZV-2 Function & Structure Torque Converter and Transmission Group

MEMO

33-1 95ZV-2 Check & Adjustment Torque Converter and Transmission Group

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

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

Clutch Oil Pressure and Time Lag Measuring clutch oil pressure

Gauge port 1. Location:

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

Main pressure

H clutch

Lock-up clutch 2nd speed clutch R clutch (option) 1st speed 3rd speed clutch L clutch clutch

Measurement instrument - Pressure gauge - Tachometer (MODM)

Transmission oil pressure test port location 95V2E33001

2. Measuring port: PF 1/4 3. Oil pressure gauge: 5 MPa (50 kgf/cm2) (1000 psi) with 2~3 m (6~10 ft.) hose Note Warm-up the engine before measuring the clutch oil pressure and time lag

33-3 95ZV-2 Check & Adjustment Torque Converter and Transmission Group Clutch Oil Pressure and Time Lag

Standard measurement value 1st speed

2.2±0.2 (22±2) (313±28)

Except 1st

2.4±0.2 (24±2) (341±28)

1st speed

2.5±0.2 (25±2) (356±28)

Except 1st

2.9±0.2 (30±2) (427±28)

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

Engine speed High idle

Clutch time lag (sec)

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

9. As the clutch oil pressure rises just after the engine is started, adjust the engine at high-idling before the pressure measurement. 10. Measure and record the pressure in each speed range. (High-idling at the 1st speed, high-idling at the other speeds) Note Change the transmission speed range while keeping the shift lever at the neutral position. Check that the pressure instantaneously lowers just after speed change, and then rises to the original pressure again.

0.3±0.1

Possible causes for low clutch pressure Clutch oil pressure measurement procedure 1. Press the brake pedal, and set and confirm the transmission shift lever is at the neutral position. 2. Set and confirm the parking brake is at the "ON" position. 3. Press the brake pedal, and lower the bucket onto the ground. 4. Stop the engine. 5. Attach the pressure gauge to the pressure measurement port. Place the gauge inside the operator's area, and start the engine. 6. As the clutch oil pressure rises just after the engine is started, keep the engine at low-idling before the pressure measurement. 7. Measure and record the pressure in each speed range. (Low-idling at the 1st speed, low-idling at the other speeds) 8. Set the declutch ON/OFF switch to ON. Press down the brake pedal all the way to the floor to avoid the “fuel saving mode at idle time”. Note In the “fuel saving mode at idle time”, the engine is not activated promptly and may not reach the maximum revolution.

Possible cause

Solution

Malfunctioning modulator valve (1) operation

Inspection & repair

Malfunctioning modulator valve (2) operation

Inspection & repair

Defective MCU

Replacement

Oil leakage from clutch

Disassembly & repair

33-4 95ZV-2 Check & Adjustment Torque Converter and Transmission Group Clutch Oil Pressure and Time Lag

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

Measurement instrument Stop watch

Standard measurement value 0.3 ± 0.1 sec Note Neutral → 1st forward speed at engine speed: 1,500 min-1 (rpm)

Time lag measurement procedure 1. Press the brake pedal, and set and confirm the transmission shift lever is at the neutral position. 2. Set and confirm the parking brake is at the "ON" position. 3. Press the brake pedal. 4. Lower the boom to the lowest limit, and fully roll back the bucket until the bucket contacts to the stopper. 5. Set the parking brake switch to the "OFF" position. Do not apply the service brakes. 6. Set the transmission shift lever to the neutral 1st speed. 7. Keep the engine speed at 1,500 min-1 (rpm). 8. Move the shift lever to the forward position. At the same time, start the stop watch to measure the time required before the machine moves.

Possible causes for clutch time lag Possible cause

Solution

Defective pressure sensor

Replacement

Malfunctioning modulator valve (1) operation

Inspection & repair

Malfunctioning modulator valve (2) operation

Inspection & repair

Defective MCU

Replacement

Defective clutch

Disassembly & repair

42-1 95ZV-2 Function & Structure Hydraulic Group

95ZV-2 Function & Structure Hydraulic Group Flushing Hydraulic Circuit........................................ 42-2 Cautions on Hydraulic Parts Replacement.............. 42-3 Hydraulic Circuit Symbols ....................................... 42-4 Hydraulic System Operation.................................... 42-8 Layout of Hydraulic Units ........................................ 42-10 Hydraulic Tank......................................................... 42-11 Hydraulic Pump ....................................................... 42-17 Hydraulic Cylinder ................................................... 42-20 Loading System ...................................................... 42-23 Reducing Valve (for Pilot Pressure) ........................ 42-24 Pilot valve (S/N 9001~9250) ................................... 42-25 Pilot valve (S/N 9251~9255) ................................... 42-30 Pilot valve (S/N 9256~) ........................................... 42-35 Multiple Control Valve (KML35A/2T003B)............... 42-40 Adapter (Orifice) ...................................................... 42-51 Ride Control (OPT).................................................. 42-52 Steering System ...................................................... 42-62 Orbitrol® ................................................................... 42-63 Steering Valve (KVS32-A4.0/20) ............................. 42-70 Stop Valve ............................................................... 42-82 Reducing Valve (for Orbitrol®) ................................. 42-84 Steering Line Filter .................................................. 42-85 K-Lever (OPT) ......................................................... 42-86 Efficient Loading System......................................... 42-92 Fan Motor System ................................................... 42-96 Fan Motor Line ........................................................ 42-97 Reversing Fan Motor Line (OPT) ............................ 42-108 Secondary Steering ................................................. 42-113

42-2 95ZV-2 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, reducing valves, or relief valves, and cause another malfunction. To prevent such problems, be sure to remove all the debris from the system.

42-3 95ZV-2 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.

42-4 95ZV-2 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

42-5 95ZV-2 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

42-6 95ZV-2 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

42-7 95ZV-2 Function & Structure Hydraulic Group Hydraulic Circuit Symbols

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

(2)

Manual shut off valve

Pressure switch

Accumulator

Electric motor

Internal combustion

Power source

Filter or strainer

Heater

Cooler

Pressure gauge

Temperature gauge

Flow meter

42-8 95ZV-2 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) - Steering valve (4) - Line filter (81) - Reducing valve (18) - Orbitrol® (14) - Stop valve (15) - Steering cylinder (8)

- Hydraulic pump (2) - Unloader valve (22) - Line filter (81) - Check valve (32) - Reducing valve (38) - Pilot valve (16) - Multiple control valve (3) - Boom cylinders (5) - Bucket cylinders (6)

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).

Oil from pump (2) 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 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).

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.

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 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 cylinders (6).

A small amount of pilot oil supplied from Orbitrol® (14) controls steering valve (4) to realize steering operations.

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.

42-9 95ZV-2 Function & Structure Hydraulic Group Hydraulic System Operation 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. Oil returns from steering cylinders (8) flows through steering valve (4) and oil cooler or cooler bypass valve (11).

Fan motor system The fan motor system consists of the following components.

Finally it returns to the tank through return filter (12).

- Hydraulic pump (2) - Unloader valve (22) - Fan motor (71) - Proportional relief valve (72)

Efficient loading system

The cooling fan is driven by hydraulic motor (71). The pressure oil from unloader valve (22) flows into the port P of fan motor and then turns fan motor (71).

The efficient loading system consists of the following components. - Hydraulic pump (2) - 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 (hydraulic pump (1)) flow into steering valve (4) P port. When the steering wheel is not turned, this oil is discharged from steering valve (4) P.B. port. On the other hand, the oil discharged from the main pump (front pump of (2)) opens the check valve, because cracking pressure of check valve (63) is less than the setting pressure of relief valve (62). The oil from switch pump and main pump are joined together and flow into multiple control valve (3) P port. When the ELS switch is turned on and the ELS 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 (front pump of (2)) opens relief valve (62) and all the hydraulic oil from the main pump goes to the hydraulic tank. But the oil from the steering valve P.B. port flow into multiple control valve (3) P port. Therefore when the ELS is operated, most of the engine power is applied to the wheels to exert maximum driving force by turning off the loading pump and reducing the pump driving load on engine.

Three kinds of signals sent from the engine water temperature sensor (S/N 9001~9150), ECM (S/N 9151~), torque converter oil temperature sensor, and hydraulic oil temperature sensor, are input into the MCU as information to regulate the maximum fan revolution. The fan revolution is regulated by proportional relief valve (72). The setting pressure of proportional relief valve (72) is changed in proportion as the engine revolution and electric current value from MCU.

Ride control system (OPT) Refer to "Ride Control (OPT)" page 42-52 for the information.

42-10 95ZV-2 Function & Structure Hydraulic Group Layout of Hydraulic Units

Layout of Hydraulic Units

16 15

95V2E42001

1. Multiple control valve 2. Pilot valve 3. Orbitrol® 4. Steering valve 5. Hydraulic pump (for steering) 6. Hydraulic pump (for loading, for pilot and brake) 7. Fan motor 8. Proportional relief valve (for fan) 9. Bucket cylinder

10. Boom cylinder 11. Steering cylinder 12. Reducing valve (steering pilot) 13. Reducing valve (loading pilot) 14. T/C line filter 15. ELS valve 16. Secondary steering pump 17. Stop valve

42-11 95ZV-2 Function & Structure Hydraulic Group Hydraulic Tank

Hydraulic Tank Hydraulic Tank (S/N 9001~9300) 10

Viewed from top

9 8

A-A

As seen from chassis out

Outside of machine

To chassis

15,16 A 14 12

1. Hydraulic tank 2. Oil level gauge 3. Breather valve (tank cap) 4. Filter 5. Suction strainer (loading, pilot & brake) 6. Suction strainer (steering) 7. Return filter element 8. Filter bypass valve 9. Spring 10. Cover

11. Drain plug 12. Inspection port 13. Vent pipe (to axle housing) (S/N ~9250) 14. Temperature sensor 15. Oil level sensor 16. Flange bolt :11.8 N-m (1.2 kgf-m) Don’t use the air tool when tightening.

95V2E42002

42-12 95ZV-2 Function & Structure Hydraulic Group Hydraulic Tank

Hydraulic tank breather valve (tank cap) (S/N 9001~9300) 1

4 5

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.

42-13 95ZV-2 Function & Structure Hydraulic Group Hydraulic Tank

Hydraulic Tank (S/N 9301~) 10

Viewed from top

9 8

A-A

As seen from chassis out

Outside of machine

To chassis

15,16 A 14 12

1. Hydraulic tank 2. Oil level gauge 3. Breather valve (tank cap) 4. — 5. Suction strainer (loading, pilot & brake) 6. Suction strainer (steering) 7. Return filter element 8. Filter bypass valve 9. Spring 10. Cover

11. Drain plug 12. Inspection port 13. Plug 14. Temperature sensor 15. Oil level sensor 16. Flange bolt :11.8 N-m (1.2 kgf-m) Don’t use the air tool when tightening.

K95V2U42004

42-14 95ZV-2 Function & Structure Hydraulic Group Hydraulic Tank

Hydraulic tank breather valve (tank cap)(S/N 9301~) When the pressure inside the hydraulic tank drops below the outside air pressure, the outside air flows through filter element (2) and to valve assembly (4). Suction valve (b) is then opened to let the air flow into the tank.

PUSH

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

1 6

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

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.

a b 5 K65D2J42001

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

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

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

42-15 95ZV-2 Function & Structure Hydraulic Group Hydraulic Tank

Hydraulic tank specifications Type

Semi-closed type

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

150 (40 US gal)

Filtration area (cm2)

25,500

Filtration particle size (µm)

Return filter

28 2

Relief valve opening pressure (filter bypass) (MPa) (kgf/cm ) (psi) Loading Pilot & brake Suction strainer

0.1±0.02 (1.0±0.2) (14±2.8)

Filtration area (cm )

2,550

Filtration particle size (µm)

105

Filtration area (cm )

2,550

Steering Filtration particle size (µm)

105 2

Breather valve (oil filling port) (S/N 9001~9300)

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

1 (0.01) (0.14)

Discharge valve setting pressure (kPa) (kgf/cm2) (psi)

29 (0.3) (4.3)

Filtration area (cm2)

235

Filtration particle size (µm)

Pushing load before turning cap required for venting pressure, removing or installing cap N (kgf) (lb) Suction valve setting pressure (kPa) (kgf/cm2) (psi) Breather valve (oil filling port) (S/N 9301~)

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

186.2~215.6 (19~22) (42~48) 3.9 (0.04) (0.57) 29 (0.3) (4.3)

Filtration area (cm2)

160

Filtration particle size (µm)

42-16 95ZV-2 Function & Structure Hydraulic Group Hydraulic Tank

Hydraulic oil level check

Bucket on ground

Hydraulic tank

(40 US gal)

150 L

Oil level sight gauge

95ZV42010

Before checking the hydraulic oil level, observe the following items: - Check that the machine is on level ground. - Check the hydraulic oil level before operation (when oil is not warm). - Lower the boom to the lowest limit, and set the bucket level on the ground. Check that the oil level is at the center of the oil level sight gauge. Oil amount 150 L (40 US gal) Note If the oil is at operating temperature 60°C ~ 90°C (140°F ~ 200°F) the oil level may be at or near the top of the oil level sight gauge.

42-17 95ZV-2 Function & Structure Hydraulic Group Hydraulic Pump

Hydraulic Pump Loading and pilot and brake pump/Steering pump 5

2 6

3 4 7

8 (S/N 9179~)

K95V2U42005

5. Oil seal 6. Bushing 7. Wear plate (floating type) 8. Damper (S/N 9179~)

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

Loading and pilot and brake pump/Steering pump specifications Two types of pump are different in only one place. Loading and pilot and brake pump has two discharge ports, but steering pump has one because of the common discharge port.

Applicable circuit Theoretical discharge Maximum operation pressure Maximum speed

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

Front

Rear

For loading

For brake and pilot

For steering

80.0

71.3

20.6±0.5 (210±5) (2,986±71)

20.6±0.5 (210±5) (2,986±71) 2,500

42-18 95ZV-2 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.

42-19 95ZV-2 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)).

42-20 95ZV-2 Function & Structure Hydraulic Group Hydraulic Cylinder

Hydraulic Cylinder 21. Wear ring 22. Stop ring 23. Bushing 24. — 25. Bolt 26. Washer 27. Plug 28. O-ring 29. Plug 30. Piston packing

11. O-ring 12. Slipper ring 13. Back ring 14. O-ring 15. Wear ring 16. Piston nut 17. Stop ring 18. Flange bolt 19. — 20. Dust seal

1. Piston 2. Piston rod 3. Cylinder tube 4. Rod cover 5. Dust seal 6. Backup ring 7. U-packing 8. Buffer ring 9. Bushing 10. Backup ring

Boom cylinder

20,23

21 16 15 14 12,13 1

6,7 10,11 9

5,17

18 3

4 97ZV42025

: Piston nut (16): 6,669 N-m (680 kgf-m) (4,920 lb-ft) : Bolt (18): 843 N-m (86 kgf-m) (622 lb-ft)

Bucket cylinder 20 23

16 15 30 15 1

11 6 17 9 10 4 8 7 5 25

20 23

A 27,28 (Gauge port PF1/4)

27,28 (Gauge port PF1/4)

5 A

(S/N 9194~)

: Piston nut (16): 5,900±300 N-m (602±30.6 kgf-m) (4,353±221 lb-ft) Bolt (25): 880±90 N-m (89.7±9.2 kgf-m) (649±67 lb-ft)

K95V2E42005

42-21 95ZV-2 Function & Structure Hydraulic Group Hydraulic Cylinder

Steering cylinder

20,23

15 14 13 12 1

8 6,7 10,11 9 11 17 5

20,23

97ZV42027

: Rod cover (4): 1,765 N-m (180 kgf-m) (1,302 lb-ft) : Piston nut (16): 1,275 N-m (130 kgf-m) (941 lb-ft)

42-22 95ZV-2 Function & Structure Hydraulic Group Hydraulic Cylinder

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

Pin hole (inner diameter x width)

Piston rod

ø100 x 226 (3.93 x 8.90)

Cylinder

ø100 x 228.5 (3.93 x 9.00)

Inner diameter x rod diameter x stroke Bucket cylinder

Pin hole (inner diameter x width)

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

Piston rod

ø90 x 100 (3.54 x 3.93)

Cylinder

ø90 x 100 (3.54 x 3.93)

Inner diameter x rod diameter x stroke Steering cylinder

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

ø90 x ø50 x 600 (3.54 x 1.96 x 23.62)

Piston rod

ø50 x 70 (1.97 x 2.75)

Cylinder

ø50 x 70 (1.97 x 2.75)

42-23 95ZV-2 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 control valve

Oil packs

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.

42-24 95ZV-2 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)

Orifice 2

From front brake accumulator circuit

(Z2)

(PPI)

Tank Valve assembly

Note: Valve is shown rotated 180º from normal.

A Orifice 1

Passage Z

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

85V2E42005

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)

42-25 95ZV-2 Function & Structure Hydraulic Group Pilot valve (S/N 9001~9250)

Pilot valve (S/N 9001~9250) 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

A (Port 1, 2)

From Bottom

B (Port 3, 4)

K115V2U42003

42-26 95ZV-2 Function & Structure Hydraulic Group Pilot valve (S/N 9001~9250)

Dump

Roll back (Detent)

Float (Detent) Down

Raise (Detent)

2 7

3 9

4 6

Identifying mark

8 10

2 5 Identifying mark

9 10

13 23

To tank port

14 15

From pump port

17 Port1 Port2 To/from MCV oil packs

Port3 Port4 To/from MCV oil packs

For bucket control

For boom control

(Section A-A)

(Section B-B)

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

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

115V2U42021

42-27 95ZV-2 Function & Structure Hydraulic Group Pilot valve (S/N 9001~9250)

Pilot valve function 1

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

21 19

Pilot valve operation (modulated position) 3 Predetent section

10 10

22 14

23 14

15 24

Lever is in the neutral position 85V2E42009

P Reducing valve Multiple control valve Oil pack

From front brake accumulator

85V2E42008

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.

42-28 95ZV-2 Function & Structure Hydraulic Group Pilot valve (S/N 9001~9250)

21 19

Predetent section

25 13 22

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.

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.

42-29 95ZV-2 Function & Structure Hydraulic Group Pilot valve (S/N 9001~9250)

Pre-detent and detent magnet solenoid 1 21 20

21 19 20

3 2 18

7 3

8 9

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

10 T T

P Actuation of electromagnetic detent 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.

42-30 95ZV-2 Function & Structure Hydraulic Group Pilot valve (S/N 9251~9255)

Pilot valve (S/N 9251~9255) 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

A (Port 1, 2)

B (Port 3, 4)

From Bottom K115V2U42003

42-31 95ZV-2 Function & Structure Hydraulic Group Pilot valve (S/N 9251~9255)

Dump

Roll back (Detent)

Float (Detent) Down

Raise (Detent)

2 7

3 9

4 6

Identifying mark

8 10

2 5 Identifying mark

9 10

11 12 23 23

To tank port

14 15

From pump port

17 Port1

Port2

Port3

To/from MCV oil packs

For bucket control (Section A-A)

For boom control (Section B-B)

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

Port4

K92V2E42001

42-32 95ZV-2 Function & Structure Hydraulic Group Pilot valve (S/N 9251~9255)

Pilot valve function 1

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

21 19

Pilot valve operation (modulated position) 3 Predetent section

10 10

22 14

23 14

15 24

Lever is in the neutral position K92V2E42003

P Reducing valve Multiple control valve Oil pack

From front brake accumulator

K92V2E42002

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.

42-33 95ZV-2 Function & Structure Hydraulic Group Pilot valve (S/N 9251~9255)

21 20

Predetent section

Lever is shifted from the neutral K92V2E42004

42-34 95ZV-2 Function & Structure Hydraulic Group Pilot valve (S/N 9251~9255)

Pre-detent and detent magnet solenoid 1 21 20

21 19 20

3 2 18

7 3

8 9

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

10 T

P Actuation of electromagnetic detent K92V2E42006

Actuation of pre-detent K92V2E42005

42-35 95ZV-2 Function & Structure Hydraulic Group Pilot valve (S/N 9256~)

Pilot valve (S/N 9256~) Float/Down

Raise (Detent)

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

Dump

From Top 18.20

White (Male) (for port 4 solenoid)

16.20

For bucket control

For boom control

P T 1

A 1

(Port 1, 2)

B (Port 3, 4)

From Bottom 90Z542003

42-36 95ZV-2 Function & Structure Hydraulic Group Pilot valve (S/N 9256~)

Dump

Roll back (Detent)

Float (Detent) Down

Raise (Detent)

2 7

3 9

4 6

Identifying mark

2 5 Identifying mark 9 10 11 12 23

14 15

16 From pump port

To tank port

15 24

Port1

Port2

Port3

To/from MCV oil packs

For bucket control (Section A-A)

For boom control (Section B-B)

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

Port4

90Z542004

42-37 95ZV-2 Function & Structure Hydraulic Group Pilot valve (S/N 9256~)

Pilot valve function 1

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

21 19

Pilot valve operation (modulated position) 3 Predetent section

10 10

22 14

23 14

15 24

Lever is in the neutral position 90Z542006

P Reducing valve Multiple control valve Oil pack

From front brake accumulator

90Z542005

42-38 95ZV-2 Function & Structure Hydraulic Group Pilot valve (S/N 9256~)

21 20

Predetent section

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

Lever is shifted from the neutral 90Z542007

42-39 95ZV-2 Function & Structure Hydraulic Group Pilot valve (S/N 9256~)

Pre-detent and detent magnet solenoid 1 21 20

21 19 20

3 2 18

7 3

8 9

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

T P

Actuation of electromagnetic detent 90Z542009

Actuation of pre-detent 90Z542008

42-40 95ZV-2 Function & Structure Hydraulic Group Multiple Control Valve (KML35A/2T003B)

Multiple Control Valve (KML35A/2T003B)

7 3 B2

b2 C

C B1

b1 B

B P

2 P

A 1

A-A

Bucket Spool

Boom Spool

6 B1

6 B2

A1 4

B-B

C-C 95ZV42074

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

42-41 95ZV-2 Function & Structure Hydraulic Group Multiple Control Valve (KML35A/2T003B)

Boom

B2 A2

Multiple control valve specifications

Bucket

B1 A1

Model

KML35A/2T003B

Main relief valve setting pressure

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

Overload relief valve setting pressure

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

b2 b1 Hydraulic line diagram

P 95ZV42023

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

Overload 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

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

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

Multiple control valve main relief valve

Main relief valve operation Relief poppet

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

Plunger Orifice 1

Passage B Tank port

Pump port

Spring Body seat Passage A Seat Filter

Spring

95V2E42005

Passage C Adjusting screw

Passage D Tank port

Pump port

Lock nut Cap nut

Plug

Plunger 95V2E42006

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

42-43 95ZV-2 Function & Structure Hydraulic Group Multiple Control Valve (KML35A/2T003B) Note Clogging of the orifice in plunger will cause low pressure. Another possible cause of low pressure is contamination in, or damage to, the seat of relief poppet or plunger.

Adjusting set pressure Remove the cap nut. 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.

42-44 95ZV-2 Function & Structure Hydraulic Group Multiple Control Valve (KML35A/2T003B)

Multiple control valve overload relief valve (with make-up function) (Installed on both the rod and bottom sides of the bucket circuit)

Overload relief valve operation When the oil pressure is at the preset valve or less

Relief poppet

Passage A

Orifice 1 Plunger Plunger seat

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.

Tank port

Spring Passage B Seat

Cylinder port 95V2E42007

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

Passage C

Passage D

Plunger

Adjusting screw

Lock nut Body

Tank port

Cylinder port 95V2E42008

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

42-45 95ZV-2 Function & Structure Hydraulic Group Multiple Control Valve (KML35A/2T003B)

Make-up valve operation

Adjusting set pressure Plunger Plunger seat Adjusting screw Spring

Tank port

Cylinder port

Passage E

Tank port

When the pressure at the cylinder port becomes less than tank pressure, the plunger seat is moved to the right by the pressure area difference of the plunger seat between the right and left. The plunger seat opens the port and the oil flows to the cylinder port through passage E. It prevents a vacuum (negative pressure) in the cylinder.

Cylinder port 95V2E42010

95V2E42009

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.

Note The make-up valve function is non-adjustable.

Lock nut

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)

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

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

42-46 95ZV-2 Function & Structure Hydraulic Group Multiple Control Valve (KML35A/2T003B)

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

D A1

From pilot valve

Pa1

To pilot valve Pb1

Spool

C From pump

95ZV42024

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

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

42-47 95ZV-2 Function & Structure Hydraulic Group Multiple Control Valve (KML35A/2T003B) 2. "Bucket Dump" position

To pilot valve

Pa1

From pilot valve Pb1

Spool

C From pump

95ZV42025

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

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

42-48 95ZV-2 Function & Structure Hydraulic Group Multiple Control Valve (KML35A/2T003B)

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

D B2

A2 From pilot valve

Pa2

To pilot valve Pb2

Spool

C From pump

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

95ZV42026

42-49 95ZV-2 Function & Structure Hydraulic Group Multiple Control Valve (KML35A/2T003B) 2. "Boom Down" position

D A2

To pilot valve

Pa2

From pilot valve Pb2

Spool

C From pump

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

95ZV42027

42-50 95ZV-2 Function & Structure Hydraulic Group Multiple Control Valve (KML35A/2T003B) 3. "Boom Float" position

A2 To pilot valve

Pa2

From pilot valve Pb2

Spool

From pump

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

95ZV42028

42-51 95ZV-2 Function & Structure Hydraulic Group Adapter (Orifice)

Adapter (Orifice)

ø1.3 mm

O-ring

Orifice

Adapter

Installation position

Port b2

Multiple control valve

80ZV42018

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

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

42-52 95ZV-2 Function & Structure Hydraulic Group Ride Control (OPT)

Ride Control (OPT) Ride control hydraulic circuit 4 (15)

(18)

(16)

(H)

(X) 3

(Ac)

(Ac2)

(T)

Capacity: 9.5 L Gas pressure: 1.96 MPa (20 kgf/cm2) (284.2 psi)

(Ac1)

(14) (Ac1)

(5)

From multiple control valve

1 (13)

(br) (R)

Multiple control valve P line

Multiple control valve T line

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

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

(11)

(T)

95V2E42011

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 mile/h), solenoid valves (11)(16) come to ON by a signal from the machine control unit (MCU), then the ride control works. When the machine travelling speed goes down to 5 km/ h (3.1 mile/h) or slower, no signal transferred from the MCU, as a result, the ride control does not work.

42-53 95ZV-2 Function & Structure Hydraulic Group Ride Control (OPT)

Ride control operation Preparation mode (ride control switch is OFF) 4 (15)

(18)

(16)

(H)

(X) 3

(Ac)

(Ac2)

(T)

Capacity: 9.5 L Gas pressure: 1.96 MPa (20 kgf/cm2) (284.2 psi)

(Ac1)

(14) (Ac1)

(5)

From multiple control valve

1 (13)

(br) (R)

Multiple control valve P line

Multiple control valve T line

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

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

(11) 95V2E42011

42-54 95ZV-2 Function & Structure Hydraulic Group Ride Control (OPT)

Running mode (ride control switch is ON) 4 (15)

(18)

(16)

(H)

(X) 3

(Ac)

(Ac2)

(T)

(Ac1)

Capacity: 9.5 L Gas pressure:

(Ac1)

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

(14)

(5)

From multiple control valve

1 (13) Multiple control valve P line

Multiple control valve T line

(br)

(R)

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

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

(11)

115V2E42029

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

42-55 95ZV-2 Function & Structure Hydraulic Group Ride Control (OPT)

Ride control valve assembly (Reducing valve circuit) Outline drawing

1 Tank

Pump

2 (T) (P)

(R)

Boom cylinder rod side

(Ac1) Accumulator

4 6 5

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

(T) #2

#3,#4

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

(br) Hydraulic circuit 95V2E42012

42-56 95ZV-2 Function & Structure Hydraulic Group Ride Control (OPT)

Reducing valve

Check valve

Passage A

Accumulator

Bleeder valve

Passage B Passage B Tank

Poppet

Tank Orifice 2

Sleeve

Ball Reducing valve

95V2E42014

Orifice 1 Pump

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

Passage A Plunger

Check valve 95V2E42013

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

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

42-57 95ZV-2 Function & Structure Hydraulic Group Ride Control (OPT)

Solenoid valve

Solenoid

Chamber A Spring Orifice

Boom cylinder rod side

Sleeve

Seat face Spool Tank

95V2E42015

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

Solenoid specifications Voltage

DC 24 V

Current

0.92 A

Resistance

26.2 Ω

42-58 95ZV-2 Function & Structure Hydraulic Group Ride Control (OPT)

Ride control valve assembly (Accumulator circuit) Outline drawing 6

2 1

3 4 T

Tank

Boom cylinder bottom side

AC1

Reducing valve

AC2

AC Accumulator

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

95V2E42016

#3,#4 #2 (H) #5 (X) (Ac1) (T)

(Ac2)

(Ac)

Hydraulic circuit

95V2E42017

42-59 95ZV-2 Function & Structure Hydraulic Group Ride Control (OPT)

Shuttle valve

Solenoid valve

Movable iron core Passage A

Solenoid valve Solenoid Passage B

Accumulator

Rod Passage C

Ball Boom cylinder bottom side

Spool

Passage B 95V2E42018

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

Tank Shuttle valve

Passage A A

Check valve

Sleeve 95V2E42019

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

DC 24 V

Current

0.92 A

Resistance

26.2 Ω

42-60 95ZV-2 Function & Structure Hydraulic Group Ride Control (OPT)

Check valve Passage B

Reducing valve (sol. valve)

Pressure receive face E Poppet

Passage A

Passage C Boom cylinder bottom side

Shuttle valve

Passage D

Pressure receive face F

Sleeve

Seat face Accumulator

95V2E42020

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

42-61 95ZV-2 Function & Structure Hydraulic Group Ride Control (OPT)

Accumulator (for ride control)

7 2

3 13 10

12 11 5 8 9 6

95ZV52058

1. Body 2. Hydraulic cap 3. Gas cap 4. Piston 5. V-O ring

11. Gas valve O ring 12. Gas valve guard 13. Bolt

6. Back up ring 7. Wear ring 8. O-ring 9. Back up ring 10. Gas valve

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).

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)

Capacity (l)

9.5

42-62 95ZV-2 Function & Structure Hydraulic Group Steering System

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

From reducing valve

Orbitrol®

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

Steering cylinder

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

Stop valve

Stop valve RH

While the steering wheel is not turned, almost all 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.

Oil cooler

Finally it returns to the tank through the return filter.

Return filter

42-63 95ZV-2 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

6 7

T L Valve

1 2

3 4

Rotor

85V2E42018

42-64 95ZV-2 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® specifications

- 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.

Theoretical discharge (cm3/rev)

120

Operation pressure MPa (kgf/cm2) (psi)

3.5 (36) (512)

Model

- 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

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. - Rotor (4) rotation is transmitted to the valve part by means of the connected drive shaft (5), and the degree of valve opening is regulated depending on how fast the steering wheel is being turned.

ND-K5-D

42-65 95ZV-2 Function & Structure Hydraulic Group Orbitrol®

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

L Oil hole

6 7

Oil groove

1 2

70ZV42025

3 4

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.

42-66 95ZV-2 Function & Structure Hydraulic Group Orbitrol®

Turn (When the steering wheel is being turned)

8 6 1

6 7

T L

2 Oil hole

5 1

R Oil groove

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

42-67 95ZV-2 Function & Structure Hydraulic Group Orbitrol®

Orbitrol® feed-back mechanism operation

Spool

Sleeve

Cross pin

Drive shaft Steering valve Pa port Steering valve Pb port

Stator

Rotor

K80V2J42003

- When an angle of displacement (deviation in 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.

42-68 95ZV-2 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

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.

42-69 95ZV-2 Function & Structure Hydraulic Group Orbitrol®

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

Drive shaft (1/14 rotation)

Drive shaft (1/7 rotation)

Rotor (rotation) Stator (fixed)

Locus of rotor center

1 7

1 2

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

- Inside the rotor there is a stator with 7 internal gears that is fixed to the housing and a 6-tooth rotor that is engaged with the stator. - Half of the chamber formed by the stator and the rotor is connected to the high-pressure side and the other half to the low-pressure side. When high-pressure oil flows into the chamber, the rotor is forced to turn in the direction that will expand the area of the chamber (by means of pressure difference). - 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.

42-70 95ZV-2 Function & Structure Hydraulic Group Steering Valve (KVS32-A4.0/20)

Steering Valve (KVS32-A4.0/20) 7

ø 3.0 mm (0.118") P

(G)

3 MR A

5 T P. B.

(F) 2 3 MR

ø 3.0 mm (0.118")

A-A (LC)

4 AR

B-B

6 95V2E42021

1. Steering spool 2. Flow control spool 3. Main relief valve 4. Overload relief valve (with make-up valve) 5. Check valve 6. Orifice [ø 0.7 mm] (with filter) 7. Gauge port

42-71 95ZV-2 Function & Structure Hydraulic Group Steering Valve (KVS32-A4.0/20) 1. Steering spool

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 spools are check valves which apply a back pressure to oil returning from the cylinders.

AR BR Pa

(G)

Pb 0.7 RF

T MR

3.0 Orifice

P Hydraulic circuit

P. B. Pc 95V2E42022

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

2. Flow control spool 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 oil pressure caused by external force and a vacuum in the steering oil line. Model

KVS32-A4.0/20

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)

42-72 95ZV-2 Function & Structure Hydraulic Group Steering Valve (KVS32-A4.0/20)

Steering valve operation Neutral position (Steering spool in "Neutral")

Loading circuit

95V2E42023

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

- When the pump line pressure increases to 0.63 MPa (6.4 kgf/cm2) (91.4 psi), 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.

42-73 95ZV-2 Function & Structure Hydraulic Group Steering Valve (KVS32-A4.0/20)

Left turn position

Loading circuit

Pump

Pilot pressure

Check valve

1 Tank Variable throttle

95V2E42024

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

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

42-74 95ZV-2 Function & Structure Hydraulic Group Steering Valve (KVS32-A4.0/20) - 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. - 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.

Steering spool variable throttle

Variable throttle 95V2E42025

When the steering spool 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 spool to the left. The pressure difference varies depending on the opening area of the variable throttle and the passing oil flow rate, and the control pressure is set to 0.63 MPa (6.4 kgf/cm2) (91.4 psi).

42-75 95ZV-2 Function & Structure Hydraulic Group Steering Valve (KVS32-A4.0/20)

Steering valve flow control spool Loading circuit Pump

Spring

PA PB B

Variable throttle

Steering circuit

Loading circuit Pump

PA PB

Steering circuit

95V2E42026

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

42-76 95ZV-2 Function & Structure Hydraulic Group Steering Valve (KVS32-A4.0/20)

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

Loading circuit

Pump

Flow control spool Filter

Steering spool

Cylinder

Tank

Cylinder

95V2E42027

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

42-77 95ZV-2 Function & Structure Hydraulic Group Steering Valve (KVS32-A4.0/20)

When the pressure exceeds the preset value

Loading circuit

Pump

Flow control spool

A B

Steering spool

Tank

95V2E42028

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

42-78 95ZV-2 Function & Structure Hydraulic Group Steering Valve (KVS32-A4.0/20)

Steering valve overload relief valve External force

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

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

Tank 95V2E42029

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.

42-79 95ZV-2 Function & Structure Hydraulic Group Steering Valve (KVS32-A4.0/20)

Overload relief valve operation C

Make-up valve operation K

G A Cylinder

Cylinder

E D

Tank

115ZV42052

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

Cylinder

E D

Tank

115ZV42053

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

Tank

115ZV42054

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

42-80 95ZV-2 Function & Structure Hydraulic Group Steering Valve (KVS32-A4.0/20)

Steering pilot circuit and its operation

From pump Orbitrol®

Reducing valve To tank

Filter

Steering valve

To tank

Cylinder

Stop valve

End cover

Flow amplifier notch Pilot line

Pilot orifice Tank

K97V2J42006

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

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

42-81 95ZV-2 Function & Structure Hydraulic Group Steering Valve (KVS32-A4.0/20)

Return spring force

Return spring

Pilot oil

Hydraulic force

Pilot pressure

Flow amplifier notch and pilot orifice

End cover Pilot orifice Flow amplifier notch Pilot line

Flow amp. notch opening

K115V2J42005

Pilot orifice

Return spring force

Hydraulic force

Pilot pressure

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

Flow amp. notch opening

Pilot orifice 80V2U42005

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

80V2U42006

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

42-82 95ZV-2 Function & Structure Hydraulic Group Stop Valve

Stop Valve 17.0 mm (S/N ~9257) 14.5 mm (S/N 9258~9300) 16.0 mm (S/N 9301~) (Full stroke)

From Orbitrol®

A B

To steering valve

3 (S/N 9251~) K115V2E42003

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

97ZV42042

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

42-83 95ZV-2 Function & Structure Hydraulic Group Stop Valve

Stop valve function

Stopper (bolt)

Stop valve operation

Port A Port B From To steering valve Orbitrol® Spool

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.

95V2E42049

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

42-84 95ZV-2 Function & Structure Hydraulic Group Reducing Valve (for Orbitrol®)

Reducing Valve (for Orbitrol®)

Spring

(T)

Sleeve

Tank Plunger Pump

Passage Z

(A)

B A

B A Passage Y

(TS)

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)

42-85 95ZV-2 Function & Structure Hydraulic Group Steering Line Filter

Steering Line Filter

From pump (steering valve)

To reducing valve

FILTER

5 70ZV42040

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

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

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

Front

Center pin center line

Reducing valve

Line filter

Rear chassis

Installation position for steering pilot line filter

95V2E42032

42-86 95ZV-2 Function & Structure Hydraulic Group K-Lever (OPT)

K-Lever (OPT) Hydraulic circuit

[K-Lever handle]

1 4 2 Horn switch

R N F

Solenoid valve

95V2U42009

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

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 possible by 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. Orbitrol®

The K-Lever handle is connected to a potentiometer. This potentiometer changes the input voltage from 2.5 V DC down to 0 V DC, or from 2.5 V DC up to 5 V DC and is interpreted as input voltage at the MCU (machine control unit). 2.5 V DC is input for no steering action. Raising or lowering the voltage creates steering input. Solenoid valve

95V2U42008

42-87 95ZV-2 Function & Structure Hydraulic Group K-Lever (OPT)

Hydraulic line diagram

Solenoid valve assembly Orbitrol®

120 3 cm /rev

Stop valve

A B

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

A P.B.

Steering valve

95 m

Reducing valve

95V2U42010

42-88 95ZV-2 Function & Structure Hydraulic Group K-Lever (OPT)

Hydraulic line From Orbitrol® (R) Steering valve

(R) (L)

(P) (T)

3 2

From Orbitrol® (L)

Orbitrol®

2 3 (T)

(P)

1 4

(P)

(R) (L)

(T)

2 1

1. High pressure hose 2. High pressure hose 3. High pressure hose 4. High pressure hose

View A-A 95V2U42011

42-89 95ZV-2 Function & Structure Hydraulic Group K-Lever (OPT)

Solenoid valve mount

Front

95V2U42012

1. Solenoid valve assembly 2. Orbitrol®

42-90 95ZV-2 Function & Structure Hydraulic Group K-Lever (OPT)

Solenoid valve assembly (1/2)

Front

2 Orbitrol®

PG2

1 3

B-B

B 1 T1

L1 2

Sol. a

PG5

Sol. b

B X P

A B 4

PG3 PG4 L1 R1

PG1

1. Block 2. Solenoid valve assembly 3. Adapter 4. Plug

PG3

PG4

L0 R0

A-A

T1 P1

PG5

T0 P0

PG1 PG2 Hydraulic line

95V2U42013

42-91 95ZV-2 Function & Structure Hydraulic Group K-Lever (OPT)

Solenoid valve assembly (2/2)

9 8

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.

42-92 95ZV-2 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

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.

85V2E42054

Note The efficient loading system works under the condition that the engine revolution is lower than 1,000 min-1, even if the efficient loading system switch is OFF position. When the engine revolution becomes higher than 1,300 min-1, it stops working.

42-93 95ZV-2 Function & Structure Hydraulic Group Efficient Loading System

Mounting of the ELS valve 3

ELS valve

From main pump

Center pin center line

(P)

(A) Multiple control valve

(T)

Rear chassis

To hydraulic tank

Hydraulic line

2 P

1 3 Axle center line

Detail of ELS valve section 95V2E42033

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

42-94 95ZV-2 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

5,8

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

42-95 95ZV-2 Function & Structure Hydraulic Group Efficient Loading System

Efficient loading system operation While the ELS is not operating

While the ELS is operating

Multiple control valve P line

From main pump

To hydraulic tank

95V2U42002

95V2U42003

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 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.

42-96 95ZV-2 Function & Structure Hydraulic Group Fan Motor System

Fan Motor System Mounting of fan motor 2

19.0 mm (0.75 in)

18.0 mm (0.71 in)

19.6 mm (0.77 in)

18.7 mm (0.74 in)

T1 L2

(S/N ~9257)

(S/N 9258~) A-Detail

T2 In case of using new fan with old frange Washer x2 (additional parts) 3

(62710-18121)

B 6

2 3 1

19.0 mm (0.75 in) 18.7 mm (0.74 in)

L2 Flange bolt x2 (alteration parts) (61802-12040)

Gauge port (PF3/8) B-Detail K95V2E42003

1. Fan motor 2. Fan (S/N ~9257) 3. Flange (S/N ~9257) 4. Fan (S/N 9258~) 5. Flange (S/N 9258~) 6. Proportional relief valve

: T1: 93.7 N-m (9.55 kgf-m) (69 lb-ft) T2: 441~539 N-m (45~55 kgf-m) (326~398 lb-ft) L2: With lubrication oil (Engine oil or gear oil)

42-97 95ZV-2 Function & Structure Hydraulic Group Fan Motor Line

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

Fan revolution (min-1)

1,300 Stepless control range

910

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

(750)

0 (Hibernate 725 800 mode)

Low temperature [below 60ºC (160ºF)]

1,200

(1,115) Engine revolution (min-1)

(1,577) Values inside ( ) are for reference.

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

Cooling fan

Fan motor (1)

K95V2E42002

The cooling fan is driven by the hydraulic motor. The pressure oil from the unloader valve flows into the port P of fan motor, and then, turns fan motor (1). Three kinds of signals sent from the engine water temperature sensor (S/N 9001~9150), ECM (S/N 9151~), torque converter oil temperature sensor, and hydraulic oil temperature sensor, are input into the MCU as information to regulate the maximum fan revolution. The fan revolution is regulated by proportional relief valve (2). The setting pressure of the proportional relief valve is changed in proportion as the electric current value from MCU.

To return filter Proportional relief valve (2) Hydraulic circuit diagram

From unloader valve 95V2E42041

Note Hydraulic oil temperature must be at operating temperature to do this fan revolution test. When proportional relief wire is disconnected, fan revolution should go to high speed mode.

42-98 95ZV-2 Function & Structure Hydraulic Group Fan Motor Line

Number of revolutions of fan (min-1)

Output current F for control of the fan revolution Proportional relief valve [mA]

Proportional relief valve [mA]

About

910

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

1,300

0 0 80 (176)

( C)

110

(201.2) ( F) T E/G

(230)

The signal of the engine coolant temperature

115 ( C)

95 ( C)

(239) ( F)

(194) T H/D

(203) ( F)

T T/M The signal of the torque converter oil temperature

The signal of the hydraulic oil temperature

Control of the fan revolution 95V2E42050

When the input electric current value to proportional relief valve (2) is maximum (approximately 190 mA), the fan revolution is minimum value (910 min-1) because bypass oil amount at proportional relief valve (2) is increased. When this value is minimum (0 mA), the fan revolution is maximum value (1,300 min-1) because bypass oil amount at proportional relief valve (2) is decreased. For example, when the engine water temperature is low, the electric current value from the MCU to proportional relief valve (2) is big. As a result, bypass oil amount from port P to fan motor (1) line becomes big, and then the fan revolution becomes low. When the torque converter oil temperature is below 110ºC (230ºF) and the hydraulic oil temperature is below 90ºC (194ºF), the fan revolution is controlled only by engine water temperature.

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 proportional relief valve (2).

42-99 95ZV-2 Function & Structure Hydraulic Group Fan Motor Line

Hydraulic circuit (fan motor normal rotation) Fan motor (1)

Make-up valve (3)

Safety valve (4)

Proportional relief valve (2)

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

Brake circuit

For brake and pilot pump

Unloader valve

Hydraulic tank

Hydraulic circuit diagram 95V2E42043

Make-up valve 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. When engine stops, the pressurized oil from the pump is not supplied to fan motor (1) inlet port, as a result, the fan motor revolution speed gradually decreases.

Oil supply is stopped, however the fan is still turning by the inertial force. This condition generates negative pressure at the motor inlet port. To prevent generation of negative pressure, make-up valve (3) opens so that the oil in the tank port flows into the fan motor inlet port.

42-100 95ZV-2 Function & Structure Hydraulic Group Fan Motor Line

Safety valve When accelerating engine, pump discharge pressure may rise extremely high. To prevent the fan motor line from damages, safety valve (4) is installed. If the pump discharge pressure exceeds the set pressure, safety valve (4) relieves the pressurized oil to the tank port.

42-101 95ZV-2 Function & Structure Hydraulic Group Fan Motor Line

Proportional relief valve (S/N 9001~9150) The proportional relief valve is installed between the unloader valve and the fan motor. This valve is the normally closed, pilot operated type. The setting pressure of the proportional relief valve is changed in proportion as the engine revolution and electric current value from the MCU.

Proportional relief valve operation When the oil pressure is at the preset value or less

Plunger

Solenoid

Chamber A

Lock nut

Body

Adjusting screw

Inlet pressure

Orifice 1 Spring 1

Orifice 2 Pilot poppet

Moving iron core

Spring 2

Coil lock nut 95V2E42044

The pressurized oil from the pump (the unloader valve) flows into the chamber A through the orifice 1, the plunger is pressed against the body by the spring 2 force. When the solenoid coil is not energized, the setting pressure is regulated by the spring 2 force. If the solenoid coil is energized by the signal of the MCU, the pressure setting is changed. As the electric current is applied to the coil, the movable iron core is pulled to the right and pushes the spring 2, so the spring 2 force is reduced with the increasing current, the setting pressure also decreases. Once a constant electronic signal is given, the pilot poppet is held in a given potion, holding the setting pressure. This is maintained by the balance between the electronic spring 2 force and inlet pressure.

42-102 95ZV-2 Function & Structure Hydraulic Group Fan Motor Line When the oil pressure exceeds the set point

Plunger

Chamber A

Solenoid Lock nut

Body

Adjusting screw Tank port Inlet pressure

Orifice 1 Spring 1

Orifice 2

Pilot poppet Moving iron core

Spring 2

Coil lock nut 95V2E42045

When the oil pressure against the pilot poppet through the orifice 2 rises above the setting pressure, pilot poppet is moved to the right and opens the port. Then the oil in the chamber A flows to the tank through clearance between the body and sleeve. As a result, the pressure in the chamber A rapidly lowers and plunger is moved to the right. Then the plunger opens the port to the tank port and the pressurized oil in the pump port escapes to the tank port.

Adjusting set pressure Disconnect the cable connector of proportional relief valve and loosen the lock nut and adjust the pressure by the adjusting screw. Turn clockwise the adjusting screw to raise the set pressure, or turn counterclockwise the adjusting screw to lower the set pressure. After adjustment, be sure to tighten the lock nut High pressure set: 18.1±0.5 MPa (185±5 kgf/cm2) (2,625±71 psi) at 0 mA

42-103 95ZV-2 Function & Structure Hydraulic Group Fan Motor Line

Proportional relief valve (S/N 9151~)

(G1) T1

9 10

(G1) P1

(P1) 4

(T1)

P2 (G1)

(G3/8) PG2

(PG2)

(P2) 1

(PG1)

(T2)

T2 (G1)

PG1 (G1/4)

2 8

Hydraulic line diagram

K95V2U42001

1. Block 2. Relief valve 3. Elbow adapter 4. Elbow adapter 5. Adapter 6. Plug 7. Plug (gauge port) 8. Plug 9. Relief valve 10. Solenoid valve

42-104 95ZV-2 Function & Structure Hydraulic Group Fan Motor Line

Adjusting set pressure It is not possible to adjust the set pressure on the machine. Replace relief valve cartridge (9), if necessary. : Relief valve (2): 60~70 N-m (6.1~7.1 kgf-m) (44~51 lb-ft) : Relief valve (9): 35~40 N-m (3.5~4.0 kgf-m) (25~29 lb-ft)

K95V2U42002

42-105 95ZV-2 Function & Structure Hydraulic Group Fan Motor Line

Fan motor

Port P

Port Tc

Port T 115V2E42030

Fan motor specifications Displacement capacity

3 3 90.3+2 -0 cm /rev (55.1 in /rev)

Pressure

21.3 MPa (217 kgf/cm2) (3,089 psi)

Speed

1,600 min-1

Flow

144 L/min (38 gal/min)

Control method

Continuous variable control with the proportional valve (not included in fan motor)

Rating

Speed control

42-106 95ZV-2 Function & Structure Hydraulic Group Fan Motor Line

Fan motor structure 1

A-A

14 P

TC 17

T 16

15 B-B

1. Output shaft 2. Case 3. Thrust plate 4. Piston assy 5. Cylinder block 6. Valve plate 7. Retainer guide 8. Retainer shoe 9. Main bearing

K95V2J42001

10. Sub bearing 11. Oil seal 12. End cover 13. Center spring 14. Make-up valve 15. Safety valve 16. Main spool 17. Spring

42-107 95ZV-2 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.

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

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

85V2E42043

This force pushes thrust plate (3) fixed at a certain angle α for output shaft (1), and it is divided into two component force F2 and F3. Among the component forces, radial component force F3 generates the torque T (T=F3 x ri) at each piston (4) located at a half of plate (6) separated by Y-Y line linking a top dead center to a bottom dead center.

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

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

85V2E42044

4 5

Supply side

3 Discharge side

85V2E42045

42-108 95ZV-2 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.

42-109 95ZV-2 Function & Structure Hydraulic Group Reversing Fan Motor Line (OPT)

Reversing fan motor (OPT) This figure is shown the optional reversing fan motor.

Reversing solenoid (Electrical connector)

Port P

Gauge port (M10 x 1.25)

Port Tc

Port T

95V2E42046

Fan motor specifications Displacement capacity

3 3 90.3+2 -0 cm /rev (55.1 in /rev)

Pressure

21.3 MPa (217 kgf/cm2) (3,089 psi)

Speed

1,600 min-1

Flow

144 L/min (38 gal/min)

Control method

Continuous variable control with the proportional valve (not included in fan motor)

Rating

Speed control

42-110 95ZV-2 Function & Structure Hydraulic Group Reversing Fan Motor Line (OPT) Fan motor structure 1

A-A

20 14 P

MB 19

TC 17

T 16

15 B-B

1. Output shaft 2. Case 3. Thrust plate 4. Piston assy 5. Cylinder block 6. Valve plate 7. Retainer guide 8. Retainer shoe 9. Main bearing 10. Sub bearing

K95V2J42002

11. Oil seal 12. End cover 13. Center spring 14. Make-up valve 15. Safety valve 16. Main spool 17. Spring 18. Filter (15 µm) (*) 19. Selector valve (*) 20. Reversing solenoid (*) (*) Optional parts for reversing fan motor

42-111 95ZV-2 Function & Structure Hydraulic Group Reversing Fan Motor Line (OPT)

Reversing fan control chart Reversing control

Normal control ON

Reversing solenoid valve

OFF

FVR1 Proportional solenoid valve output current Fv Proportional solenoid valve

FVR2

t FV1

t 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

t FV2

t AR1

1,800

t AR2

F VR1

Approx. 190

F VR2

85V2E42047

42-112 95ZV-2 Function & Structure Hydraulic Group Reversing Fan Motor Line (OPT)

Hydraulic circuit (Reverse rotation) Fan motor (1)

Reverse solenoid (6)

Selector valve (5)

To MCU (Reversing cooling fan switch)

Make-up valve (3)

Safety valve (4) MCU (Engine water temp. sensor T/C oil temp. sensor Hydraulic oil temp. sensor)

Proportional relief valve (2)

Brake circuit

For brake and pilot pump

Unloader valve

Hydraulic tank

Hydraulic line (reverse revolution)

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

95V2E42047a

42-113 95ZV-2 Function & Structure Hydraulic Group Secondary Steering

Secondary Steering Secondary steering motor and pump

Secondary steering relay (V4)

Pressure sensor

(E7) (H8)

Torque converter

(P4)

(P3)

Hydraulic pump

Check valve

Secondary steering motor and pump

Steering valve (X3)

Hydraulic circuit Electrical circuit

Check valve Check valve

K95V2E42004

Secondary steering operation Machine speed signal

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

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. ON

Machine speed

OFF

(km/h)

85V2E42051

42-114 95ZV-2 Function & Structure Hydraulic Group Secondary Steering

Speed sensor Pilot lamp

To steering valve

F13

MCU

Pressure sensor

Check valve

Check valve G1/2 G1/2

+24 V

Secondary steering motor and pump

G1/2 G1/2

G3/8

11.7MPa (119 kgf/cm2) (1696 psi)

10 cm3/rev G1/2

Check valve Secondary steering relay

G1/2

+24 V

Secondary steering motor and pump 11.7MPa (119 kgf/cm2) (1696 psi)

10 cm3/rev

80.0 71.3 cm3/rev cm3/rev

Magnetic switch (on motor and pump) Steering pump Hydraulic line Electrical circuit Secondary steering circuit 95V2E42036

42-115 95ZV-2 Function & Structure Hydraulic Group Secondary Steering

Secondary steering motor and pump CW rotation

Magnetic switch

Relief valve

+24 V

Motor

+24 V

Pump

Customer's power connection

Relief valve 11.7 MPa (119.3 kgf/cm2)

Customer's MCU connection

Customer's ground connection Electric/Hydraulic schematic 95V2E42039

Secondary steering motor and pump Model

ND-K2-D

Discharge (cm3/rev)

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

11.7 (119.3) (1,696)

85V2E42052

42-116 95ZV-2 Function & Structure Hydraulic Group

MEMO

43-1 95ZV-2 Check & Adjustment Hydraulic Group

95ZV-2 Check & Adjustment Hydraulic Group Loading/Steering Circuit Relief Valve/Ride Control Circuit Reducing Valve (OPT) ........................................................................... 43-2 Hydraulic Cylinder ................................................... 43-14 Stop Valve ............................................................... 43-17

43-2 95ZV-2 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 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 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)

43-3 95ZV-2 Check & Adjustment Hydraulic Group Loading/Steering Circuit Relief Valve/Ride Control Circuit Reducing Valve (OPT) Valve assembly

Gauge port Gauge port location

Port size

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

(PPI)

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

(Z2) (PA) (PARKING)

(Z)

(Z1) ACF

(ACCF)

(ACCR)

(TA)

Pilot line pressure (Reducing valve)

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

(4)

Bucket cylinder

(P)

Reducing valve (for pilot)

Note North America equipped M/c's have a quick connector in port (3) for testing.

85V2E43006

(2) (1) K97V2J43003

Multiple control valve

Make-up valve

Overload relief valve

(T)

Main relief valve

(3) 95ZV43002

43-4 95ZV-2 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

Cap Lock nut

2. Press the brake pedal. Set and confirm the transmission shift lever is neutral position. 3. Set and confirm the parking brake switch to the "ON" position. 4. Depress the brake pedal.

Adjusting screw

95ZV43004

5. Lower the boom to the lowest limit. 6. Attach the pressure gauge 30 MPa (300 kgf/cm2) (5,000 psi) to the bucket cylinder bottom side (2).

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

7. Set the declutch ON/OFF switch to ON. Press the brake pedal all the way to the floor.

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

Note To avoid "fuel saving mode at idle time". In "fuel saving mode at idle time", not activated promptly and engine may not reach the maximum revolution. Press the brake pedal all the way to the floor with the declutch ON/OFF switch to ON, release this mode. 8. Move the bucket control lever to the roll back position. Hold the lever at that position. 9. Increase the engine speed to the maximum, and measure and record the pressure using the pressure gauge.

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

43-5 95ZV-2 Check & Adjustment Hydraulic Group Loading/Steering Circuit Relief Valve/Ride Control Circuit Reducing Valve (OPT)

Measuring loading circuit overload relief pressure 1. Attach the pressure gauge to the port (3). ((1) for the rod side, (2) for the bottom side, (3) for the both sides.)

Adjusting overload relief pressure

Lock nut

2. Adjust the main relief valve pressure to 24.5 MPa (250 kgf/cm2) (3,555 psi) + 1/4 additional turn, so the pressure is above the overload relief pressure. Bucket cylinder bottom side (gauge port (2) or (3))

Adjusting screw

1. Lower the boom to the lowest limit. 95ZV43005

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 (gauge port (1) or (3)) 1. Keep the boom horizontal. 2. Move the bucket control lever to the dump position, hold and then measure and record the pressure.

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.

43-6 95ZV-2 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 the port (4).

Adjusting screw

2. Set the shift lever to the forward position. Note To avoid "Hibernate mode". 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.

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 After the completion of the adjustment of the pilot line pressure, be sure to tighten the lock nut.

43-7 95ZV-2 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

Measurement instruments

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.

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 Ride control line pressure (reducing valve) MPa (kgf/cm2) (psi) Valve assembly (Accumulator circuit)

Valve assembly (Reducing valve circuit)

8.34±0.3 (85±3) (1,209±43.5)

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

Gauge port Gauge port location Reducing pressure

95V2E43002

AC2

Port size G (PF) 1/4 with O-ring

43-8 95ZV-2 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 Loosen the lock nut of the reducing valve 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.

X T

IMPORTANT Tank H

Boom cylinder bottom side

AC1

Reducing valve

Plug

AC2

Accumulator

Valve assembly (Accumulator circuit)

Pump

Tank (T)

95V2E43003

Reducing valve Lock nut

(P)

Adjusting screw (R) (Ac1)

Air bleeder nipple

Valve assembly (Reducing valve circuit)

95V2E43004

1. Loosen the air bleeder nipple for releasing internal pressure from accumulator circuit. 2. Attach the pressure gauge to the gage port AC2. : Plug AC2: 16.7~20.6 N-m (1.7~2.1 kgf-m) 3. Keep the engine speed at low idle and then measure and record the pressure.

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

43-9 95ZV-2 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

Measurement instruments Pressure gauge 30 MPa (300 kgf/cm2) (5,000 psi) (for loading line with 3 m (10 ft.) hose and steering line with 1.5~3 m (4~10 ft.) hose) 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 temperature: 50±5ºC (120±9ºF)

43-10 95ZV-2 Check & Adjustment Hydraulic Group Loading/Steering Circuit Relief Valve/Ride Control Circuit Reducing Valve (OPT)

Gauge port Gauge port location

Port size

Main relief pressure (1), (2)

G (PF) 1/4 with O-ring

(3)

Rc (PT 1/8)

Overload relief pressure Reducing pressure

Steering valve

Main relief valve

Overload relief valve 95ZV43006

43-11 95ZV-2 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. Set and confirm the transmission shift lever is neutral position. 3. Set and confirm the parking brake switch to the "ON" position. 4. Depress the brake pedal.

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 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.

Steering cylinder

Adjusting steering line main pressure

(2)

Lock nut Note North America equipped M/c's have quick connectors at ports (1) and (2).

Adjusting screw

(1)

70ZV43007

5. Attach the pressure gauge to the gauge port ((1) or (2)). 6. Set the declutch ON/OFF switch to ON. Press the brake pedal all the way to the floor. Note To avoid "fuel saving mode at idle time". In "fuel saving mode at idle time", not activated promptly and engine may not reach the maximum revolution. Press the brake pedal all the way to the floor with the declutch ON/OFF switch to ON, release this mode. 7. In case the pressure gauge is installed to (1), steer the machine to the left until the front and rear chassis contact each other. Continue to hold the steering wheel fully turned. 8. Increase the engine speed to high idle, and measure and record the pressure.

95ZV43007

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

43-12 95ZV-2 Check & Adjustment Hydraulic Group Loading/Steering Circuit Relief Valve/Ride Control Circuit Reducing Valve (OPT)

Measuring steering circuit overload relief pressure

Adjusting overload relief pressure Lock nut Adjusting screw

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. 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.

95ZV43008

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.

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.

43-13 95ZV-2 Check & Adjustment Hydraulic Group Loading/Steering Circuit Relief Valve/Ride Control Circuit Reducing Valve (OPT)

Measuring pilot circuit relief pressure (reducing pressure)

Adjusting screw

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

Lock nut

IMPORTANT After the completion of the adjustment of the pilot line pressure, be sure to tighten the lock nut.

(T)

(A)

(3) (TS)

(B)

115ZV43007

1. Attach the pressure gauge to the port (3). Gauge port plug width across flat: 5 mm 2. Move the bucket control lever to the roll back position. 3. Set the shift lever to the forward position. Note To avoid "Hibernate mode". 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. 5. Hold the bucket control lever at the roll back position and record the pressure.

43-14 95ZV-2 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

43-15 95ZV-2 Check & Adjustment Hydraulic Group Hydraulic Cylinder Reference

Mark (Vinyl tape) Scale 95ZV43009

Drift rate depends on the viscosity of the hydraulic oil and its temperature. In other words, high temperature of the hydraulic oil reduces the viscosity. Reduction in oil viscosity increases oil leakage through the seals, and increases the drift rate. Cold thick oil reduces the drift rate.

IMPORTANT At the completion of measurement, if the vinyl tape used for measurement is not removed from the cylinder rod, the tape may be caught by the rod seal. The tape will cause oil leakage from the rod seal. To prevent oil leakage, be sure to remove the vinyl tape.

43-16 95ZV-2 Check & Adjustment Hydraulic Group Hydraulic Cylinder

Possible causes of excessive cylinder drift

Boom cylinder

Bucket cylinder Bucket cylinder

Boom cylinder

Boom cylinder rod side flange

Bucket cylinder rod side flange

Possible cause

95ZV03002

Solution

Damaged cylinder piston seal / barrel

Disassembly & repair

Defective multiple control valve overload relief valve

Disassembly & repair

Oil leakage from multiple control valve bucket spool

Disassembly & repair

- Identifying defective part Pressure is applied to the bucket cylinder bottom side to support the bucket. There should be no pressure applied to the cylinder rod side. Keep the boom and bucket horizontal, and stop the engine. Carefully loosen the split flange (see the arrow) on the cylinder rod side. If the compressed oil spouts from the cylinder, judge that the piston seal and/or cylinder barrel is damaged. If the compressed oil spouts from the hose side, judge that the piston seal of the other cylinder is defective. If no compressed oil spouts from the cylinder, judge that the cause is the defective multiple control overload relief valve or oil leakage from the main spool of multiple control valve. Note If only a few drops come out per minute it is considered normal.

Possible cause

95ZV03003

Solution

Damaged cylinder piston seal / barrel

Disassembly & repair

Oil leakage from multiple control valve boom spool

Disassembly & repair

- Identifying defective part Just like the bucket cylinder, no pressure should be applied to the rod side of the boom cylinder when the weight of the boom is resting on the boom cylinders. Carefully loosen the split flange (see the arrow) for the pipe on the cylinder rod side. If the compressed oil spouts from the cylinder, judge that the piston seal and/or barrel of the boom cylinder is damaged. If the compressed oil spouts from the pipe side, judge that the piston seal of the other cylinder is defective. If no oil spouts from the split flange, judge that oil is leaking from the multiple control valve spool.

43-17 95ZV-2 Check & Adjustment Hydraulic Group Stop Valve

Stop Valve Stop valve adjustment procedure

Reference dimension Front chassis

Stop valve (rear chassis)

Stopper (bolt)

(L.H, R.H)

Front chassis

Rear chassis

Reference dimension 23~27.5 mm (0.9~1.1 in) Stopper (bolt) length

Reference dimension 28~48 mm (1.1~1.9 in) Clearance between machine body and stopper

115ZV43005

115ZV43004

Articulation angle ( º)

WARNING When the machine turns, the clearance in the articulation area closes. As a result, people may be caught, leading to a severe accident. To prevent such an accident, observe the following items strictly when adjusting the steering stopper. - Stop the engine before starting adjustment of the stopper bolt. - When confirming the operation after setup, keep proper distance from the articulation area of the machine. The stop valve works when the spool is pushed in 3 mm (0.118 in). Adjust the stopper bolt by using the following procedure. - Adjust the stopper (bolt) length so that the clearance between the machine body and the stopper becomes the reference dimension "28~48 mm (1.102~1.890 in)" shown in the table below.

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

28 38 48 (1.102) (1.496) (1.890)

Stopper (bolt) length (mm) (in)

23 25 27.5 (0.906) (0.984) (1.083)

*The target value should be the articulation angle "36º". - After adjustment, turn the steering wheel slowly at a rate of 5 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)

43-18 95ZV-2 Check & Adjustment Hydraulic Group

MEMO

52-1 95ZV-2 Function & Structure Brake Group

95ZV-2 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 Brake Valve ............................................................. 52-10 Service Brake .......................................................... 52-14 Parking Brake.......................................................... 52-22 Parking Brake Manual Release............................... 52-29 Brake Circuit Check Valve....................................... 52-31 Auto Brake .............................................................. 52-32 Pressure Sensor (for stop lamp and declutch) ........ 52-34

52-2 95ZV-2 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 and the parking brake are the wet disc type. (Refer to "Hydraulic & Brake Circuit (S/N 9001~9250)" page 92-4 and "Brake Circuit" page 92-6.)

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 parking brake is the spring applied oil pressure released type. Turning on the parking switch turns off solenoid valve (35) for parking, returns the oil in brake piston chamber (55) to the tank, pushes the piston with the spring, and makes the brake effective. Turning off the parking switch turns on solenoid valve (35) for parking, oil flows into piston chamber (55), pushes the pistons over coming the spring force, and release the brake.

Adjustment of axle internal 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.

52-3 95ZV-2 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 spring applied oil pressure released type.

95V2E52001

1. Accumulator 2. Solenoid valve (for parking) 3. Solenoid valve (for auto-brake)

4. Brake valve 5. Parking brake 6. Unloader valve

52-4 95ZV-2 Function & Structure Brake Group Unloader Valve

Unloader Valve (S/N 9001~9048)

To accumulator

B-B

To tank

8 9

To fan motor

Filter

17 Pilot port (accumulator feedback port)

16 A-A

15 12

From pump

Pump port

Fan motor port

Accumulator port

Fan motor port Pilot port (accumulator feedback port) Tank port

Tank port

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

Rc 1/8

Accumulator port Hydraulic circuit diagram

P Pilot port (accumulator feedback port)

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

Pump port Outline drawing

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

K115ZV52001

52-5 95ZV-2 Function & Structure Brake Group Unloader Valve (S/N 9049~)

To accumulator

B-B

To tank

To fan motor

21 22

25 19

26 18

10 1

3 16 Filter

4 15

Pilot port (accumulator feedback port)

A-A

From pump

Fan motor port

Accumulator port

Pump port

Fan motor port Pilot port (accumulator feedback port)

Tank port

Rc 1/8

Tank port

Accumulator port

P Pilot port (accumulator feedback port)

Hydraulic circuit diagram

1. Body 2. Spring 3. Spool 4. O-ring 5. Plug 6. Orifice 7. Orifice 8. O-ring 9. Plug 10. Plug (gauge port) 11. Governor plunger 12. Spring 13. O-ring

Pump port K115ZV52002

14. Plug 15. Pilot valve 16. Spring seat 17. Spring 18. Spring 19. O-ring 20. Plug 21. Adjusting screw 22. Lock nut 23. — 24. — 25. Seat 26. O-ring

52-6 95ZV-2 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)

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

52-7 95ZV-2 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)

(PA)

(Z)

(Z1)

(Z2)

Solenoid valve (Auto brake)

ACF

(ACCF)

Wet type parking brake

(ACCR) (PI)

(PARKING)

(TA)

Unloader valve "feed back" signal.

(P) Tank

Pump port (from unloader valve)

(T)

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 95V2U52002

WARNING

ACCR

ACCF To parking brake ACF Rc1/8

1 B

2 P

A Z2 G1/4

T ACF T Rc1/8 G1/2

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

95V2U52003

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

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

52-8 95ZV-2 Function & Structure Brake Group Valve Unit

Accumulator low pressure sensor

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

(V) 5 4 3 2 1

10 (102) (1422)

20 (204) (2844)

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

95V2E52095

52-9 95ZV-2 Function & Structure Brake Group Accumulator

Accumulator

7 2

3 13 10

12 11 5 8 9 6

95ZV52058

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

The accumulator holds a reserve of pressurized oil for the brake circuit prevent disability of the brakes caused by a problem with the pump, etc. Two accumulators are provided in the service brake line. Nitrogen gas at 2.94 MPa (30 kgf/cm2) (427 psi) is charged in the gas chamber. One accumulator of the same type is provided also in the dry type parking brake line, locate in the front chassis.

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)

3.0 (0.793)

52-10 95ZV-2 Function & Structure Brake Group Brake Valve

Brake Valve 37

A 31

54 53

47 A-A

15 A 18

20 23

Rear brake port

Accumulator port

Front brake port

11 13

Pilot port

Tank port

10 2 5 2

Accumulator port

5 Pressure sensor port

3 B

1 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

B-B

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

23. Spring 24. Case 25. Snap ring 26. Spring 27. — 28. Seat 29. Dust cover 30. Mounting plate 31. Pedal bush 32. Bolt 33. Spring washer

34. Pedal 35. Roller 36. Spacer 37. Pedal pin 38. L-pin 39. Washer 40. Pin 41. Shaft 42. Spacer 43. Joint 44. Pin

95V2E52002

45. Boot 46. Snap ring 47. Shaft 48. Bolt 49. Washer 50. Nut 51. Plate 52. Spring 53. Screw 54. Nut 55. Pedal cover

52-11 95ZV-2 Function & Structure Brake Group Brake Valve

Brake valve performance chart

Pedal pressing force (F)

N (kgf) (lbf)

299 (30.5) (67)

300 (30.6) (67)

200 (20.4) (45) 120(12.2)(27) 100 (10.2) (22)

93.3(9.5)(12)

76.1 (7.76) (17)

67.1 (6.84) (15) 0

( ) 3.9

7.4

18.5 19

Pedal stroke

Output oil pressure (Brake port)

MPa (kgf/cm2) (psi)

4.10 (42) (595)

4 (40) (580)

2 (20) (290)

0.80 (8.2) (116)

0.36 (3.7) (52)

( ) 0

3.9 5

7.4

Pedal stroke

Output oil pressure (Brake port)

MPa (kgf/cm2) (psi)

4.14 (42) (600)

4 (41) (580)

2 (20) (290)

0 0 0.41 (4.2) (59)

2 (20) (290)

4.55 4 (41) (46) (580) (660)

MPa (kgf/cm2) (psi)

Pilot oil pressure (pilot port input) K95V2U52005

52-12 95ZV-2 Function & Structure Brake Group Brake Valve

Brake valve outline

While the valve is not operating B

The brake valve is integrated into the pedal converts the pump oil pressure into the pressure corresponding to the pedal pressing force, and transmits it to the brake. The brake valve is the tandem type, and consists of two independent systems. When the right side pedal is 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. 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.

Pilot port 23

20 26

B1 Rear brake

Accumulator A1 2 5

B2 Front brake

Accumulator A2

2 5

T Tank

Pressure sensor port B-B

95V2E52003

52-13 95ZV-2 Function & Structure Brake Group Brake Valve Between spool input (18) and spools (2) in the brake valve, springs (22)(23) which convert pedal pressing force into output oil pressure are installed. 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. While the valve is not operating, each spool is returned to the non-operation position by spring (6)(13). 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.

While the valve is operating When the brake pedal is pressed, spool input (18) and pilot piston (20) are pushed by way of roller (35). Spool input (18) and pilot piston (20) make each spool (2) drop down by way of spring (22)(23). When spool (2) is pushed down, at first the passage from out-port B1, B2, and pressure sensor port to the tank port are shut down. 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. 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)(13) becomes balanced with spring load (22)(23), it returns spool (2) to shut down the passages A1-B1 and A2-B2 to hold the pressure. By this operation, spring load (22)(23)(26) by deflection are transmitted to the operator as pedal pressing force and the pressure in proportion to the pedal pressing force is obtained.

While the valve is releasing When the brake pedal is released, spool input (18) and pilot piston (20) are pushed back by spring (26). Compressed spring (22)(23) is extended, and each spool (2) is returned upward to the non-operation position by the sum of hydraulic reactive force and spring load (6)(13). After the passages from out-ports B1,B2 and pressure sensor port to in-ports A1, A2 is shut down by spool (2), the pressure of out-ports B1,B2 and pressure sensor port is opened to tank port, and then the brake operation is released.

52-14 95ZV-2 Function & Structure Brake Group Service Brake

Service Brake Piston stroke adjuster (S/N 9001~9014) 15 16 13

Service brake operation 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.

Wheel hub 14 Brake oil inlet port

12 Axle housing 1

5 4

95ZV52033

1. Internal gear hub 2. Brake piston 3. Piston return spring 4. Steel plate 5. Friction plate 6. Disc gear 7. Axle shaft 8. O-ring (for brake piston) 9. O-ring (for brake piston) 10. O-ring (for gear hub) 11. O-ring (for gear hub) 12. Air bleeder nipple 13. Socket bolt 14. Tolerance ring 15. Sleeve 16. Bushing The service brake is an enclosed wet type multi-plate hydraulic brake, and is incorporated in the axle housing. This type of service brake ensures good braking power even in muddy or sandy soil. Even if the brake disc is worn, the integrated adjustment mechanism always adjusts for a constant pedal stroke.

When the brake valves are depressed, the pressure oil in the accumulator enters the disc brake piston chamber for the front and rear wheels, pushes the piston, and generates braking power. (S/N ~9250) 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.

52-15 95ZV-2 Function & Structure Brake Group Service Brake

Service brake friction plate

6.8 0.1 (0.268 0.004 in) 5.0 0.15 (0.197 0.006 in)

(H)

400 (15.7 in)

1.2 (0.047 in)

0.65 mm (0.026 in) Detailed drawing of groove

95V2U52004

Each friction plate has linings (paper material) on the contact faces on both sides. To reassemble the brake disc plates, be sure to align holes (H) of three friction plates with each other to ensure smooth flow of gear cooling oil.

52-16 95ZV-2 Function & Structure Brake Group Service Brake

Service brake steel plate

The steel plate shown in the lower figure has the section (A) where several teeth are intentionally absent. This steel plate should be installed on the brake backing plate side (outer side of the machine body). The section (A) of this plate is used for measurement of friction plate wear. If this steel plate is installed incorrectly, measurement of wear is disabled. Therefore, this steel plate should be installed correctly with regard to the tooth location so that the teeth cut-off section is located (or indexed) as shown in the figure.

Upper side Spring pins

Internal gear

There is no inside or outside on this plate either. It may be installed either way.

Upper side Spring pins

95ZV52034

A brake disc includes three steel plates, and the tooth pattern of three steel plates differ from each other. Carefully install the steel plates. The steel plate shown in the upper figure should be installed on the piston side. As to the installation direction, this steel plate can be installed either side inward as there is no inward or outward direction.

52-17 95ZV-2 Function & Structure Brake Group Service Brake

Service brake piston A 5

6 2

6 A

1. Holes for piston return spring (12 equivalent divisions of circumference) 2. Holes for brake pedal stroke adjustment mechanism (S/N 9001~9014) (4 equivalent divisions of circumference, M10 x 1.5) 3. Holes for pushing down piston (4 equivalent divisions of circumference) 4. Holes for removing piston (2 equivalent divisions of circumference, M10 x 1.5) 5. Holes to drain oil from piston rear side 6. Cooling oil passage

A-A 95ZV52035

52-18 95ZV-2 Function & Structure Brake Group Service Brake

Service brake pedal stroke adjusting mechanism (S/N 9001~9014)

Fig. 2

1.2 mm (0.047 in) Piston

Brake stroke adjusting mechanism

95ZV52007

95ZV52036

This is the automatic adjuster function which always offers a constant pedal stroke even if the brake disc is worn. Fig. 1

When the brake disc is worn and the brake piston is shifted by approximately 1.2 mm (0.047 in) or more, the sleeve is gradually pulled out to the left by the socket bolt by the amount corresponding to the wear. At that time, there is clearance of approximately 1.2 mm (0.047 in) between the sleeve and the socket bolt. Fig. 3

1.2 mm (0.047 in)

Piston Sleeve

Tolerance ring

Approx. 1.2 mm (0.047 in)

Socket bolt 95ZV52061

Bushing 115ZV52028

When the brake disk is not worn and the hydraulic pressure is not applied on the brake piston, the piston is pulled back by the return spring. At that time, there is clearance of approximately 1.2 mm (0.047 in) between the sleeve and the socket bolt.

When the brake pedal is released and the hydraulic pressure is not applied on the brake piston, the brake piston is pulled back by the return spring by approximately 1.2 mm (0.047 in), and stopped by the sleeve. In other words, the brake piston return amount is set to approximately 1.2 mm (0.047 in) so that a constant pedal stroke is always offered. Motions of the sleeve are regulated by the tolerance ring (spring). The sleeve is not moved by the return spring force of the piston.

52-19 95ZV-2 Function & Structure Brake Group Service Brake

Tolerance ring

Wave

Tolerance ring 95ZV52020

The tolerance ring tightens easily the shaft (sleeve) and the boss (bushing) to transmit the torque and the thrust force. The tolerance ring is a press-in ring made of elastic wave sheet steel. Installation procedure

Boss (bushing)

Tolerance ring

Shaft (sleeve)

95ZV52021

- Attach the tolerance ring to the boss (bushing). - Press-fit the shaft (sleeve).

52-20 95ZV-2 Function & Structure Brake Group Service Brake

Brake circuit air bleeding procedure Valve assembly (Brake manifold block assembly)

Solenoid valve for auto-brake

Solenoid valve for parking Hydraulic tank Step location Hydraulic tank, as seen from top

95V2E52004

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: Air bleeder nipple

1. Verify that the wheels are securely blocked, and the articulation lock is in the "locked" position.

95V2E52005

2. Charge the accumulator to full pressure, and then, shut off the engine. 3. Turn the parking brake solenoid valve release knob counterclockwise, then, back to neutral, five times at five-second intervals between each turn. Position the knob back to the normal position when finished.

Button (diameter: approximately 4 mm)

4. Connect a clear vinyl tube [About 1.5 meters (5 ft.) long] to the brake pedal air bleeder nipple, and open the bleeder nipple. Solenoid valve pressure nut

Solenoid valve Auto brake solenoid valve

95V2E52006

5. Press the auto-brake solenoid valve release button five times at five-second intervals between each turn. Position the knob back to the normal position when finished. 6. Close the bleeder nipple and remove the vinyl tube from the brake valve.

52-21 95ZV-2 Function & Structure Brake Group Service Brake

Bleeding air from brake pipes and axle housing hubs

Bleeding air from parking brake housing Air bleeder nipple

Air bleeder nipple

Vinyl tube

2nd propeller shaft Vinyl tube 115V2E52010 70ZV52019

1. Connect a vinyl tube to the air bleeder nipple provided in the axle housing, and place an oil can for hydraulic oil recovery. (The air bleeder nipple is equivalent to the one provided in the left brake valve). 2. Loosen the air bleeder nipple a little. Press and hold the left brake pedal until oil containing no air comes from the air bleeder nipple. After that, tighten the air bleeder nipple. Perform this operation for each of the four wheels. : Air bleeder nipple 9 N-m (0.9 kgf-m) (6.5 lb-ft)

1. Connect a vinyl tube to the air bleeder nipple provided in the axle housing, and place an oil can for hydraulic oil recovery. (The air bleeder nipple is equivalent to the one provided in the brake valve). 2. Loosen the air bleeder nipple a little. Turn the park brake solenoid valve release knob counterclockwise until oil containing no air comes from the air bleeder nipple. After that, tighten the air bleeder nipple. : Air bleeder nipple 9 N-m (0.9 kgf-m) (6.5 lb-ft) Position this release knob to the normal position when finished.

52-22 95ZV-2 Function & Structure Brake Group Parking Brake

Parking Brake (S/N 9001~9088) 2nd Propeller shaft

13 1 7 17 22 8

10 9

3 19 21

2 12 11

18 16 20

Front differential assy

K95V2U52002

1. Housing 2. Piston 3. Housing 4. Spring 5. Spring 6. Head pin 7. Bolt 8. Straight pin 9. O-ring 10. Back-up ring 11. Friction disc

12. Separation disc 13. Flange nut 14. Nut 15. Gear 16. Housing 17. Oil seal 18. Oil seal 19. Pin 20. Spring pin 21. Spring 22. Oil seal (Double lip) (S/N 9066~)

52-23 95ZV-2 Function & Structure Brake Group Parking Brake (S/N 9089~9250)

2nd Propeller shaft

1 7 14 15 8

3 17 19

2 11 10

16 13 18

Front differential assy

K95V2U52001

1. Housing 2. Piston 3. Housing 4. Spring 5. Spring 6. Head pin 7. Bolt 8. Straight pin 9. O-ring 10. Friction disc

11. Separation disc 12. Gear 13. Housing 14. Oil seal (single lip) 15. Oil seal (double lip) 16. Oil seal (single lip) 17. Pin 18. Spring pin 19. Spring

52-24 95ZV-2 Function & Structure Brake Group Parking Brake (S/N 9251~)

2nd Propeller shaft

1 7 14 15

8 3 2

17 19

11 10 16 13 18

Front differential assy

K95V2U52003

1. Housing 2. Piston 3. Housing 4. Spring 5. Spring 6. Housing 7. Bolt 8. Straight pin 9. O-ring 10. Friction disc

11. Separation disc 12. Gear 13. Housing 14. Oil seal (single lip) 15. Oil seal (double lip) 16. Oil seal (single lip) 17. Pin 18. Spring pin 19. Spring

52-25 95ZV-2 Function & Structure Brake Group Parking Brake

Parking brake operation

5~6 mm (0.197~0.236 in)

(S/N 9001~9088)

5 A

1 7

Brake oil

95V2E52008

(S/N 9089~9250)

1 5 4

7 Brake oil

K97V2J52008

52-26 95ZV-2 Function & Structure Brake Group Parking Brake (S/N 9251~)

5 1 4

Brake oil

K95V2U52004

The parking brake is the spring applied oil pressure released type. Turning on the parking switch turns off the solenoid valve for parking, returns the oil in the brake piston chamber to the tank, pushes piston (2) with springs (4)(5), and makes the brake effective. Turning off the parking switch turns on the solenoid valve for parking, oil flows into the piston chamber, pushes piston (2) to the upward over coming spring force (4)(5), and release the brake.

OFF

Solenoid valve

Power OFF

Power ON

Brake piston chamber

Oil discharge

Oil charge

Braking

Released

Parking brake

- To check the wear on parking brake, stop the engine and measure the dimension A. A: the dimension from the end face of manual release bolt (7) to machined surface of housing (1). With new discs and plates this measures 26.6±1 mm (1.047±0.039 in) (S/N 9001~9250) 42.6±1 mm (1.677±0.039 in) (S/N 9251~) With completely worn out discs, and plates this measures 22.6±1 mm (0.890±0.039 in) (S/N 9001~9250) 38.6±1 mm (1.520±0.039 in) (S/N 9251~)

Operation of parking brake Parking switch

Parking brake wearing check

Turning the starter key off works the same as turning the parking switch "ON".

- When the parking brake is operated as emergency around maximum speed out of necessity, check the wear on parking brake.

52-27 95ZV-2 Function & Structure Brake Group Parking Brake

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

ø 220 (8.7 in) ø 330 (13.0 in)

0.82 mm (0.032 in) or more 1.0 mm (0.039 in)

5.7 mm (0.224 in) Detail drawing of groove 95V2E52009

1. Core plate 2. Lining (paper material)

Parking brake steel plate

ø 394 (15.5 in)

ø 220 (8.7 in)

P.C (14 .D 3 6 .4 i n) 5 m m

5.0±0.1 mm (0.197±0.004 in)

Flatness: 0.5 mm (0.020 in) or less 95V2E52010

52-28 95ZV-2 Function & Structure Brake Group Parking Brake

Parking brake solenoid valve Spring chamber (brake actuator) B

Reducing valve

Solenoid

Knob

T Seat face A

Seat face B

Manual release (counterclockwise rotation)

Spool

Tank

P T Hydraulic circuit diagram

Solenoid valve operation

Solenoid valve specifications Voltage

Amp

a 0

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 Ω

85V2E52007

52-29 95ZV-2 Function & Structure Brake Group Parking Brake Manual Release

Parking Brake Manual Release 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.

(S/N 9001~9088)

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.

1 7

WARNING If the flange nuts are not returned to the original position, the parking brake is disabled and may result in a severe accident. Make sure to return the flange nuts to the original position after manually releasing the parking brake.

95V2E52011

1. Remove each of two places of lock nuts (14) from manual release bolt (7) and tighten flange nuts (13) alternately until contacting with housing (1). 2. Furthermore tighten each of the two places of flange nuts (13) alternately and evenly. When flange nuts (13) are tightened until you feel flange nuts (13) are rather tight; the brake is released. Reference After contacting with housing (1), approximately 3 or 4 additional turns of flange nuts (13) will release the parking brake.

52-30 95ZV-2 Function & Structure Brake Group Parking Brake Manual Release (S/N 9089~)

Top Hose band

Rubber cap

7 1

Lock bolt

Flange nut

Detail of A K97V2J52009

1. Remove the lock bolt on the front differential and remove the flange nuts from both parts (A). 2. Loosen the hose band and remove the rubber cap from manual release bolt (7). 3. Install the flange nuts, which were removed at step 1, to manual release bolt (7). 4. Tighten the flange nuts alternately and evenly until contacting with housing (1). 5. Then, tighten the flange nuts until you feel the nuts are rather tight; the brake is released. Reference After contacting with housing (1), approximately 3 or 4 additional turns of the flange nuts will release the parking brake.

52-31 95ZV-2 Function & Structure Brake Group Brake Circuit Check Valve

Brake Circuit Check Valve

Poppet (T)

(P) (TA)

Pump supply through reducing valve

Seat face

(PARKING)

(ACCR)

(ACCF) (PA) (Z1)

(Z2)

(ACF)

(Z)

(PPI)

B (ACCF) Reducing valve

Accumulator Valve assembly

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 85V2E52010

52-32 95ZV-2 Function & Structure Brake Group Auto Brake

Auto Brake When the traveling direction is switched over between forward and reverse at a machine speed of 14 km/h (8.75 mph) or more, the auto brake is applied to protect the transmission clutches. When the machine speed is too high, the auto brake is applied also to prevent problems caused by excess speed in the engine and the transmission (over speeding).

Auto brake operation set value 1. When the traveling direction is switched over between forward and reverse at a machine speed of 14 km/h (8.75 mph) or more at any speed position. 2. When the machine speed is too high in each speed range. Actual speed will vary with tire size. Speed range

Auto brake circuit

1st

Approximately 20 (12.5)

2nd

Approximately 22 (13.75)

Approximately 24 (15.0)

3rd

Approximately 36 (22.5)

4th/A

Approximately 40 (25.0)

—

Shown in the "released" position To rear service brake

To front service brake

From unloader valve (Pump)

MCU signal From reducing valve (Pump)

95V2E52012

When the auto brake signal enters from the MCU to the solenoid valve for auto brake, solenoid valve (29) is energized and magnetized. The pilot oil from the reducing valve enters the pilot port of left brake valve (23) through adapter tee (37), and actuates the pilot piston and the spool of the brake valve. When the spool is moved over, the high-pressure oil coming from the pump through the unloader valve enters the front and rear brake piston chambers to apply the service brake.

Set value km/h (mph) F

52-33 95ZV-2 Function & Structure Brake Group Auto Brake

Solenoid valve (for Autobrake circuit) Not activated

Brake valve

Solenoid

Spool

P Reducing valve

T Seat face A

Seat face B

Tank

P T Hydraulic circuit diagram

95V2E52013

When the auto brake actuation signal is not given by the MCU (that is, when the power is not supplied to the solenoid), the seat face A is closed and the seat face B is open. As a result, the brake valve port is connected to the tank, and the auto brake is not applied.

Solenoid specifications Voltage

DC 24 V

Current

0.92 A

Resistance

26.2 Ω

When the auto brake actuation signal is given by the MCU (that is, when the power is supplied to the solenoid), the spool is pushed to the left, the seat face A is open, and the seat face B is closed. As a result, the oil from the reducing valve enters the brake valve, and the brake is applied.

Amp

a 0

Volt

Varistor 95ZV42079

Note The varistor (variable resistor) is used for the solenoid coil to protect the circuit.

52-34 95ZV-2 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 62-50".

Pressure sensor (for stop lamp) This pressure sensor that set valve is controlled by the MCU is installed between the brake valve and the front brake. When the brake pedal is depressed and the pressure increases to the set valve of the MCU (0.51 MPa (5.2 kgf/cm2) (74.0 psi)), the stop lamp turns on.

Pressure sensor for stop lamp and declutch Left brake valve

95V2E52014

52-35 95ZV-2 Function & Structure Brake Group Pressure Sensor (for stop lamp and declutch)

Pressure sensor (stop lamp) (S/N 9001~9300)

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

85V2E52012

(V) 5

Output voltage

4 3 2 1

1 (10) (140)

2 (20) (285)

3 (30) (435)

4 (40) (570)

5 (50) (715)

MPa (kgf/cm2) (psi)

Pressure 65V2E52003

52-36 95ZV-2 Function & Structure Brake Group Pressure Sensor (for stop lamp and declutch)

Pressure sensor (stop lamp) (S/N 9301~)

GND

Vout

Vdd

View A K80V2U52003

(V) 5

Output voltage

1.08* (11)(157)

4.31* (44)(625) Pressure

5.4 (55)(783)

MPa (kgf/cm2)(psi) *: Calibration point

K80V2U52004

53-1 95ZV-2 Check & Adjustment Brake Group

95ZV-2 Check & Adjustment Brake Group Brake Circuit Oil Pressure ....................................... 53-2 Service Brake .......................................................... 53-6 Parking Brake.......................................................... 53-10

53-2 95ZV-2 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.

53-3 95ZV-2 Check & Adjustment Brake Group Brake Circuit Oil Pressure

Unloader valve setting pressure measurement

Unloader valve setting pressure adjustment (S/N 9001~9048)

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 9049~)

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. : Port plug: 11.3 N-m (1.15 kgf-m) (8.3 lb-ft) 4. Start the engine, and keep the speed at low idle. Measure and record the pressure when the pointer of the pressure gauge stops rising (cut-out pressure). 5. Keep the engine at low idle, and repeatedly depress and release the brake pedal to reduce the accumulator pressure. Measure and record the pressure when the pointer of the pressure gauge stops and then starts rising again (cut-in pressure). 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 62-88 and 9246 for information.

Pump port Unloader valve

K115ZV53002

1. Remove cap nut (24) and loosen lock nut (22). : Lock nut (22): 16.7 N-m (1.7 kgf-m) (12.3 lb-ft) Cap nut (24): 78.5 N-m (8.0 kgf-m) (57.86 lb-ft) 2. Adjust the pressure by adjusting screw (21). Turn the screw clockwise to raise the pressure. Note In a case that the "ON" or "OFF" pressure does not match the standard setting pressure, set the "ON" (cutin) pressure to the standard setting pressure.

53-4 95ZV-2 Check & Adjustment Brake Group Brake Circuit Oil Pressure

Brake valve oil pressure

Brake valve oil pressure measurement Measurement instrument

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.

la ng

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)

85V2E53002

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 value displayed on the MODM. Refer to "Brake Pedal Output Oil Pressure" of MODM "Input/Output Monitor" page 62-88 and 92-46 for information.

53-5 95ZV-2 Check & Adjustment Brake Group Brake Circuit Oil Pressure

Brake valve performance

Output oil pressure (brake port)

MPa (kgf/cm2) (psi)

4.10 (42) (595)

4 (40) (580)

2 (20) (290)

0.80 (8.2) (116)

0.36 (3.7) (52) 0

3.9 5

7.4

18.5 19

(deg)

Pedal stroke

95V2E53001

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.

53-6 95ZV-2 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.

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.

Condition

WARNING

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

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.

Braking distance 20 m (22 1/4 yard) or shorter

1. Lower the boom to the lowest limit, and roll back the bucket fully until the bucket contacts to the stopper.

Possible causes of extremely long braking distance

2. Set the parking brake switch to the "OFF" position.

Possible cause

Solution

Low brake line pressure

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.

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

Solution

Low brake line pressure

Check and repair

Friction plate wear

Check and repair

Brake valve malfunction

Check and repair

53-7 95ZV-2 Check & Adjustment Brake Group Service Brake

Service brake friction plate wear measurement A

Air bleeder nipple

Slide calipers

Brake backing plate

Steel plate Friction plate

95ZV53004

WARNING Oil inlet port

Internal gear

Top about 5º

Spring pin

Inner steel plate

Spring pin

Outer steel plate

95ZV53005

Unexpected movement of machine could cause serious injury or death. To prevent such an accident, observe the following items before checking the brake friction plate wear: - Park the machine on level ground. - Apply the parking brake. - Stop the engine. - Determine the signals between the persons related to this work for engine starting to prevent an accident. - Prohibit any person from walking into the dangerous area.

IMPORTANT After inserting calipers, do not rotate the wheels. If the wheels are rotated, the calipers may be caught and broken by the reduction gear. In this case, the reduction gear must be disassembled.

53-8 95ZV-2 Check & Adjustment Brake Group Service Brake

Measurement procedure Turn the planetary gear so that the oil supply plug is positioned at ±5º from the top. Check that the teeth of steel plate are as shown in the figure in page 53-7 (only one section of the plate circumference is as shown in the figure). Insert calipers to the inner steel plate to measure the dimension A. Note During measurement, be sure the service brake is applied. The wear limit for dimension A is 25.1 mm (0.988 in). Note that dimension A is 28.6 mm (1.126 in) when the plate is new and unused. Note To aid quick measurement on the front axle-raise the front of the machine so the front tires clear the ground by about 25 mm (1 in). This allows easy rotation of the wheel to align the gear teeth.

53-9 95ZV-2 Check & Adjustment Brake Group Service Brake

Cautions on installing brake discs

Upper side Brake piston

When only the friction plates or the steel plates are to be replaced, if the brake piston and brake stroke adjusting mechanism are installed as they are, the brake may drag and the brake discs may seize. Push back the brake piston and brake stroke adjusting mechanism by using the following procedure. 1. Loosen the axle housing air bleeder nipple. 2. Insert bolts into four holes for pushing back the brake piston, then tighten the four bolts evenly. The piston should return evenly. Bolt size for pushing brake piston back (4 required) M10 x 1.5 - 45~50 (1.8~1.97 in) (Fully threaded)

For pushing down the brake piston

3. After pushing back the piston, confirm dimension A from the piston end face to the wheel hub end face.

IMPORTANT Wheel bearings must be adjusted correctly to get an accurate measurement for dimension A. Dimension should be equal at top and bottom. A: 161.90~163.30 mm (6.37~6.43 in) K97V2J53002

Note Piston stroke B: 1.20~1.90 mm (0.047~0.075 in) 4. After confirming that the piston is fully retracted (Dimension A is correct) remove all four bolts.

A B

Wheel hub

Brake piston K97V2J53003

5. After finishing the installation work, bleed air completely from the brake line.

53-10 95ZV-2 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.

WARNING

3. Parking switch ON

Standard measurement value

1. Set the parking brake switch to the "ON" position.

No movement on 1/5 slope

2. Disconnect the cable connector of parking brake solenoid valve.

Condition 1. Test course 1/5 slope (Approx. 11º 19') 2. Bucket empty

Possible cause of machine moving during brake performance check Possible cause

Solution

Wear or breakage of brake disc

Check and repair

Parking brake switch malfunction

Check and repair

Parking brake solenoid valve malfunction

Check and repair

3. Set the parking brake switch to the “OFF” position. 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 discs are worn. At the completion of parking brake test, be sure to connect the connector of electrical line to the solenoid valve again. Possible cause

Solution

Wear or breakage of brake disc

Check and repair

Parking brake switch malfunction

Check and repair

Parking brake solenoid valve malfunction

Check and repair

62-1 95ZV-2 Function & Structure Electrical Group

95ZV-2 Function & Structure Electrical Group How to Use Electrical Wiring Diagram .................... 62-2 Electrical Cable Color Codes .................................. 62-8 Electrical Circuit Symbols........................................ 62-9 Sensor Mount .......................................................... 62-10 Fuse ........................................................................ 62-11 Engine Start Circuit.................................................. 62-14 Power Generating/Charging Circuit......................... 62-22 ECM (Engine Controller) ......................................... 62-23 Transmission Control Circuit and Monitor Circuit .... 62-37 Instrument Panel and Switch................................... 62-63 MODM ..................................................................... 62-68 Electrical Detent Circuit ........................................... 62-107 Diode ....................................................................... 62-114

62-2 95ZV-2 Function & Structure Electrical Group How to Use Electrical Wiring Diagram

How to Use Electrical Wiring Diagram Example 10

10 9

20 19 18 17 16

15 14 13 12 11 21

40 39

32 31

WIDTH LAMP RELAY

RIDE CONTROL NEUTRAL RELAY RELAY

BACK LAMP RELAY

HORN RELAY

MCU FAULT RELAY

RB B611

LgSb YV H133 E214

RL SbP H610 E220

RL LB H128 E219

GW GL H127 B501

R R D114 D114

Br Lg D112 D103

G L D102 D002

R Lg D111 D103

G G D107 D107

A520 C201 H129

LgW L A405 D001 1

LgW E218

(BLACK)

(BLUE)

(1) (2)

6 D507 A306 F306 OR RO RW

A905 RLg

A503 YB

1 D112 E802 E803 Br GL GO

C206 A302 F303 E312 PB RBr RY WO

E523 G302 SbY BrB

C205 F504 F704 F804 RB RL GW PL

E109 G402 A105 E522 W BrW WP BrL

E501 C801 A005 B304 WL RG RGy LgG 40

E520 E108 F004 LgL W LgSb 36

E804 WY

E601 BrR

(3)

The address method is used for electrical wiring diagrams. For this method, a symbol is attached to each connector and connector terminal in order to easily locate the other terminal where the other end of the cable is connected. Example 1 Symbol under (or above) connector, such as F6: Shows the address of the connector. Example 2 Symbol at the multi-terminal connector, such as 1 and 10: Shows the terminal number and the numbering direction.

95ZV62001

Example 3 Checking the other connector terminal where F704 RL (item (3)) is connected: 1. F704 Shows that the terminal is connected to the 4th terminal of the F7 connector. Check the description in the 4th terminal of the F7 connector (F704), it shows that the F704 terminal is connected to H128. This means that the 4th terminal of the F7 connector is connected to the 28th terminal of the H1 connector. 2. RL Shows the color of the wire "RL" represents that the insulation color is red, and "L" represents a blue stripe is on the red insulation.

62-3 95ZV-2 Function & Structure Electrical Group Utilisation des schémas des câblages électriques (FRANÇAIS)

Utilisation des schémas des câblages électriques (FRANÇAIS) Exemple 10

10 9

20 19 18 17 16

15 14 13 12 11 21

40 39

32 31

Relais de la lampe d’ écartement

Relais du contrôle de marche

Relais neutre

Relais de la lampe arrière

Relais du klaxon

RB B611

LgSb YV H133 E214

RL SbP H610 E220

RL LB H128 E219

GW GL H127 B501

R R D114 D114

Br Lg D112 D103

G L D102 D002

R Lg D111 D103

G G D107 D107

A520 C201 H129

LgW E218

LgW L A405 D001 1

Relais de défaillance du contrôleur

(Noir)

(Blue)

(1) (2)

6 D507 A306 F306 OR RO RW

A905 RLg

A503 YB

1 D112 E802 E803 Br GL GO

C206 A302 F303 E312 PB RBr RY WO

E523 G302 SbY BrB

C205 F504 F704 F804 RB RL GW PL

E109 G402 A105 E522 W BrW WP BrL

E501 C801 A005 B304 WL RG RGy LgG 40

E520 E108 F004 LgL W LgSb 36

E804 WY

E601 BrR 31

(3)

Les schémas des câblages électriques sont basés sur la méthode de l’adressage. Suivant cette méthode, un symbole correspond à chaque connecteur et à chaque borne du connecteur de manière à localiser facilement la borne de connection de l’autre extrémité du câble. Exemple 1 Symbole au-dessous (ou au-dessus) du connecteur, comme F6: Il indique l’adresse du connecteur. Exemple 2 Symbole sur le connecteur multibornes, comme 1 et 10: Il indique le numéro de la borne et le sens de la numérotation.

95ZV62001

Exemple 3 Contrôle de la borne du connecteur à laquelle F704 RL (point (3)) est connectée: 1. F704 Indique que la borne est connectée à la 4ème borne du connecteur F7. Contrôlez la description de la 4ème borne du connecteur F7 (F704), elle indique que la borne F704 est connectée à H128. Ceci signifie que la 4ème borne du connecteur F7 est connectée à la 28ème borne du connecteur H1. 2. RL Indique la couleur du fil. “RL” signifie que la couleur de l’isolation est rouge, et “L” que la raie bleu est sur l’isolation rouge.

62-4 95ZV-2 Function & Structure Electrical Group Verwendung des elektrischen Schaltplans (DEUTSCH)

Verwendung des elektrischen Schaltplans (DEUTSCH) Beispiel 10

10 9

20 19 18 17 16

15 14 13 12 11 21

40 39

32 31

Breitenleuchtenrelais

Fahrtsteuerrelais

Neutrales Relais

Rückleuchtenrelais

Hupenrelais

RB B611

LgSb YV H133 E214

RL SbP H610 E220

RL LB H128 E219

GW GL H127 B501

R R D114 D114

Br Lg D112 D103

G L D102 D002

R Lg D111 D103

G G D107 D107

A520 C201 H129

Reglerfehlerrelais

LgW L A405 D001 1

LgW E218

(Schwarz)

(Blau)

(1) (2)

6 D507 A306 F306 OR RO RW

A905 RLg

A503 YB

1 D112 E802 E803 GL GO Br

C206 A302 F303 E312 PB RBr RY WO

E523 G302 SbY BrB

C205 F504 F704 F804 PL RB RL GW

E109 G402 A105 E522 W BrW WP BrL

E501 C801 A005 B304 WL RG RGy LgG 40

E520 E108 F004 LgL W LgSb 36

E804 WY

E601 BrR 31

(3)

Für den elektrischen Schaltplan wird die Adressenmethode verwendet. Damit wird jeder Steckvorrichtung und jeder Anschlußklemme ein Symbol zugeordnet, damit die Klemme, an die das andere Ende des Kabels angeschlossen werden muß, leicht gefunden werden kann. Beispiel 1 Symbol unterhalb (oder oberhalb) der Steckvorrichtung, wie z. B. F6: Zeigt die Adresse der Steckvorrichtung an. Beispiel 2 Symbol an der Mehrklemmen- Anschlußstelle, wie z. B. 1 und 10: Zeigt die Klemmennummer und die Zählrichtung an.

95ZV62001

Beispiel 3 Überprüfung der anderen Steckvorrichtungsklemme, wo F704 RL (Artikel (3)) angeschlossen ist: 1. F704 Zeigt, daß die Klemme an die vierte Klemme der F7-Steckvorrichtung angeschlossen ist. Überprüfen Sie die Beschreibung in der vierten Klemme des F7-Steckvorrichtung (F704). Zie gibt an, daß die Steckvorrichtung F704 an H128 angeschlossen ist. Dies bedeutet, daß die vierte Klemme der F7-Steckvorrichtung an die 28. Klemme der H1-Steckvorrichtung angeschlossen ist. 2. RL Zeigt die Farbe des Kabels an. „ RL ” bedeutet, daß der lsolierdraht rot ist, und „ L ” bedeutet, daß sich auf dem roten lsoliermaterial ein blauer Streifen befindet.

62-5 95ZV-2 Function & Structure Electrical Group Modalità di utilizzo dello schema dei collegamenti elettrici (ITALIANO)

Modalità di utilizzo dello schema dei collegamenti elettrici (ITALIANO) Esempio 10

10 9

20 19 18 17 16

15 14 13 12 11 21

40 39

32 31

Relè di larghezza della lampada

Relè di controllo della guida

Relè neutro

Relè della lampada posteriore

Relè del clacson

RB B611

LgSb YV H133 E214

RL SbP H610 E220

RL LB H128 E219

GW GL H127 B501

R R D114 D114

Br Lg D112 D103

G L D102 D002

R Lg D111 D103

G G D107 D107

A520 C201 H129

LgW E218

LgW L A405 D001 1

Relè del controller d’ errore

(Nero)

(Blu)

(1) (2)

6 D507 A306 F306 OR RO RW

A905 RLg

A503 YB

1 D112 E802 E803 Br GL GO

C206 A302 F303 E312 PB RBr RY WO

E523 G302 SbY BrB

C205 F504 F704 F804 RB RL GW PL

E109 G402 A105 E522 W BrW WP BrL

E501 C801 A005 B304 WL RG RGy LgG 40

E520 E108 F004 LgL W LgSb 36

E804 WY

E601 BrR 31

(3)

Per gli schemi elettrici si utilizza il metodo degli indirizzi, in base al quale a ciascun connettore e a ogni suo contatto viene associato un simbolo che permette di identificare agevolmente il contatto cui è collegata l’altra estremità del cavo. Esempio 1 simbolo al di sopra o al di sotto del connettore, ad esempio F6: Mostra l’indirizzo del connettore. Esempio 2 simbolo presso un connettore a più contatti, ad esempio 1 e 10: Mostra il numero del contatto e il senso di numerazione.

95ZV62001

Esempio 3 verifica del contatto dell’altro connettore cui è collegato F704 RL (elemento (3)): 1. F704 Indica che il terminale è collegato al contatto n. 4 del connettore F7. Verificare la descrizione del contatto n.4 del connettore F7 (F704): essa mostra che il contatto F704 è collegato a H128. Ciò indica che il contatto n.4 del connettore F7 è collegato al contatto n. 28 del connettore H1. 2. RL Indica il colore del cavo: “RL” significa che il colore dell’isolante è rosso, e “L” rappresenta che una linea blu è presente sull’isolazione rossa.

62-6 95ZV-2 Function & Structure Electrical Group Cómo utilizar un Diagrama de Alambrado Eléctrico (ESPAÑOL)

Cómo utilizar un Diagrama de Alambrado Eléctrico (ESPAÑOL) Ejemplo 10

10 9

20 19 18 17 16

15 14 13 12 11 21

40 39

32 31

Relé de la lámpara ancha

Relé de control de recorrido

Relé neutro

Relé de la lámpara trasera

Relé de la bocina

RB B611

LgSb YV H133 E214

RL SbP H610 E220

RL LB H128 E219

GW GL H127 B501

R R D114 D114

Br Lg D112 D103

G L D102 D002

R Lg D111 D103

G G D107 D107

A520 C201 H129

LgW E218

LgW L A405 D001 1

Relé de fallos del controlador

(Negro)

(Azul)

(1) (2)

6 D507 A306 F306 OR RO RW

A905 RLg

A503 YB

1 D112 E802 E803 Br GL GO

C206 A302 F303 E312 PB RBr RY WO

E523 G302 SbY BrB

C205 F504 F704 F804 RB RL GW PL

E109 G402 A105 E522 W BrW WP BrL

E501 C801 A005 B304 WL RG RGy LgG 40

E520 E108 F004 LgL W LgSb 36

E804 WY

E601 BrR 31

(3)

El método de dirección se utiliza para diagrama de alambrado eléctrico. Para este método, se pega un símbolo a cada conector y terminal de conector a fin de localizar fácilmente el otro terminal al cual se conecta el otro extremo del cable. Ejemplo 1 Símbolo debajo (o encima) de conector, tal como F6: Muestra la dirección del conector. Ejemplo 2 Símbolo en el conector del multiterminal, tal como 1 y 10: Muestra el número de terminal y la dirección de numerado.

95ZV62001

Ejemplo 3 Comprobando el otro terminal de conector donde se conecta F704 RL (ítem (3)): 1. F704 Muestra que el terminal está conectado al terminal 4o del conector F7. Compruebe la descripción en el terminal 4o del conector F7 (F704). Esto muestra que el terminal F704 está conectado a H128 y significa que el terminal 4o del conector F7 está conectado al terminal 28o del conector H1. 2. RL Muestra el color del alambre “RL” y representa que el color aislante es rojo, y “L” representa que una raya azul está en el aislamiento rojo.

62-7 95ZV-2 Function & Structure Electrical Group Como Utilizar o Diagrama de Ligações Eléctricas (PORTUGUÊS)

Como Utilizar o Diagrama de Ligações Eléctricas (PORTUGUÊS) Exemplo 10

10 9

20 19 18 17 16

15 14 13 12 11 21

40 39

32 31

Relé de luz de largura

Relé de controlo de viagem

Relé do ponto morto

Relé da luz traseira

Relé da buzina

RB B611

LgSb YV H133 E214

RL SbP H610 E220

RL LB H128 E219

GW GL H127 B501

R R D114 D114

Br Lg D112 D103

G L D102 D002

R Lg D111 D103

G G D107 D107

A520 C201 H129

LgW E218

LgW L A405 D001 1

Relé de controlo de falha

(Preto)

(Azul)

(1) (2)

6 D507 A306 F306 OR RO RW

A905 RLg

A503 YB

1 D112 E802 E803 Br GL GO

C206 A302 F303 E312 PB RBr RY WO

E523 G302 SbY BrB

C205 F504 F704 F804 RB RL GW PL

E109 G402 A105 E522 W BrW WP BrL

E501 C801 A005 B304 WL RG RGy LgG 40

E520 E108 F004 LgL W LgSb 36

E804 WY

E601 BrR 31

(3)

O método de endereçamento é utilizado para os diagramas de ligações eléctricas. Para este método, cada conector e terminal de conector tem um símbolo acoplado para facilitar a localização do outro terminal onde a outra extremidade do cabo deve ser ligada. Exemplo 1 Símbolo por baixo (ou por cima) do conector, como F6: Indica o endereço do conector. Exemplo 2 Símbolo no conector de multiterminais, como 1 e 10: Indica o número do terminal e a direcção da numeração.

95ZV62001

Exemplo 3 Verificar o outro terminal de conectores, no qual F704 RL (item (3)) é ligado: 1. F704 Ilustra que o terminal é ligado ao 4o terminal do conector F7. Verifique a descrição no 4o terminal do conector F7 (F704), indica que o terminal F704 está ligado ao H128. Isto significa que o 4o terminal do conector F7 está ligado ao 28o terminal do conector H1. 2. RL Indica a cor do fio. “RL” representa que a cor do isolamento é vermelha e “L” representa uma faixa azul está no isolamento vermelho.

62-8 95ZV-2 Function & Structure Electrical Group Electrical Cable Color Codes

Electrical Cable Color Codes Color of stripe Color of insulation

Y G (yellow) (green)

(sky blue)

Br (brown)

L (blue)

W (white)

R (red)

YSb

YBr

SbW

SbR

B O Lg (black) (orange) (light green)

Y (yellow)

G (green)

Sb (sky blue)

SbY

SbG

Br (brown)

BrY

BrG

BrL

BrW

BrR

BrB

L (blue)

LBr

W (white)

WBr

R (red)

RBr

B (black)

O (orange)

OSb

Lg (light green)

LgY

LgG

LgSb

P (pink) Gy (grey)

GyY

P (pink)

SbO

SbLg

SbP

LLg

RLg

BLg

LgL

LgW

LgR

LgB

GyG

GyL

GyW

GyR

LgBr

V (violet)

Insulation color Stripe color

70ZV62001

V (violet)

YGy

WV RGy

PB GyB

Gy (grey)

P GyO

Gy V

62-9 95ZV-2 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

62-10 95ZV-2 Function & Structure Electrical Group Sensor Mount

Sensor Mount 1

5 95V2E62001

1. Machine speed sensor 2. T/C oil temperature sensor 3. Air cleaner sensor 4. E/G coolant temperature sensor (S/N 9001~9150) 5. Hydraulic oil level sensor 6. Hydraulic oil temperature sensor 7. Coolant level alarm sensor

62-11 95ZV-2 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) 6 fuses 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)

20A

15A

R. WORK LIGHT

SPARE

10A

BOOM KICKOUT BUCKET LEVELER

30A

15A

TURN SIGNAL

SPARE

30A

PARKING BRAKE MCU (MACHINE)

20A

15A

F. WORK LIGHT

SPARE

10A

AIR SUS. SEAT (OPT)

15A

SPARE

15A

SPARE

15A

4WAY FLASHER HORN ROOM LAMP RADIO

10A

SPARE

15A

PREHEAT

BUZZER MONITOR LAMP TACHOMETER

NEUTRAL RELAY

BATTERY RELAY ECM (ENGINE)

Protective circuit LIGHTING HEAD LIGHT

15A SPARE 5A

For cab

Fuse box for cab

Fuse box for chassis

90V2E62002

Fuse No.

Fuse capacity (A)

SPARE

Protective circuit

R. WIPER / WASHER

10A

F. WIPER / WASHER

10A

MODM CIGAR LIGHTER

15A

SPARE

DC-DC CONVERTER

10A

SPARE

10A

SPARE

20A

SPARE

AIRCON

10A

AIRCON

20A

AIRCON

20A

SPARE

SPARE 20A SPARE 15A SPARE 10A SPARE 5A

62-12 95ZV-2 Function & Structure Electrical Group Fuse For engine controller (ECM) Fuse No.

Fuse capacity (A)

Protective circuit

10A

ECM (ENGINE)

7.5A

SPARE

7.5A

SPARE

7.5A

SPARE

10A

ECM (ENGINE)

10A

SPARE

Fusible link

Fuse box for ECM

K97V2J62001

62-13 95ZV-2 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) 5 [W ]

(081) (085) W W

12V

(065) 1.25 F15 WR

R1 BR B AC R2 C

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

(063) 1.25 WR

(013) (Lg)

Starter

Battery relay (1)

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.

B C

[R ]x6 (910~ 915)

Magnetic S/W (702) 5

[R ] (701) 1.25

[BW ] WG(704)

(703)

Voltage relay

NR (013) (Lg)

F13

(705) (WG)

(707) WL

Charge lamp 20

70A

(706) 1.25 WL R

(2)

Alternator

(005-a) ES (L)

M1 M2

100

Secondary steering pumps (OPT)

M M

Preheat lamp (720) (BG)

(012) BW 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) 1.25 G

30A

(708) WP

(015)

F13

15A

F12 (012) BW

F14

(064) 1.25 G

(062) BW

MCU

Battery

ECM (38)

During engine stop - All the electrical circuit will not function. - Engine can not be started.

70ZV62010

100

30A

(060) (901) 5 W [W ]

During engine operation - Engine will stop automatically. - All the power for all electrical circuit will be OFF.

Fuse element

12V

Problem (symptom)

Air heater

Heater relay

ACC’

To pilot lamp

Fusible link location

95V2U62010

The fusible link is located in the box as shown in the above figures. If excessive current flows through the starter switch or the electric line downstream of the starter switch due to shortcircuit, the fuse element will be blown to protect the circuit. The condition of the fuse element can be seen through the transparent cover. Determine the cause before replacing the fusible link. For replacement of a fusible link, remove 2 bolts and pull it up.

62-14 95ZV-2 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

30A

B12

Fusible link

12V

Battery

ECM

B11

Diode unit

F15 5A

23A D12 D05

Starter motor

Battery relay

D03 (1)

D10

70A

D04

12V

B18

D11

E04 E12 E03 E11

F14

E24

Shift lever F/R position

E05 E06 E17

B C

+24 V

Magnetic switch 3

Voltage relay

Neutral relay MCU E24

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

Alternator

95V2U62011

62-15 95ZV-2 Function & Structure Electrical Group Engine Start Circuit

Neutral starter To prevent the machine from unexpected movement at engine start up, the machine is so designed that the engine can start only while the shift lever is in the neutral (N) position.

Shift lever neutral (N) position When the starter switch is turned to the ON position while the shift lever is located in the N position, the coil actuation circuit of the neutral relay is connected to the ground of the MCU unit and the contact of the neutral relay is switched over to ON. 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.

62-16 95ZV-2 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

BR R2

W3 W5

Preheat

WB x 2

Off

To heater relay

WR x 2

BR AC

To battery relay

BBG G

R1 BR

From battery

Connection table

BW WR WR BG WB WB

1.25

W5 W3

To neutral relay

Start

85V2E62013

62-17 95ZV-2 Function & Structure Electrical Group Engine Start Circuit

ECM safety features

Battery relay

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.

Terminals for coil energizing current (4 mm)

Moving contact Main contacts

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

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.

62-18 95ZV-2 Function & Structure Electrical Group Engine Start Circuit

Alternator I terminal wire 12V

Diode unit 12V

30A

Battery (1)

ECM F15

R1 BR B AC R2 C

(2) (3)

(2)(3): Diode unit

Charge circuit

WR WP

F13

F14

F12

15A

Suppression diode

WV:To battery relay WR:To starter switch terminal AC (VIA F15) and to ECM WP:To alternator

From alternator I 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 I terminal.

62-19 95ZV-2 Function & Structure Electrical Group Engine Start Circuit

SbP

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

Energized

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 Ω

62-20 95ZV-2 Function & Structure Electrical Group Engine Start Circuit

Magnetic switch

Rating 24 V x 200 A

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.

62-21 95ZV-2 Function & Structure Electrical Group Engine Start Circuit

Voltage relay

Note The illustrations show the de-energized condition.

(S/N 9001~9048)

Once the engine is started, the alternator starts generating electric power. 1

When electric current is supplied from the alternator R terminal to the voltage relay, the voltage relay is magnetized and is turned OFF.

Consequently the magnetic switch turns OFF and no electric current flows to the starter motor terminal C, disengaging the starter motor.

3 1

4 70ZV62020

Voltage relay Contact point closed

Contact point open

(S/N 9049~) Blue

K70V2J62005

Voltage relay Contact point closed

Contact point open

62-22 95ZV-2 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

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.

62-23 95ZV-2 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 (081) W

(031) GY

F31 10A

B (085) W

(035) GR

F35 10A

(730) (BrR)

STOP

(731) (BrB)

WARNING

(013) (LG)

F13

(732) MAINTENANCE (BrW )

28 (015) WR

F15

(161) W

(E15)

REMOTE THROTTLE 5 GY (743)

(745) BO

(746) BO

THROTTLE PEDAL THROTTLE OPENING SENSOR

BrW (733) YV (734) BLg (735)

E 48 47

(751) GyR

E/G OIL PRESS.

49 29

IDLE S/W

30 GyY (736)

OFF IDLE

40 GyW(737)

IDLE

DIAGNOSTIC S/W BrG (738)

S2H 44

PG (739)

(m)

PW (740)

DEC (741) BL

10 AI TC

(B15) (A34)

36 26

SbY (209) Sb (205) SbW(203) SbL (204)

SC (GL ) (213) (GB ) (214)

CAN

S2S

24 46

S2L

RESISTOR

INC/DEC S/W INC

S2H

(060) W

B C

S2L

S2S

(YL ) (747)

(Y0 ) (748)

G A

DATA LINK CONNECTOR

23 43 20

ECM

E/G ECM connection diagram 95V2E62022

62-24 95ZV-2 Function & Structure Electrical Group ECM (Engine Controller)

Monitor lamp test

ON Key switch OFF

Approx. 2 sec

ON Engine maintenance lamp

Orange

OFF ON

Lights when abnormality occurs.

Engine warning lamp OFF

Yellow

ON Engine stop lamp

Red

OFF

95ZV62025

STOP

Engine maintenance lamp (S/N 9001~9150) Engine warning lamp Engine stop lamp 95V2U62019a

When the starter switch is set to ON, three engine monitor lamps (engine protection, engine warning and engine stop) are lit for approximately 2 seconds. After that, if there is an abnormality in a circuit, a corresponding monitor lamp lights.

62-25 95ZV-2 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) Diag. switch (Part Number: 35010-60130)

Step 1. Starter switch key "OFF" Step 2. Diagnostic switch "ON" Step 3. Starter switch key "ON"

Inc./Dec. switch (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"

OFF

PREHEAT

START

K80V2J62009

ON OFF Orange 1 sec

1 sec ON OFF Yellow ON OFF Red

0.5 sec Second digit

First digit 1 sec

Third digit 1 sec

Fault code

Fault code (continued) 115V2E62008

62-26 95ZV-2 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 maintenance lamp Orange

OFF ON

Engine warning lamp Yellow

OFF ON

Engine stop lamp

STOP

Red

OFF

[When there is fault code] ON Engine maintenance lamp Orange

OFF 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. ON Engine maintenance lamp Orange

OFF 1 sec

1 sec

ON Engine warning lamp Yellow

OFF ON

Engine stop lamp

STOP

Red

OFF

Following page explains more. 115V2E62009

62-27 95ZV-2 Function & Structure Electrical Group ECM (Engine Controller)

Increment decrement switch (option) Diag. switch (Part Number: 35010-60130)

G R L W

- Adjusting the engine idle revolution

Inc./Dec. switch (Part Number : 35010-60180)

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 "-".

62-28 95ZV-2 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 95ZV-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)

62-29 95ZV-2 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)

62-30 95ZV-2 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)

62-31 95ZV-2 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)

62-32 95ZV-2 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)

62-33 95ZV-2 Function & Structure Electrical Group ECM (Engine Controller)

62-34 95ZV-2 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)

BLg (735)

48 47 49

W IDLE S/W OFF IDLE

GyY (736) G GyW (737)

IDLE

E C M 3 13

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

95V2U62003

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

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

Ω at pedal up position

Ω 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

G-O

Open

L-O

Open

62-35 95ZV-2 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.

Pedal stop

Stroke

Pedal angle K65V2U62004

17 Installation angle 45

Note Part “A” is added on S/N 9301 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).

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

0 Pedal Angle

85V2E62019

62-36 95ZV-2 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.

62-37 95ZV-2 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

62-38 95ZV-2 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

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

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.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

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

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

A33

A34

B10

B11

B12

B13

B14

B15

B16

B17

B18

B19

B20

B21

B22

B23

B24

To S6

B25

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.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

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

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

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

C33

C34

D10

D11

D12

D13

D14

D15

D16

D17

D18

D19

D20

D21

D22

D23

D24

D25

D26

To S9

Connector details 85V2U62009

62-39 95ZV-2 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit

Machine control unit (MCU) connection diagram

(L)

(005-B)

(L)

(005-A)

ACC’ (005) 2 L

TO PARKING S/W

30A

F10

G (010)

L x4 (005-A~005-D)

ACC’ E05 WL (707)

E06

E17

E03 E04 E11 E12 B18

E24

B12 LR (126)

23A

D04

LW (120) LO (123) LG (122) LY (121)

B10

YO (232)

A03 D12 D05

B13

D03

B01

D10

YW (233)

S/S SHIFT S/W R

D19

(273)

NEUTRAL RELAY

MCU FAILURE RELAY

LIFT KICKOUT RELAY

LOWER KICKOUT RELAY

B04

S/S SHIFT S/W F

LgW (101) BrB (258)

OPT

MCU

F N R

B11

D11

SHIFT LEVER

LBr (128)

(SbP) (145)

A18

YGy (242)

SECONDARY STEERING MOTOR RELAY COIL

(146) LR

F SOLENOID VALVE

(147) LB

H SOLENOID VALVE

(148) LBR

R SOLENOID VALVE

(141) LY

1ST SPEED SOLENOID VALVE

D26 (LY )

YV (231)

S/S SHIFT SELECTION S/W ARMREST S/W

A02

LB (230)

LY (121)

SHIFT DOWN S/W

(YL) (124)

DOWNSHIFT S/W

YSb (125)

SHIFT HOLD S/W

LP (168)

DECLUTCH SET-UP

(GW)(210)

SLIP CONTROL S/W LIFT KICKOUT SET-UP LOWER KICKOUT SET-UP LOWER KICKOUT S/W

BrG (255) BW (271)

D24

(GB) (277)

D07

A08

Lg (222)

REVERSAL FAN S/W

LgY (223)

(Y) (105)

RECALL S/W RESET S/W

(R) (106) LLg (165) GO (164) GyW (200) GL (265) (GyW ) (260)

F13

E (013) (Lg) YO (176)

D15 D23 D22 C13

A17 B14 A07 A04 A01 B03

C24

PARKING SOL (162) LgG

C25 C34

C30 C12

B05

E01 B07

OFF

D SOLENOID VALVE

WR (170)

BRAKE SOLENOID VALVE

LLg (140)

LU SOLENOID VALVE RIDE CONTROL SOLENOID VALVE

LgL (261) GB (267)

EFFICIENT LOADING SYSTEM SELECTION SOLENOID VALVE

GB (278)

PRESS. INC. SOLENOID VALVE

LgL (225) (154) LgR

REVERSAL FAN SOLENOID VALVE

(150) LgR

T/M CONTROL SOLENOID VALVE

E02

(236) BR (237) BL (226) LgB

S/S SOLENOID VALVE R

1A 1A

S/S SOLENOID VALVE L (221) LgB

FAN SPEED CONTROL SOLENOID VALVE

C23 F13

C22 C33

A21 A29

C16 C11

A14 A28 A19

C06

A15

A27 A12

(005-b) (L)

LP (149)

D21 D01

4th INDICATOR RELAY

(LW)

A16 E

(163) (SbW)

OFF ON

LgL (182)

AIR CLEANER CLOGGING S/W

DECLUTCH

Gy (750) BrY (181)

HYD. OIL LEVEL S/W

(LgY) (167)

DECLUTCH S/W

E/G OIL PRESS S/W

(144) LW

D14 D17

3rd SPEED SOLENOID VALVE

(LO)

B06

AUTO FAN REVERSAL S/W

(143) LO

D06

C31

PRESS. INC. S/W

2nd SPEED SOLENOID VALVE

4S (132)(LG)

(LG) A05

LG (122)

SHIFT UP S/W

(142) LG

D18

(LgR) (130) (GR ) (135) (GyB ) (103) (LbY) (173) (GY) (749) (GyG) (753) (GyL) (190) (LgW) (192) (O ) (241)

(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

PARKING S/W

FUEL EFFICIENT MODE S/W

EFFICIENT LOADING SYSTEM S/W

RIDE CONTROL S/W X

MCU FAILURE

(LgW) (102)

(LgSb) (112)

WARNING BUZZER

K95V2E62001

62-40 95ZV-2 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit

A26 SbO (183)

T/M OIL FILTER S/W

Sb (184)

RADIATOR WATER LEVEL S/W

YR (405)

FUEL LEVEL F

YB (406)

FUEL LEVEL 3/4

YL (407)

FUEL LEVEL 1/2

YBr (408)

FUEL LEVEL 1/4

YG (409)

FUEL LEVEL 1/8

A13

C14

A20 C15 A30 C17 A32 C28 A24

C20 C29

A11

C21

A33 A22

A31 V (100)

A23

E09(+5V)

S/S POTENTIOMETER (OPT) G (234)

B09

(SbO) (193)

T/M OIL FILTER WARNING LAMP RADIATOR WATER LEVEL WARNING LAMP AUTO BRAKE INDICATOR LAMP TRACTION CONTROL INDICATOR LAMP (OPT) REVERSAL FAN INDICATOR LAMP (OPT) S/S INDICATOR LAMP (OPT)

(Sb ) (194) (GY)

(169)

(OSb) (211) (RL)

(235)

(LgB)

(224)

(YR ) (410) (YB)

(411)

(YL)

(412)

(YBr)

(413)

(YG)

(414)

LgBr (104)

FUEL LEVEL F FUEL LEVEL 3/4 FUEL LEVEL 1/2 FUEL LEVEL 1/4 FUEL LEVEL E BUZZER

E19

BOOM ANGLE SENSOR BrR (251)

E34

C26

(YB ) (401)

E/G COOLANT TEMP. GAUGE

DECLUTCH SENSOR (LgR) (166)

E27

E21

(BrW)

(402)

T/M OIL TEMP. GAUGE

BRAKE OIL PRESS. SENSOR 1 SbY (171) E30 B24

BRAKE OIL PRESS. SENSOR 2

(400) (WL )

METER OUTPUT (TACHOMETER)

SbY (172) E22

T/M PRESS. SENSOR YGy (151) C19

EFFICIENT LOADING SYSTEM PRESS. SENSOR

GyB (266)

SECONDARY STEERING PRESS. SENSOR (OPT)

SbR (240) GyG (754)

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) Y (160)

MACHINE SPEED SENSOR E/G SPEED SENSOR

ECM(11)

W (161) Y (159)

C01

C27 A06

B25 E31

B08

E32

A09

E23

B15

E07

A34

E16

A25

YSb (403) SbR (208) SbP (202) SbW (203) SbLg (204) (GW) (212)

E15 A10 E08 B19

(RL)(330) (RG)(331)

HOUR METER DRIVE E/G IDLE SELECTION

ECM(41)

E/G DROOP SELECTION 1

ECM(23)

E/G DROOP SELECTION 2

E P (107)

DESTINATION SWITCH 1 DESTINATION SWITCH 2 A/M SELECTION ODOMETER SELECTION TIRE DIA. SELECTION SPEED SENSOR SELECTION METER SELECTION

PL (108) PG (109) PB (110)

E TO BACK-UP LAMP TO BRAKE LAMP

(100) V

PW (111)

YB (115) YG (116) YL (117) YO (118) YBr (119)

C02

D16 D25 D08

(RIN1)B16 (DOUT1)B22

MCU PROGRAM REWRITE

GL (810)

S2H S2L S2S

(CANH0)E29 (CANL0)E20

MAIN MCU

RS232C

GR (811)

D09

+5V FEW RESET RXD TXD MD2 GND

C03 D02

TRACTION CONTROL SELECTION (OPT)

(E09) (OUT_FEW)B23 (OUT_RES)E33 (RXD0)E25 (TXD0)B26 (OUT_MD2)B17

E/G TORQUE SELECTION

CAN

K95V2U62002

Note Refer to Section 92 for the detailed electrical connection diagram for the MCU including modification information.

62-41 95ZV-2 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit

Machine control unit (MCU) function Forward/reverse (F/R) shifting and speed change To solenoid valve for each clutch

F/R clutch solenoid valve

N R

+24 V

Shift lever

Solenoid valve for clutch

L H

Surge suppression diode (incorporated in solenoid valve)

R 1

A 23

Modulation mechanism

Clutch valve

Clutch piston

1 Speed indicator lamp (instrument panel)

Downshift button

+24 V

Torque converter pump

During energized: Clutch is engaged. During de-engaged: Clutch is disen-

Machine with lockup clutch: MCU

Lockup clutch piston

To solenoid valve for each clutch

Machine speed sensor

LU E/G speed sensor

ECM

Solenoid valve Solenoid valve for clutch

+24 V Modulation mechanism

Clutch valve

AUTO indicator lamp

Clutch piston

ON when shift lever in A position Torque converter pump

During energized: Clutch is engaged. During de-engaged: Clutch is disengaged.

95V2U62012

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 through the modulation mechanism and the clutch valve. 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 through the clutch valve, 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 transmission is set to the neutral position. In addition, if two or more speed commands are input at the same time, the speed range previously engaged is selected. 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.

62-42 95ZV-2 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit Shift lever

KNIGHT BEAM CO,LTD BM51-111 JAPAN >PAMXD6-G50<

Forward F

Neutral N

Reverse R

1st speed

2nd speed

3rd speed Auto

Grounding for speed change side (B) 1st speed (GW)

2nd speed (GL)

Auto (G)

3rd speed (GY)

F (GR)

Unused

R (GB)

Grounding for F/R side (B)

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. The lockup clutch (OPT) is automatically engaged or disengaged in the forward operation only.

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.

62-43 95ZV-2 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit

Automatic shift

Operation of solenoid valve Clutch solenoid valve

Shift up

10.8 N-m (1.1 kgf-m) (8 lb-ft)

Shift down

Speed

F4 3

+ side

SKM6 G24D

K W E 6 K- 21/ N 13.0 11.0

– side

Reverse

View from A

10.0 12.0

20.5 22.5

Speed km/h

Forward

Automatic shift map (Normal mode)

95V2E62005

35 N-m (3.6 kgf-m) (26 lb-ft) Shift up 80ZV62012

Shift down

F4 Solenoid valve (with built-in diode) Rated voltage

DC 24 V

Coil resistance value

Approx. 27 Ω

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 the auto brake is actuated or the declutch brake is applied, the forward or reverse (F or R) clutch solenoid valve is turned off and the transmission is set to neutral.

13.0 11.0

Reverse

8.5 10.5

18.0 20.0

Speed km/h

Automatic shift map (Fuel efficient mode)

Forward 95V2E62006

When the shift lever is set to A position, the AUTO indicator lamp on the instrument panel will light and one of the solenoid valves will be automatically energized according to the machine speed and engine speed. In addition, the speed indicator lamp will light. The input signal for automatic shift is controlled by the pulse generated by the speed sensor and ECM.

62-44 95ZV-2 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit

Automatic shift (with lock-up solenoid) Shift up Shift down

Speed

F4L F4 F3L 3 2

13.0 11.0

Reverse

10.0 12.0

15.0 17.0

24.5 26.5

28.0 30.0

Forward Speed km/h 95V2E62007 Automatic shift map (Normal mode)

Shift up Shift down

Speed

F4L F4 F3L 3 2

13.0 11.0

Reverse

8.5 10.5

13.0 15.0

22.5 24.5

26.0 28.0

Forward Speed km/h Automatic shift map (Fuel efficient mode) 95V2E62008

62-45 95ZV-2 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit

Machine speed sensor

Clearance: 0.4~1.6 mm (0.016~0.063 in) 70V2U62008

Internal resistance *

2.3±0.2 kΩ (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 Ω or ∞ Ω 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.

62-46 95ZV-2 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit

Switching from automatic to manual

Downshift button operation Downshift button

LgL SbY GR A502 A507 A701

A/M SELECTION B PG S902 1

SbLg A608

SbL H718

GR T103

LY Gy Gy LP LgB A708 A506 A807 A808 A604 H201 RL GyB GyG GyL LP 0 A609 H128 A809 A505 A501 H207 T801 GB LG YGy LgSb LO YSb LLg LW SbP H121 A709 E804 H122 A710 A901 H110 A711 F202 H204 H202 H203

SbP RG F701 H139

SbR LgBr L BrB LgW LR F102 G602 T001 T901 F901 H205 LBr H206

WL GyG A806 H136

WO SbW GL H117 H703 T104

LgL BL E502 E001

(BLACK) S4

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

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.

62-47 95ZV-2 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit

Modulation at clutch switching MCU

Shift lever

2 3

Output current control

Clutch selection input signal

+ 24 V

B05

ON during modulation

Modulator valve (1)

Modulator valve (2)

A17 + 24 V

Pressure sensor Machine speed sensor E/G speed sensor

95V2U62016

Modulator valve (2)

Modulator valve (1)

ø 3.0 ø 0.9 To T/M clutch To T/C

Modulator valve (1) From pump ø 0.9 orifice

ø 3.0 orifice

95V2U62017

The rise time of clutch oil pressure is controlled by modulator valve (1) and modulator valve (2) to shorten the time lag and reduce shock that occurs when shifting between forward and reverse, and between gears.

Modulator valve unit hyd. circuit

95V2E62012

IMPORTANT Note orifice placement below MV2. Do not mix or lose orifices or transmission failure will occur!

62-48 95ZV-2 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit Modulator valve (1) [MV1]

- Initial charging (t1)

Clutch oil pressure during clutch application is controlled according to the current passing through the coil of MV1. The pressure rises and falls along with the current.

The current flow through the coil of MV1 immediately after clutch selection is maintained as high as it was before clutch selection (400 mA). This allows a lot of oil to flow rapidly into the empty clutch piston chamber, reducing the time lag. - Charging (t2)

Operation of modulator valve (1), (2) and clutch pressure change.

On completion of the initial charging, the current through the coil of MV1 is sharply reduced (170 mA). This reduced current is maintained until the end of the charging to prevent a sudden pressure rise and shift shock.

Clutch selection

- Completion of the charging ON Low clutch solenoid valve 1st clutch solenoid valve

OFF ON Completion of charging

Modulator valve (1) Current flow (mA)

Approx. 400 mA

Approx. 170 mA

- Pressure rise (t3)

0 ON Modulator valve (2)

Main pressure

The clutch oil pressure rises gradually in proportion to the current rise.

OFF

Pressure MPa(psi)

0 Low clutch pressure Pressure MPa(psi)

The pressure sensor in the line to the clutch piston chamber sends electrical signal to the MCU. When the charging is completed, due to no pressure drop in the line, the MCU determines it by the signal sent from the sensor. Then the MCU sends signal to rise the current through the MV1 coil gradually.

95V2E62020

Note - If the MV1 coil is damaged or disconnected, the clutch oil pressure rises only 0.2~0.5 MPa (28~71 psi) and the pressure value is not enough to engage the clutch. - MCU provides the protection program so as to rise the control current again at the time of 0.5 seconds after decreasing the MV1 control current when the pressure sensor is damaged.

62-49 95ZV-2 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit Modulator valve (2) [MV2] This valve assists MV1 in controlling (lowering) the clutch oil pressure. Unlike MV1, it performs an ON and OFF operation. Controlling the clutch oil pressure Modulator valve (2) is energized simultaneously when the current in MV1 changes from high to low current flow. It is de-energized some time after the current in MV1 returns to a higher level and the clutch oil pressure reaches the specified value. Note Modulator valve (2) If MV2 is damaged or disconnected, the machine will have severe shift shock during clutch engagement. In this case, the lowest clutch pressure will be only about 0.7~1.0 MPa (100~142 psi) during charging. The highest clutch oil pressure reaches the specified value.

62-50 95ZV-2 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit

Adjustable declutch preset switch 200

Clutch OFF

Clutch ON

310

510

(kPa)

Declutch sensor

85V2E62028

Declutch selector 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. Pressure sensor for stop lamp and declutch Left brake valve

95V2E52014

Switch 70V2U62015

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.

62-51 95ZV-2 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit

Back-up alarm

Back-up lights

Shift lever

Back-up alarm MCU

+24 V

2 3

A10

85V2E62027

When the shift lever is set to the reverse (R) position, the back-up lamp will light, and the buzzer will sound.

62-52 95ZV-2 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit

Parking brake

5A F13

+ 24V

Monitor lamp

Parking brake

Parking (ON)

Running (OFF) Parking switch

L ON OFF MCU

D01

30A F5 + 24V

95V2E62014

The parking brake solenoid valve activates the parking brake. Parking switch ON:

Parking switch OFF:

When the power of the solenoid valve is turned off, no oil will be fed to the piston chamber of the parking brake. The piston presses the brake disc with the spring force to actuate the parking brake. 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 piston chamber, the spring is compressed, and the parking brake is released.

Parking brake operation Parking switch

Monitor lamp

Buzzer

Parking brake solenoid valve

Parking *

"Parking" position (pulled up)

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.

62-53 95ZV-2 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit Solenoid valve for parking brake Spring chamber (brake actuator) B

Reducing valve

Solenoid

Knob

T Seat face A

Manual release (counterclockwise rotation)

Spool

Seat face B Tank

115V2E62020

Solenoid specifications Rated voltage

Hydraulic circuit diagram

95ZV52045

Auto brake solenoid valve Valve assembly

Parking brake solenoid valve Hydraulic tank Valve location

95V2E62025

DC 24 V

Rated current

0.92 A

Resistance

26.2 Ω

62-54 95ZV-2 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit

Auto brake

Input side

Output side

MCU

Shift lever

Shift lever position selector signal

Solenoid valve for auto brake

1 23A

+24V

B14

Auto brake monitor lamp, buzzer

+24V

Machine speed

A20 Machine speed sensor

B13

B01

B04

Solenoid valve for forward/reverse clutch

Installation position of solenoid valve for auto brake. Refer to the description on the solenoid valve for parking brake.

95V2E62015

When the traveling direction is switched over between forward and reverse at a machine speed of 14 km/h (8.75 mph) or more, the auto brake is applied to protect the transmission clutches.

Shown in the "released" position To rear service brake

To front service brake

When the machine speed is too high, the auto brake is applied also to prevent troubles caused by excess speed in the engine and the transmission.

23 PI

When the auto brake signal enters from the MCU to solenoid valve (36) for auto brake and solenoid valve (36) is energized and magnetized, the pilot oil from the reducing valve enters the pilot port of brake valve (23), and actuates the pilot piston and the spool of the brake valve.

1.0

1.2 From unloader valve (Pump)

When the spool is switched over, the high-pressure oil coming from the pump through the unloader valve enters the front and rear brake piston chambers to apply the service brake.

MCU signal From reducing valve (Pump)

95V2E62016

At this time, the neutral indicator lamp and the auto brake indicator lamp on the instrument panel light, and buzzer sounds. While the auto brake is applied, the forward/reverse clutches of the transmission are disengaged and kept in the neutral status until the actual machine speed decreases and reaches the set value.

62-55 95ZV-2 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit When the traveling direction is switched over between forward and reverse at a machine speed of 14 km/h (8.75 mph) or more

When machine speed is excessive Operation chart (Example: Machine speed excessive in forward direction)

Operation chart (Example: Shifting from forward to reverse)

Machine speed

Machine Machine speed: speed: Shifting between 3 km/h 2 km/h forward and reverse (1.9 mph) (1.25 mph)

F solenoid valve

Speed clutch solenoid valve

OFF

115ZV62067

OFF

R solenoid valve

When the machine speed reaches or exceeds the set value, the service brake is applied as in the above case. When the machine speed drops below the specified value, the service brake is released.

ON Neutral indicator lamp OFF

OFF ON

Brake solenoid valve Monitor lamp Buzzer

ON Brake solenoid valve OFF OFF Monitor lamp Buzzer Neutral indicator lamp Service brake operating

T/M in neutral

ON OFF

Machine speed

F solenoid valve

T/M in neutral

OFF

During service brake application, the transmission is placed in neutral.

Service brake operating 95V2E62017

When the traveling direction is switched over between forward and reverse at a machine speed 14 km/h (8.75 mph) or more at any speed position, the power of the solenoid valve for auto brake turns on and the service brake is applied until the machine speed is reduced to 2 km/h (1.25 mph). At the same time, the power of all solenoid valves for forward/reverse clutches is turned off, and the transmission is set to the neutral position. When the machine speed reaches 3 km/h (1.9 mph), the clutch for the opposite direction is engaged. (However, the brake remains applied until the machine speed becomes approximately 2 km/h (1.25 mph).

Speed range

Set value

1st

About 20 km/hr

12.5 mph

2nd

About 22 km/hr

13.8 mph

3rd

About 36 km/hr

22.5 mph

4th

About 40 km/hr

25.0 mph

62-56 95ZV-2 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit Auto brake solenoid valve

Brake valve (shuttle valve)

Reducing valve

Spool

Solenoid

T Seat face A

Seat face B

Tank

P T Hydraulic circuit diagram

95ZV52052

Auto brake solenoid valve Valve assembly

Parking brake solenoid valve Hydraulic tank Valve location

Solenoid specifications Rated voltage

DC 24 V

Rated current

0.92 A

Resistance

26.2 Ω

95V2E62025

62-57 95ZV-2 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 If a warning is given as a result of self-diagnosis of the MCU

LgW

The MCU has a self-diagnosis function incorporated in it, and if the computer program becomes abnormal due to abuse or defect, a dangerous condition may occur, the monitor lamp lights up and all the outputs from the MCU are turned OFF.

LgW

Body blue

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.

Electrical circuit

When installing a new MCU on the machine, all specifications must be registered into the MCU through the MODM.

Chassis side coupler

85V2E62030

Rating

DC 24 V

Operation voltage

16 V or less

Reset voltage

2.4 V or more

Coil resistance

320 Ω

MCU fault relay (Normally closed)

62-58 95ZV-2 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit

Secondary steering function (OPT)

Speed sensor

To steering valve

Pilot lamp F13

MCU

Pressure sensor

Check valve

Check valve G1/2 G1/2

+24 V

Secondary steering motor and pump

G1/2 G1/2

G3/8

11.7MPa (119 kgf/cm2) (1696 psi)

10 cm3/rev G1/2

Check valve Secondary steering relay

G1/2

+24 V

Secondary steering motor and pump 11.7MPa (119 kgf/cm2) (1696 psi)

10 cm3/rev

80.0 71.3 cm3/rev cm3/rev

Magnetic switch (on motor and pump) Steering pump Hydraulic line Electrical circuit

95V2E42036

In normal operation, the oil from the steering pump 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

62-59 95ZV-2 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit

The signal from MCU to magnetic switch

Machine speed signal

Machine speed

OFF

(km/h)

85V2E42051

62-60 95ZV-2 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.

Item to be monitored

Machine control unit (MCU)

Lighting color

Defective machine control unit (MCU)

Brake oil pressure

Engine oil pressure (red)

Engine coolant temperature (red)

Torque converter oil (transmission) temperature

(red)

Clogged air cleaner (red)

Clogged transmission oil filter

Buzzer

Lamp test

Remarks

—

(red)

(red) 3

Operation condition Symbol

(red)

Charging condition

Unloader valve accumulator port oil pressure is lower than 3.9±0.5 MPa (40±3 kgf/cm2) (569±71 psi) While engine running, 0.1 MPa (1.1 kgf/cm2) (16 psi) or less for more than 2 seconds 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

—

Pressure difference at 50±2ºC (122±4ºF) or more is 0.3 MPa (45±4 psi) or more

—

Defective charge system

—

For items 1~7, 10

—

(red) 9

Central alarm

Flashing type

(red) 10

Steering oil pressure (option)

Engine cooling water level

Auto brake operation

(red)

When operates, steering pressure is less than 0.4 MPa (4 kgf/cm2) (57 psi). Machine speed more than 2 km/h When engine cooling water level drops (before start up only)

When auto-brake works (red)

(red) 13

Hydraulic oil level (red)

Hydraulic oil level is low when the engine is stopped

—

F/R: No buzzer sounds

62-61 95ZV-2 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit

Monitor lamp No.

Item to be monitored

Lighting color

Operation condition

Buzzer

Lamp test

Symbol

—

Engine protection lamp (orange)

Engine warning lamp (yellow)

Any fault in engine detected by ECM (Engine controller)

—

Engine stop lamp (red)

(2 sec.)

Remarks

62-62 95ZV-2 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit

Operation monitor lamps Monitor lamp No.

Monitor item

Lighting color

Lighting condition

Remarks

Symbol

Parking

Red

When parking brake switch is set to ON

Declutch

Green

When declutch switch is set to ON

Working light

Green

When working light (rear) switch is set to ON

Preheat

Orange

When starter switch is in the PREHEAT position

Turn signal indicator (left)

Green

When turn signal lever (left) is actuated

Turn signal indicator (right)

Green

When turn signal lever (right) is actuated

High beam

Blue

When head lamp is set to high beam

Auto shift

Green

When transmission shift lever is set to automatic position

Neutral

Green

When transmission shift lever is set to neutral position

Transmission status

Yellow

When transmission shift lever is set to corresponding gear (1~4)

Caution on storage of individual instrument panel

IMPORTANT

Gauge pointer

Pointer axis Axis hole

When storing the instrument panel individually, make sure that the panel face (transparent face) faces upward. If the panel face faces below the vertical direction, the damper oil may leak from meter pointer axis holes.

Main body frame

Meter

Damper oil

Magnet

70ZV62039

62-63 95ZV-2 Function & Structure Electrical Group Instrument Panel and Switch

Instrument Panel and Switch Instrument panel

20 39 17

19 5 18

11(37) 12

27 13

34 14 35

15 29 16 STOP

40 36

24 25(37)

22 7

95V2U62018

1. Tachometer 2. Engine coolant temperature gauge 3. Transmission oil temperature gauge 4. Fuel gauge 5. Parking brake indicator lamp 6. F/R switch indicator lamp (green) 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 (option) 26. Working light switch (front) 27. Working light switch (rear) 28. Fuel efficient mode switch 29. Selection switch for shift lever or F/R switch 30. Four-way flasher switch (option) 31. Engine protection lamp 32. Engine warning lamp 33. Engine stop lamp 34. Efficient loading system switch 35. Declutch selector switch (S/N 9001~9150) 36. Coolant level warning lamp 37. Hydraulic oil level warning lamp 38. Declutch selector lamp 39. Auto brake indicator lamp 40. Transmission oil filter warning lamp

62-64 95ZV-2 Function & Structure Electrical Group Instrument Panel and Switch

Instrument panel rear surface

CN4 1

CN1

5 L2

L14 Hour meter

L10

12P

L20

58 57

16P

L10

56 L10

L10 S

L15

L21

L3 L16

L10

L17 E

L5 L6

CN3

L12

L13

L11

Engine water temperature sensor

L18

L10

L19

L8 E

Transmission oil temperature sensor

CN2

L22

L23

L24

L25

L26

L27

20P 19

Layout of connector pins (Instrument panel side) CN1(8P)

CN2(20P)

9 10 11 12 13 14 15 16 17 18

29 30 31 32 33 34

41 42 43 44

19 20

35 36 37 38 39 40

49 50

3 4

6 7

CN3(12P/16P)

22 23 24 25 26 27 28

CN4(2P) A7

A8 46 47 48

53 54 55 56

57 95ZV62124

Pin No.

Signal

Lamp No.

Pin No.

Signal

Lamp No.

Pin No.

—

Signal

Lamp No.

Engine water level alarm

Charge lamp

—

Air cleaner clogging alarm

Fuel level lamp (F)

—

T/M oil temperature alarm

Fuel level lamp (3/4)

—

Converter (–)

Engine water temperature alarm

Fuel level lamp (1/2)

—

Engine oil pressure alarm

Fuel level lamp (1/4)

—

Brake oil pressure alarm

Fuel level lamp (E)

—

MCU failure alarm

GND (–)

—

Work lamp

L18

+24 V power supply

—

Central alarm lamp

L14

—

GND (–)

—

+24 V power supply

—

Secondary steering (option)

L22

—

AUTO lamp

L20

Auto brake

L16

Converter (+)

— — —

Declutch lamp

— L17

—

L19

Reversal fan (option)

L23

—

Engine warning lamp

L25

—

Engine protection lamp

L24

—

High-beam lamp

L12

Engine stop lamp

L26

Neutral

L21

Turn signal (left) lamp

L13

—

L27

+24 V power supply

—

Turn signal (right) lamp

L11

E/G water temperature gauge

—

1st speed indication

—

T/M oil temperature gauge

—

2nd speed indication

—

Hour meter (–)

—

Hour meter (+)

—

3rd speed indication

—

Instrument panel illumination

L10

4th speed indication

—

T/M oil filter clogging alarm

Parking brake lamp

L15

—

62-65 95ZV-2 Function & Structure Electrical Group Instrument Panel and Switch

Gauge circuit

Controller

Grounding

Power supply 24V

S E

15V

Viewed from rear surface of instrument panel K90ZV62016

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. Note If a gauge is removed from the panel, the resistance between the terminals will differ from the standard value shown in the table. Gauge

Engine water temperature 97ºC(206ºF)

T/C, T/M oil temperature 110ºC(230ºF)

100ºC(212ºF)

35ºC(95ºF)

103ºC(217ºF)

100ºC(212ºF)

120ºC(248ºF)

50ºC(122ºF)

125ºC(257ºF)

Indication

White

Red

White

Resistance between S and E (Ω)

120~125

75~80

Resistance between S and V (Ω)

120~125

85~90

Resistance between E and V (Ω)

170~190

130~150

62-66 95ZV-2 Function & Structure Electrical Group Instrument Panel and Switch Temperature sensor (For engine water temperature (S/N 9001~9150), torque converter oil temperature and hydraulic oil temperature)

115V2E62023

Temperature of detection part (ºC)

80 [176ºF]

90 [194ºF]

100 [212ºF]

120 [248ºF]

Resistance (kΩ)

6.2~6.9

4.7~5.2

3.6~3.9

2.1~2.4

62-67 95ZV-2 Function & Structure Electrical Group Instrument Panel and Switch

Fuel gauge circuit

The level sensor provided inside the fuel tank is equipped with five float switches. When the oil level becomes low, the contact of the corresponding float switches turns on. The float switch signals are transmitted to the MCU, electrically processed, then only one lamp corresponding to the gauge level lights on the instrument panel.

MCU Level sensor C14 C15

YB (406)

FUEL LEVEL 3/4

YL (407)

FUEL LEVEL 1/2

YBr (408)

FUEL LEVEL 1/4

YG (409)

FUEL LEVEL 1/8

Indicator +24V lamps

C17

Float switch switching and indicator lamp lighting status

C28 C20

C21

A11 A33

A22 A31 A23

(YR ) (410)

FUEL LEVEL F FUEL LEVEL 3/4 FUEL LEVEL 1/2 FUEL LEVEL 1/4 FUEL LEVEL E

(YB) (411) (YL) (412) (YBr) (413) (YG) (414)

Indicator lamp ◎ : Flashing ● : Lit – : Extinguished

Float switch ○ : ON × : OFF

C29

Actual fuel level

YR (405)

FUEL LEVEL F

1/4 1/2 3/4

F or more

–

●

From F to 3/4

○

–

From 3/4 to 1/2 ×

○

–

●

● –

–

From 1/2 to 1/4 ×

○

–

●

–

From 1/4 to E

○

●

–

E or less

○

◎

–

Any other pattern

Example of failure: When the wire of the "1/2" float switch is broken, the indicator lamps for "1/4" and "E" do not light even if the fuel amount becomes 1/2 or less.

Float switch

3/4 ON 1/2 ON 1/4 ON 1/8 ON Fuel level sensor (Brown)

(Black) 3/4

E (Yellow)

(White) 1/2

1/8 (Green)

(Red) 1/4 View A

K115V2E62003

62-68 95ZV-2 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

62-69 95ZV-2 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 92-41.

(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.

62-70 95ZV-2 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.

(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.

62-71 95ZV-2 Function & Structure Electrical Group MODM

Information Monitor

1. Outside air temperature

(Refer to page 92-43)

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 92-41 and 92-43.

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".

62-72 95ZV-2 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 [

(step forward)] button and release.

90ZV-262026

90ZV-262027

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".

62-73 95ZV-2 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.

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.

62-74 95ZV-2 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 92-42.

62-75 95ZV-2 Function & Structure Electrical Group MODM

Replacement Monitor

2. Fuel filter

(Refer to page 92-44)

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.

62-76 95ZV-2 Function & Structure Electrical Group MODM

3. Coolant filter (80ZV-2 ~ 135ZV-2 only)

4. Torque converter and transmission filter

Press the [

(step forward)] button and release.

80V2U62011

80V2U62012

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.

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.

62-77 95ZV-2 Function & Structure Electrical Group MODM

5. Hydraulic return filter

6. Engine oil

Press the [

(step forward)] button and release.

80V2U62013

80V2U62014

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.

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.

62-78 95ZV-2 Function & Structure Electrical Group MODM

7. Torque converter and transmission oil

8. Axle oil

Press the [

(step forward)] button and release.

80V2U62015

80V2U62016

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.

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.

62-79 95ZV-2 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.

62-80 95ZV-2 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.

62-81 95ZV-2 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 92-45) 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 92-41.

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.

62-82 95ZV-2 Function & Structure Electrical Group MODM

2. Inactive faults (Checking history ∗) 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.

Selection of machine fault log and engine fault log 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

62-83 95ZV-2 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 95ZV-2 S/N 9254 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.

62-84 95ZV-2 Function & Structure Electrical Group MODM

Clear active fault log (error pop up) (S/N 9001~9166) When a fault occurs, the corresponding fault code is forcibly displayed on the screen. When two or more active faults occur, up to 5 fault codes each are displayed repeatedly. (Up to total 10 fault codes for CN and EG errors together) For deleting the displayed fault codes, press one of the [ (step forward)] button, [ (step back)] button, [ ] button or [ ] button.

80V2U62024

Then, the screen displayed before the active fault codes appears again. Active fault codes are displayed repeatedly when the starter switch is ON and will continue to display until the cause of each fault code is eliminated. If there is a fault that has been erased, and the cause is not repaired, the fault will quickly reappear in the screen due to being active. It will continue to reappear until the underlying cause of the fault is eliminated.

62-85 95ZV-2 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

62-86 95ZV-2 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 30±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 10K01)

Fuel level display table Input

Output

1/8

1/4

1/2

3/4

—

Other than above : No input signal given x : Input signal given

1/4

1/2

3/4

—

: Lamp on — : Lamp off

—

: Lamp flashing

—

Note This table applies to the 95/115/135ZV-2 units.

62-87 95ZV-2 Function & Structure Electrical Group MODM

Failure code (Output side) Code CN512

Failure

Detection condition

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 10F24)

Failure code (Engine) Refer to "Quantum fault code information" page 62-28.

62-88 95ZV-2 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 92-46)

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. When input signal is OFF, "0" is displayed under corresponding item number. Refer to "MODM: Input/Output Monitor - Input/Output Signal Correspondence Table" page 92-50. 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.

80V2U62028

The screen indicates that ride control and ELS are activated, or the switch for each one is energized. Now press the [ (step forward)] button once. You will arrive at the screen shown below.

80V2U62029

This indicates that the engine is running as the place for alternate neutral voltage under slot 3 is occupied by a 1. 80V2U62025

62-89 95ZV-2 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 (EMG 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".

62-90 95ZV-2 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 92-50. 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.

62-91 95ZV-2 Function & Structure Electrical Group MODM Next press the [ following screen.

(step forward)] button to show the

4. Electric current output monitor This indicates the milliampere (mA) of electric current that are being sent to the fan solenoid valve from the MCU.

80V2U62038

Press the [ (step forward)] button for 2 seconds or longer to show the following screen.

All values are at 0 as there are no outputs needed in this scenario. Next press the [ following screen.

(step forward)] button to show the 80V2U62042

80V2U62039

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.

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.

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.

Next press the [ following screen.

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.

(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.

Refer to fault code table for the chassis side for more detail.

62-92 95ZV-2 Function & Structure Electrical Group MODM

Parameter Setting Monitor

1. Shift inhibitor

(Refer to page 92-47)

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) - EMG STEERING - SP7 (EMG steering) - K-LEVER - SP8 (K-Lever) - TRACTION CONTROL - SP11 (Traction control)

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.

- 2 STAGE - SP13 (Efficient loading system) - BOOM SOFT LAND - SP14 (Lower kickout)

By pressing the [ (step forward)] button, you will arrive at a window as shown below.

- KICK OUT - SP15 (Lift kickout) 80V2U62043

62-93 95ZV-2 Function & Structure Electrical Group MODM Press the [ (step forward)] button to add "1" to a numerical value.

2. Ride control Now press the [ (step forward)] button once. You will arrive at the screen shown below.

80V2U62044

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. Now press the [ (step forward)] button once. You will arrive at the screen shown below.

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.

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; 0 → 1 → 2 ..... 9 → 0 → 1 → 2 ..... Press the [ (step back)] button to subtract "1" from a numerical value. The number then decreases as follows; 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.

62-94 95ZV-2 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

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

62-95 95ZV-2 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

V=Voltage The screen should appear similar to what is shown and indicates the K-Lever mA signal strength or intensity.

Potentiometer (V)

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

62-96 95ZV-2 Function & Structure Electrical Group MODM B Type

7. Traction control

Solenoid valve LH side

Next, by pressing the [ following screen is seen.

Solenoid valve RH side

Current (mA)

imax

(step forward)] button, the

i2 80V2U62058

i1 Potentiometer (V)

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.

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 62-102)

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).)

62-97 95ZV-2 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

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.

62-98 95ZV-2 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

62-99 95ZV-2 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.

(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.

62-100 95ZV-2 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 92-47) 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.

62-101 95ZV-2 Function & Structure Electrical Group MODM

Specification Setting Monitor

1. Specification setting display

(Refer to page 92-48 and 92-49)

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

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.

62-102 95ZV-2 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 92-41. 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)

62-103 95ZV-2 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 62-106 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 !

62-104 95ZV-2 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

Information monitor

Kick down (downshift button)

SP1

Always valid

Selection switch shift (shift lever or F/R switch)

SP2

Optional (EU valid)

Shift hold

SP3

Always invalid

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

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

When this is performed, the following items will be reset. - 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.

62-105 95ZV-2 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.

62-106 95ZV-2 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

Kick down (downshift button)

Valid/Invalid

Selection switch shift (shift lever or F/R switch)

Valid/Invalid

Shift hold

Valid/Invalid

Autobrake

Valid/Invalid

Ride control

Valid/Invalid

Engine speed

Net/Sensor

Sensor

Secondary steering

Valid/Invalid

K-Lever

Valid/Invalid

Engine curve

Output/Net/Invalid

Hydraulic pressure increase (power up)

∗

x∗∗

Output

Valid/Invalid

Traction control

Valid/Invalid

Tachograph

Valid/Invalid

Efficient loading system (ELS)

Valid/Invalid

Lower kickout

Valid/Invalid

Lift kickout

Valid/Invalid

Cooling fan

A type/B type/Invalid

A type

Torque converter oil temperature switch

Valid/Invalid

Engine coolant temperature switch

Valid/Invalid

Engine coolant temperature sensor

Net/Sensor

Net

Engine oil pressure switch

Valid/Invalid

Engine oil pressure sensor

Valid/Invalid

Brake pressure differential switch

Invalid/Nc/No

Brake oil level

Invalid/Nc/No

Wheel type

A or B type

A type

B type

A type

B 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.

62-107 95ZV-2 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

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 the 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

62-108 95ZV-2 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 Ω

62-109 95ZV-2 Function & Structure Electrical Group Electrical Detent Circuit

Lift kickout & lower kickout Location

4 A 5

1 Detail A

85V2E62008

1. Rotary sensor assy 2. Rod 3. Link 4. Cover 5. Cover 6. Boom

62-110 95ZV-2 Function & Structure Electrical Group Electrical Detent Circuit

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.

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.

62-111 95ZV-2 Function & Structure Electrical Group Electrical Detent Circuit

Sensor assy 4

3 3

5 1 A-A

Detail of grease applying

A 30 Position sensor detail

85V2E62009

1. Position sensor 2. Link 3. Plate 4. Shaft 5. Ball bearing

62-112 95ZV-2 Function & Structure Electrical Group Electrical Detent Circuit

A B C

View A

A Position sensor detail

CCW

70T2U62008

70T2U62009

Resistance

5 kΩ ± 1 kΩ

Electrical rotation

128º (Theoretical)

Mechanical rotation

180º

Clockwise stop

90º from elect. center

Spring return

To clockwise end of rotation

62-113 95ZV-2 Function & Structure Electrical Group Electrical Detent Circuit

Detent solenoid

Lever position: Lower kickout side

Preset height adjustment

Lever position: Lift kickout side

Push rod

Detent solenoid (for lift) Fixing disc

Detent solenoid (for lower) Fixing disc

Switch

(Upper)

85V2E62047

(Lower)

Hold

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 Ω

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.

62-114 95ZV-2 Function & Structure Electrical Group Diode

Diode Open circuit, failed in open position.

Symbols

Snap!

+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.

62-115 95ZV-2 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 Ω 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 Ω, 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

(2) (3)

(2)(3): Diode unit

F13

F14

F12

15A

Suppression diode Charge circuit

From alternator I 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

Open circuit

0 volt

Short-circuit

62-116 95ZV-2 Function & Structure Electrical Group Diode

Resistance check mode Analog type tester

R1>0

R2=

Forward check

Backward check Digital type tester

R1>0

R2=

Forward check

Backward check

Forward check

Backward check

Judgement

R Ω (0<R<∞)

∞Ω

Normal

∞Ω

Open circuit

0Ω

Short-circuit

62-117 95ZV-2 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 Snap! When the switch opens, the field collapses across the coil windings. Battery

Coil

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.)

62-118 95ZV-2 Function & Structure Electrical Group

MEMO

72-1 95ZV-2 Function & Structure Operator Station Group

95ZV-2 Function & Structure Operator Station Group Cabin ....................................................................... 72-2 Operator Seat.......................................................... 72-9 Steering and Transmission Shift Lever.................... 72-10 Air Conditioner ........................................................ 72-13

72-2 95ZV-2 Function & Structure Operator Station Group Cabin

Cabin B A

A 3

7 5 6

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

72-3 95ZV-2 Function & Structure Operator Station Group Cabin

Glass

70V2E72001

1. Front glass 2. Front side glass 3. Rear glass

72-4 95ZV-2 Function & Structure Operator Station Group Cabin

1. Part number 32011-21690

Clear glass (Outside)

2. Part number 32011-21700

Clear glass (Outside)

Laminate: 0.76 mm

T=3.0

Laminate: 0.76 mm

T=3.0

Green glass (Inside)

T=3.0

A-A

(mm) 327.5 (mm) R3

953

R3 R3

R53

1149

1195

52.5

299.5 699

646.5

70V2E72002

Note This glass must comply with ECE REG43.

70V2E72003

Note This glass must comply with ECE REG43.

72-5 95ZV-2 Function & Structure Operator Station Group Cabin

3. Part number 32011-21500

(mm) 1262.5

848

T=6.0

0 R3

1325.5

70V2E72004

Note This glass must comply with ECE REG43.

72-6 95ZV-2 Function & Structure Operator Station Group Cabin

Wiper mount Front wiper

714 (Along surface)

ace)

Wipin g ang le 56º

long su rf

R750(A

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

106

450

97ZV72005

1. Wiper motor 2. Wiper arm

3. Wiper blade 4. Washer jet nozzle

72-7 95ZV-2 Function & Structure Operator Station Group Cabin

Wiper motor Front Cabin

(Automatic stop position) 12

159200 589 24V

100

e) ol rh ø5 the a re

115

80 70

5.6

±0

(3º 10')

Wipin

g angl

e 56º

Ro tati

ng d

irec

tion

(-1) AVS0.85 W

(-2) AVS0.85 L

(+) AVS0.85 R

(S) AVS0.85 Y

(+) AVS0.85 R

( L1~L3=3.7µH C1~C3=0.2µF )

MOTOR

Circuit breaker

M L3

C3 C2 R

Washer motor

C1 L

24 V OFF LOW HIGH

SWITCH

Circuit diagram

97ZV72100

Wiper motor (front) specifications 1. Wiper motor assembly 2. Link assembly 3. Washer 4. Nut 5. Cap 6. Nut 7. Crank arm

Nominal torque

23.5 N-m (2.4 kgf-m)

Rated voltage Rotating speed Load: 1.0 N-m (0.1 kgf-m) Rotating speed Load: 4.0 N-m (0.4 kgf-m)

DC 24 V Low

46±4 min-1

High

68±7 min-1

Low

≧ 32 min-1

High

≧ 42 min-1

No-load starting voltage (Minimum)

≦ 16 V

Automatic stopping voltage (Maximum)

≧ 32 V

No-load current

≦2A

Locked rotor current

≦ 15 A

72-8 95ZV-2 Function & Structure Operator Station Group Cabin Rear

Wiping angle: 106º±3º Automatic stop position

L(+) LB (+1)

Y(S)

Cabin

AVS0.85 LB (+1) AVS0.85 L (+)

AVS0.85 WB ( )

MOTOR (Circuit breaker)

AVS0.85 Y (S)

M 2 LB

Cabin

L +

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

72-9 95ZV-2 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.

Note The seat is designed so that it is unnecessary to make any adjustment for the driver weight. 4

95ZV OM EU SEAT

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.

72-10 95ZV-2 Function & Structure Operator Station Group Steering and Transmission Shift Lever

Steering and Transmission Shift Lever Tilt quantity 56

5 4 6

Operator stand

1. Steering wheel 2. Transmission shift lever 3. Turn signal indicator and head lamp high/low selector lever 4. Handle tilt adjustment lever 5. Gas spring 6. Column shaft assembly 7. Lower column shaft 8. Orbitrol® 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.

72-11 95ZV-2 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

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)

72-12 95ZV-2 Function & Structure Operator Station Group Steering and Transmission Shift Lever

Column shaft Grease charged

Adhesive applied

1 8 10

5 Waterproof seal

13 11 11

B-B

A-A 97ZV72018

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

Shift lever Refer to "Electrical Group 62".

72-13 95ZV-2 Function & Structure Operator Station Group Air Conditioner

Air Conditioner Denso air conditioner components

4 1-1

3 1-2

1 7 9

6 13

97ZV72020

1. Air conditioner assembly 1-1 Cooling unit assembly 1-2 Blower assembly 2. Air distributor assembly 3. 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)

72-14 95ZV-2 Function & Structure Operator Station Group Air Conditioner

Denso air conditioner structure Cooling unit 37

14 57

38 13 25

50 49 24 1

9 24

23 6

5 15 4

3 16 12

97ZV72021

72-15 95ZV-2 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)

72-16 95ZV-2 Function & Structure Operator Station Group Air Conditioner

Heater and accessories

Air distributor (hood & defroster selection box) 13 3 6

7 2

7 2 5 1 1 97ZV72024

11 17

97ZV72023

1. Blower case 2. Blower case 3. Air damper case 4. Air damper case 5. Blower & blower motor 6. Servo motor 7. Door 8. — 9. — 10. Bracket 11. Pipe (for cooling motor) 12. — 13. — 14. — 15. — 16. — 17. Relay

1. Air damper case 2. Air damper case 3. — 4. — 5. — 6. Control lever 7. Door 8. — 9. Control lever 10. — 11. — 12. — 13. Servo motor actuator (AY, inside/outside air)

72-17 95ZV-2 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

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

72-18 95ZV-2 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

72-19 95ZV-2 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.

72-20 95ZV-2 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

72-21 95ZV-2 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

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.

72-22 95ZV-2 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.

72-23 95ZV-2 Function & Structure Operator Station Group Air Conditioner

Electrical circuit Control schematic drawing

Outside air sensor

Input signals

Set temperature, room temperature, water temperature, air temperature after evaporator

Insolation sensor Outside air sensor

e = Inside air temperature - Set temperature

Insolation sensor

Set temperature correction

Freeze sensor

Water temperature sensor

BLC Temperature control servo HOT Blower motor Temperature control servo

Blow-off servo

Warm-up control

Blower voltage

Water temperature (ºC)

Blower voltage/temperature control/blow-off servo motor position determination

Inside air sensor

COOL FACE B/I FLOOR Y value

Blow-off servo Compressor ON-OFF ON 3

Freeze sensor temperature (ºC)

95ZVE72018

72-24 95ZV-2 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"

72-25 95ZV-2 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.

72-26 95ZV-2 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.)

72-27 95ZV-2 Function & Structure Operator Station Group Air Conditioner 2. Stopping the automatic operation

Operating method Normal use 1. Automatic operation

Set temperature

(1) OFF switch

(3) Temperature setting switches

(5) AUTO switch

97ZV72041

Air flow quantity

(8) Air conditioner ON/OFF switch 97ZV72040

(a) Set 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.

72-28 95ZV-2 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.

(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.

72-29 95ZV-2 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.

72-30 95ZV-2 Function & Structure Operator Station Group Air Conditioner 3. Failure code deletion

Other functions Self-diagnosis function Each sensor and equipment used in the air conditioner can be diagnosed for failure.

(1) OFF switch

After completing the inspection and/or the repair, delete the failure codes memorized in the computer. If 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 E-

(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 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

72-31 95ZV-2 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

a ir

Air mixing damper B (completely closed) [In the case of maximum heating] Air mixing damper A (completely closed)

Ho t

air

Blower motor Inside/outside air selection damper Air mixing damper A

air

Inside air

Outside air

Fan

Blower motor Heater radiator

Co ld

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.

72-32 95ZV-2 Function & Structure Operator Station Group Air Conditioner

Evaporator

The evaporator is an important heat exchanger which evaporates liquid refrigerant set to low temperature and low pressure by an expansion valve, utilizes its latent heat, and absorbs heat from air (target) inside the 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.

Evaporator

(7)

(5)

(2)

By cooling, the moisture contained in the air condenses, changes into water drops, and adheres to the outside of the evaporator. If these water drops are frozen, the cooling effect deteriorates. To prevent this, attention should be paid also to proper drainage of condensed water.

(8) (1)

(6)

The refrigerant quantity supplied to the evaporator is adjusted by the expansion valve described next. In order to ensure that the refrigerant quantity is accurately adjusted, pressure drop of the refrigerant inside the evaporator should be minimal.

(3)

Refrigerant flow inside evaporator ( From expansion valve→(1) to (8) →Compressor

)

Accordingly, reduction of pressure drop is an element to enhance the performance of the evaporator. 97ZV72048

Troubleshooting the evaporator Item

Symptom

Cause

Both high pressure and low pressure are low, and air bubbles can be seen through sight glass.

- Joint portion of supply area - Cracks in evaporator main body

Blockage in circuit

Both high pressure and low pressure are low.

- Blockage inside

- Cleaning/replacement

Blockage in fins

Air quantity is small. (Filters may be clogged.)

- Blockage in fins

- Cleaning

Freezing

Air quantity is small, and low pressure is low.

- Blockage in filter (Evaporator is not preforming inadequately.)

- Cleaning/replacement

Gas leak

Action - Tightening - Repair/replacement

72-33 95ZV-2 Function & Structure Operator Station Group Air Conditioner Expansion valve operation

Expansion valve (box type)

(Evaporator)

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.

72-34 95ZV-2 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.

72-35 95ZV-2 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

Symptom

Cause

Action

Water leaks from heater core.

- Joint portion of supply area - Cracks in heater core main body

- 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

Water leak

72-36 95ZV-2 Function & Structure Operator Station Group Air Conditioner

5 4

3 2 1

Servo motor

2 3

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

72-37 95ZV-2 Function & Structure Operator Station Group Air Conditioner Blower motor assembly specifications

Blower motor assembly 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

72-38 95ZV-2 Function & Structure Operator Station Group Air Conditioner

De-icing sensor (Thermistor (or thermal resistor))

Evaporator

Appearance of thermistor 8,000 7,000

Resistance (Ω)

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

72-39 95ZV-2 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 kΩ

25ºC (77ºF)

5 kΩ

100ºC (212ºF)

0.321 Ω

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 kΩ

25ºC (77ºF)

5 kΩ

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.

72-40 95ZV-2 Function & Structure Operator Station Group Air Conditioner

Compressor and magnetic clutch

Compressor specifications

Compressor Piston

Discharge valve

3 10 5

Suction valve Diagonal plate

Suction valve

Suction/compression action

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

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]

72-41 95ZV-2 Function & Structure Operator Station Group Air Conditioner Magnet clutch specifications

Magnetic clutch

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")

72-42 95ZV-2 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.

72-43 95ZV-2 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)

72-44 95ZV-2 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 Ω

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.

72-45 95ZV-2 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.

72-46 95ZV-2 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.

72-47 95ZV-2 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.

72-48 95ZV-2 Function & Structure Operator Station Group Air Conditioner

Switch

Switch operation confirmation method

Switching pressure kPa (kgf/cm2) (psi)

Function

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)

3,136 (32) (455)

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 in pressure switch coupler shown above.

OFF

Refrigerant leak from a part of circuit.

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.

72-49 95ZV-2 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.

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.

72-50 95ZV-2 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

72-51 95ZV-2 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.

72-52 95ZV-2 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.

72-53 95ZV-2 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.

72-54 95ZV-2 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

72-55 95ZV-2 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)

High pressure charging hose (red)

95ZV72024

Quick connector (Lo)

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.

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.

72-56 95ZV-2 Function & Structure Operator Station Group Air Conditioner Leak detector

Gauge manifold 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.

72-57 95ZV-2 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

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.

72-58 95ZV-2 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.

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.

72-59 95ZV-2 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.

72-60 95ZV-2 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

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)

72-61 95ZV-2 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.

72-62 95ZV-2 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

72-63 95ZV-2 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

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.

72-64 95ZV-2 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)

72-65 95ZV-2 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.

72-66 95ZV-2 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.

72-67 95ZV-2 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)

97ZV72097

97ZV72096

Symptom - Pressure is high on both low pressure side and high pressure side. - 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.

Inspection/action point

Symptom

Cause

Inspection/action point

- 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.

Cause

- 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.

72-68 95ZV-2 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

72-69 95ZV-2 Function & Structure Operator Station Group Air Conditioner

Air conditioner troubleshooting

∗ Error code table Display

Fault diagnosis procedure

E-

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

Electrical system check

Repair/check

End

80V2E01012

Failure mode 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

72-70 95ZV-2 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

Close the window and door. Adjust the inside/outside air changeover damper. Re-set the link.

See D-2 .

See D-1 .

See C-5 .

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.

Insufficient refrigerant.

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)

High pressure both at high-pressure side and low-pressure side Low pressure both at high-pressure side and low-pressure side

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

See C-2 . See C-3 . See C-4 .

∗ 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

72-71 95ZV-2 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

72-72 95ZV-2 Function & Structure Operator Station Group Air Conditioner

85V2U72008

C-5

C-4

C-3

Over-filled refrigerant

Clogging of dust or mud, etc. in fin.

Discharge the refrigerant to proper level.

Clean(washing with water) the fin.

Execute the evacuation fully after replacing the valve and receiver with a new one respectively.

Temporary clogging(mixing of moisture content) due to frozen valve

Insufficiently cooled condenser

Replace the valve with a new one.

Relieved gas from pressure needle valve

to A-1

Replace the valve with a new one.

Replacement

Clogged valve(mixing of foreign matter)

Clogging due to foreign matter in the course of piping

Clogged receiver & drier

Perform the leak test and repair the location of failure before filling the refrigerant.

Gas leakage

Execute the evacuation fully after replacing the valve and receiver with a new one respectively.

Clogging(mixing of moisture content) due to frozen valve

Fill the refrigerant to proper level.

Replace the valve with a new one.

Relieved gas from pressure needle valve

Limited amount of refrigerant filled

Replace the valve with a new one.

Clogged valve(mixing of foreign matter)

Suction/discharge valve failure

Locked piston

Replace the compressor with a new one.

Perform the leak test and repair the location of failure before filling the refrigerant.

Gas leakage

Swash plate shoe seizure

Fill the refrigerant to proper level.

Limited amount of refrigerant filled

Frosted evaporator

Expansion valve failure

Clogging during refrigerating cycle

Limited refrigerant

Unusually low outside air temperature

Expansion valve failure

Compressor failure

Limited refrigerant

Unusually low outside air temperature

72-73 95ZV-2 Function & Structure Operator Station Group Air Conditioner

80V2E01015

D-2

D-1

C-4

Replacement

High/low-pressure switch failure

Excessively low pressure [981 kPa(10kgf/cm )or lower]

Replacement

Thermo-sensor failure

C-1

Replacement

Compressor clutch relay failure

Excessively high pressure [2452 kPa(25kgf/cm2)or over]

Replace the control panel with a new one.

Blower switch failure

High-pressure error

Replace the control panel with a new one.

Re-charging

Battery voltage drop

Air conditioner switch failure

Replacement

Rare-short in coil

Disassembling/repair

Remove the oil.

Stained clutch surface due to oil

Foreign matter caught between rotor and stator

Replace the key with a new one.

Slippage due to broken key or key insertion failure

Repair or replacement

Excessive air gap between rotor and stator

Slipped clutch

Replacement

Disconnected stator coil

72-74 95ZV-2 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"

72-75 95ZV-2 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

72-76 95ZV-2 Function & Structure Operator Station Group Air Conditioner

80V2E01018

73-1 95ZV-2 Check & Adjustment Operator Station Group

95ZV-2 Check & Adjustment Operator Station Group Air Conditioner ........................................................ 73-2

73-2 95ZV-2 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)

73-3 95ZV-2 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)

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.

73-4 95ZV-2 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).

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)

73-5 95ZV-2 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.

73-6 95ZV-2 Check & Adjustment Operator Station Group Air Conditioner

Compressor V-belt adjustment

Compressor

V-belt

Belt tensioner

K95V2U73001

No adjustment is necessary. The belt tension is automatically adjusted by the belt tensioner installed on the engine.

73-7 95ZV-2 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.

73-8 95ZV-2 Check & Adjustment Operator Station Group

MEMO

INDEX A Accelerator pedal ............................................................62-34 Accelerator pedal installation ..........................................62-36 Accumulator ......................................................................52-9 Accumulator (for ride control) .........................................42-61 Accumulator function ......................................................42-61 Accumulator low pressure sensor .....................................52-8 Adapter (Orifice) .............................................................42-51 Adjustable declutch preset switch ...................................62-50 Adjusting set pressure ....................................................42-43 Adjusting shim ..................................................................13-5 Adjusting tooth contact .....................................................23-9 Adjustment ........................................................................13-4 Adjustment method .........................................................42-91 Adjustment of air gap (between hub and rotor) in compressor magnetic clutch ......................................73-5 Adjustment of axle internal pressure ................................52-2 Adjustment of lubricating oil quantity when components of air conditioner are replaced .........73-2 Air compressor (with magnetic clutch) ............................72-17 Air Conditioner ...................................................... 72-13, 73-2 Air conditioner 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 ............................................................................73-7 All setting reset .............................................................62-104 Alternator ........................................................................62-22 Alternator I terminal wire .................................................62-18 Auto Brake ......................................................................52-32 Auto brake ......................................................................62-54 Auto brake circuit ............................................................52-32 Auto brake operation set value .......................................52-32 Automatic shift ................................................................62-43 Automatic shift (with lock-up solenoid) ................. 32-5, 62-44 Axle ...................................................................................23-5 Axle Assembly ...................................................... 22-11, 92-2 Axle nut tightening procedure ...........................................23-5 Axle Support ...................................................................22-12

B Back-up alarm .................................................................62-51 Battery relay ....................................................................62-17 Battery relay operation ....................................................62-17 Bearing installation ...........................................................23-8 Bleeding air from brake pipes and axle housing hubs ....................................................................................52-21 Bleeding air from parking brake housing ........................52-21 Bolt tightening torque ......................................................00-13 Boom cylinder .................................................................42-20 Boom spool operation .....................................................42-48 Brake Circuit .....................................................................92-6 Brake circuit air bleeding procedure ...............................52-20 Brake Circuit Check Valve ..............................................52-31 Brake Circuit Oil Pressure ................................................53-2

Brake System Outline ....................................................... 52-2 Brake Units Layout ........................................................... 52-3 Brake Valve .................................................................... 52-10 Brake valve oil pressure ................................................... 53-4 Brake valve oil pressure measurement ............................ 53-4 Brake valve outline ......................................................... 52-12 Brake valve performance ................................................. 53-5 Brake valve performance chart ...................................... 52-11 Bucket cylinder ............................................................... 42-20 Bucket hinge pin section .................................................. 13-3 Bucket leveler ............................................................... 62-107 Bucket spool operation ................................................... 42-46

C Cabin ................................................................................ 72-2 Caution for diode check method ................................... 62-115 Cautions on Hydraulic Parts Replacement ....................... 42-3 Cautions on installing brake discs .................................... 53-9 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 ............................................................... 12-7, 13-5 Changing display from one function to next ................... 62-69 Charge of refrigerant ...................................................... 72-52 Check valve .....................................32-34, 42-6, 42-56, 42-60 Clear active fault log (error pop up) (S/N 9001~9166) ........................................................ 62-84 Clear fault log ................................................................. 62-83 Clutch combination ........................................................... 32-8 Clutch Oil Pressure and Time Lag ................................... 33-2 Clutch oil pressure control at the time of engine starting ....................................... 32-29 Clutch oil pressure measurement procedure ................... 33-3 Clutch Pack .................................................................... 32-12 Clutch solenoid valve assembly ..................................... 32-35 Clutch specifications ......................................................... 32-9 Clutch valve assembly .................................................... 32-39 Column shaft .................................................................. 72-12 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 ................................................. 62-115 Control panel .................................................................. 72-24 Control schematic drawing ............................................. 72-23 Control unit ..................................................................... 72-18 Control Valve Assembly ................................................. 32-32 Coolant ........................................................................... 00-10 Coolant specification ...................................................... 00-10 Cooling circuit ................................................................. 72-22 Cooling unit .................................................................... 72-14 Cylinder natural drift ....................................................... 43-14 Cylinders .......................................................................... 42-4

Denso air conditioner components ................................. 72-13 Denso air conditioner structure ...................................... 72-14 Detent solenoid ............................................... 62-108, 62-113 Differential gear adjustment procedure ............................ 23-6 Diode ............................................................................ 62-114 Diode check method .................................................... 62-115 Diode check mode ....................................................... 62-115 Diode unit ....................................................................... 62-18 Directional control valve ................................................... 42-6 Display language ............................................................ 62-81 Downshift button operation ................................... 32-8, 62-46 Dust seal .......................................................................... 12-8

Failure diagnosis ............................................................62-25 Failure diagnostic chart ..................................................62-26 Fan motor .....................................................................42-105 Fan motor function and the operation principle ............ 42-107 Fan Motor Line ...............................................................42-97 Fan motor specifications ...............................................42-105 Fan motor structure ......................................................42-106 Fan Motor System ..........................................................42-96 Fan motor system ............................................................. 42-9 Fault diagnosis procedure ..............................................72-69 Fault log history check ....................................................62-81 Fault Log Monitor ............................................................62-81 Flanged hexagon bolt .....................................................00-16 Floor board .......................................................................12-6 Floor board mount ............................................................12-6 Flow amplifier notch and pilot orifice ..............................42-81 Flow control valve ............................................................. 42-5 Flushing Hydraulic Circuit .................................................42-2 For high/reverse and speed clutches .............................32-37 Forward 1st speed power flow path ................................32-13 Forward 2nd speed power flow path ..............................32-14 Forward 3rd speed power flow path ............................... 32-14 Forward 4th speed power flow path ............................... 32-15 Forward/reverse (F/R) shifting and speed change ......... 62-41 Friction plate: mm (in) .....................................................32-10 Front Chassis ................................................................... 12-2 Front wiper ........................................................................ 72-6 Fuel gauge circuit ........................................................... 62-67 Fuel tank ...........................................................................12-5 Function of ECM .............................................................62-23 Function of T.P.D ............................................................22-17 Fuse ................................................................................62-11 Fuse box .........................................................................62-11 Fusible link ...................................................................... 62-13

E ECM (Engine Controller) ................................................ 62-23 ECM safety features ....................................................... 62-17 Efficient Loading System ................................................ 42-92 Efficient loading system ................................................... 42-9 Efficient loading system operation ................................. 42-95 Efficient loading system outline ...................................... 42-92 Electrical Cable Color Codes ........................................... 62-8 Electrical circuit .............................................................. 72-23 Electrical Circuit Diagram (Cabin Air Conditioner) ......... 92-27 Electrical Circuit Symbols ................................................. 62-9 Electrical Connection Diagram (1/2) (S/N 9001~9250) .................................................................................... 92-22 Electrical Connection Diagram (1/2) (S/N 9251~) .......... 92-24 Electrical Connection Diagram (2/2) (S/N 9001~9250) .................................................................................... 92-23 Electrical Connection Diagram (2/2) (S/N 9251~) .......... 92-25 Electrical Detent Circuit ................................................ 62-107 Electrical Equipment Layout ........................................... 92-29 Electrical Equipment Layout (K-Lever) ........................... 92-40 Electrical Wiring Diagram ............................................... 92-16 Electrical Wiring Diagram (1/3) (S/N 9001~9048) ............ 92-7 Electrical Wiring Diagram (1/3) (S/N 9049~9250) .......... 92-10 Electrical Wiring Diagram (1/3) (S/N 9251~) .................. 92-13 Electrical Wiring Diagram (2/3) (S/N 9001~9048) ............ 92-8 Electrical Wiring Diagram (2/3) (S/N 9049~9250) .......... 92-11 Electrical Wiring Diagram (2/3) (S/N 9251~) .................. 92-14 Electrical Wiring Diagram (3/3) (S/N 9001~9048) ............ 92-9 Electrical Wiring Diagram (3/3) (S/N 9049~9250) .......... 92-12 Electrical Wiring Diagram (3/3) (S/N 9251~) .................. 92-15 Electrical Wiring Diagram (CAB) .................................... 92-19 Electrical Wiring Diagram (Cabin Air Conditioner) (S/N 5301~) ................................................................ 92-26 Electrical wiring diagram abbreviation chart ................... 92-18 Engine .............................................................................. 23-2 Engine / Transmission ...................................................... 22-4 Engine / transmission mount ............................................ 22-4 Engine diagnostic switch (option) ................................... 62-25 Engine fault log navigation ............................................. 62-83 Engine Start Circuit ........................................................ 62-14 Engine start circuit diagram ............................................ 62-14 Equipment Operation Table (Cabin Air Conditioner) ...... 92-28

G Gauge circuit ..................................................................62-65 Gear pump specifications ........................................32-6, 32-7 Gear train and number of teeth ........................................32-9 Glass ................................................................................72-3 Grease nipple installation direction ...................................13-5

H Heater and accessories ..................................................72-16 Hexagon bolt ..................................................................00-13 Hose band tightening torque .......................................... 00-17 How to assemble ..............................................................13-3 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 (S/N 9001~9250) .....................92-4 Hydraulic & Brake Circuit (S/N 9251~) .............................92-5 Hydraulic circuit ..............................................................42-86 Hydraulic circuit (fan motor normal rotation) ...................42-99 Hydraulic circuit (Reverse rotation) ..............................42-112 Hydraulic Circuit Diagram ...............................................32-20 Hydraulic Circuit Symbols .................................................42-4 Hydraulic Cylinder ...............................................42-20, 43-14

Hydraulic cylinder specifications .....................................42-22 Hydraulic line ..................................................................42-88 Hydraulic line diagram ....................................................42-87 Hydraulic lines ..................................................................42-4 Hydraulic oil level check .................................................42-16 Hydraulic Pump ..............................................................42-17 Hydraulic pump bushing lubrication ................................42-19 Hydraulic pump oil amount and steering force ...............42-68 Hydraulic pump principle ................................................42-18 Hydraulic pump wear plate .............................................42-19 Hydraulic System Diagram .............................................32-18 Hydraulic System Operation .............................................42-8 Hydraulic system operation outline ...................................42-8 Hydraulic Tank ................................................................42-11 Hydraulic Tank (S/N 9001~9300) ...................................42-11 Hydraulic Tank (S/N 9301~) ...........................................42-13 Hydraulic tank breather valve (tank cap) (S/N 9001~9300) .........................................................42-12 Hydraulic tank breather valve (tank cap)(S/N 9301~) .....42-14 Hydraulic tank specifications ..........................................42-15

I Increment decrement switch (option) ..............................62-27 Information Monitor .........................................................62-71 Information monitor display .............................................62-71 Input/Output Monitor .......................................................62-88 Input/Output monitor display ...........................................62-88 Inspection and maintenance table ....................................00-6 Installing bearing outer ring ..............................................13-5 Instrument panel .............................................................62-63 Instrument Panel and Switch ..........................................62-63 Instrument panel rear surface .........................................62-64 Interior schematic (simple explanation) ..........................32-27 Items to be monitored and operation condition ...............62-60

K K-Lever (OPT) ................................................................42-86

L Layout of Hydraulic Units ................................................42-10 Layout of main components ..............................................00-4 Left turn position .............................................................42-73 Lift kickout .....................................................................62-110 Lift kickout & lower kickout ............................................62-109 Limited Slip Differential (option) ......................................22-19 Liner ..................................................................................13-2 Linkage Pin .......................................................................13-2 Liquid gasket and screw lock agent ................................00-18 Loading and pilot and brake pump/Steering pump .........42-17 Loading and pilot and brake pump/Steering pump specifications ...............................................................42-17 Loading circuit relief valve setting pressures ....................43-2 Loading linkage .................................................................12-2 Loading linkage pin ...........................................................12-4 Loading System ..............................................................42-23 Loading system .................................................................42-8 Loading/Steering Circuit Relief Valve/ Ride Control Circuit Reducing Valve (OPT) ..................43-2 Lock-up clutch function (only forward) ..............................32-4

Lock-up clutch structure ................................................... 32-4 Lower center pin ............................................................... 12-7 Lower kickout ............................................................... 62-110 LSD function ................................................................... 22-23 LSD operation ................................................................ 22-23 LSD structure ................................................................. 22-19 Lubrication chart ............................................................. 00-11

M Machine control unit (MCU) ............................................ 62-37 Machine control unit (MCU) connection diagram ........... 62-39 Machine control unit (MCU) failure warning ................... 62-57 Machine control unit (MCU) function .............................. 62-41 Machine fault log navigation ........................................... 62-83 Machine speed sensor ................................................... 62-45 Magnetic switch .............................................................. 62-20 Main relief valve operation ............................................. 42-42 Make-up valve ................................................................ 42-99 Make-up valve operation ..................................... 42-45, 42-79 Measurement procedure .................................................. 53-8 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 MODM ............................................................................ 62-68 MODM function .............................................................. 62-68 MODM: Input/Output Monitor Input/Output Signal Correspondence Table ................ 92-50 Modulation at clutch switching ........................................ 62-47 Modulator valve 1 ........................................................... 32-28 Modulator valve 2 (D Solenoid valve) ............................. 32-29 Modulator valve function ................................................ 32-28 Modulator valve operation .............................................. 32-30 Modulator Valve Unit ...................................................... 32-25 Monitor Changeover ....................................................... 62-68 Monitor lamp test ............................................................ 62-24 Monitoring system .......................................................... 62-60 Mounting of fan motor .................................................... 42-96 Mounting of the ELS valve ............................................. 42-93 Mounting of the variable kickout sensor ......................... 42-94 Multiple Control Valve (KML35A/2T003B) ...................... 42-40 Multiple control valve boom spool .................................. 42-48 Multiple control valve bucket spool ................................. 42-46 Multiple control valve main relief valve ........................... 42-42 Multiple control valve make-up valve ............................. 42-45 Multiple control valve overload relief valve (with make-up function) ............................................... 42-44 Multiple control valve specifications ............................... 42-41

N Neutral ............................................................................ 42-65 Neutral position (Steering spool in "Neutral") ................. 42-72 Neutral relay ................................................................... 62-19 Neutral starter ................................................................ 62-15

O Oil Flow .......................................................................... 32-22 Oil flow in the torque converter line ................................ 32-22 Oil flow to the clutch ....................................................... 32-22 Oil seal installation ........................................................... 23-8 Operation methods ........................................................... 42-5 Operation monitor lamps ................................................ 62-62 Operation of parking brake ............................................. 52-26 Operation of T.P.D ......................................................... 22-18 Operator Seat ................................................................... 72-9 Orbit rotor operation principle ......................................... 42-69 Orbitrol® .......................................................................... 42-63 Orbitrol® feed-back mechanism operation ..................... 42-67 Orbitrol® operation .......................................................... 42-65 Orbitrol® specifications ................................................... 42-64 Orbitrol® structure ........................................................... 42-63 Outline .............................................................................. 00-4 Outline of MODM (Machine Operation Diagnostic Module) Operation .................................... 92-41 Overload relief valve operation ........................... 42-44, 42-79

P Parameter change ........................................................ 62-100 Parameter Setting Monitor ............................................. 62-92 Parameter setting monitor display .................................. 62-92 Parking Brake ...................................................... 52-22, 53-10 Parking brake ........................................................ 52-2, 62-52 Parking brake clearance adjustment .............................. 53-10 Parking brake friction plate ............................................. 52-27 Parking Brake Manual Release ...................................... 52-29 Parking brake operation ................................................. 52-25 Parking brake performance check ................................. 53-10 Parking brake solenoid valve ......................................... 52-28 Parking brake steel plate ................................................ 52-27 Parts to be replaced periodically ...................................... 73-7 Pilot valve (S/N 9001~9250) .......................................... 42-25 Pilot valve (S/N 9251~9255) .......................................... 42-30 Pilot valve (S/N 9256~) .................................................. 42-35 Pilot valve function ................................... 42-27, 42-32, 42-37 Pilot valve operation (modulated position) .............................................................. 42-27, 42-32, 42-37 Planetary gear .................................................................. 32-8 Possible causes for clutch time lag .................................. 33-4 Possible causes for low clutch pressure and clutch time lag ........................................................ 33-3 Possible causes of excessive cylinder drift .................... 43-16 Power flow path ................................................................ 32-2 Power Flow Path in the Transmission ............................ 32-13 Power Generating/Charging Circuit ............................... 62-22 Power Line ....................................................................... 22-2 Pre-detent and detent magnet solenoid ... 42-29, 42-34, 42-39 Preload adjustment .......................................................... 23-7 Preparation mode (ride control switch is OFF) ............... 42-53

Preset height adjustment .............................................. 62-113 Pressure control valve ......................................................42-5 Pressure relief valve .......................................................72-49 Pressure sensor .............................................................32-29 Pressure sensor (for Declutch) .......................................52-36 Pressure sensor (for declutch) .......................................52-34 Pressure Sensor (for stop lamp and declutch) ...............52-34 Pressure sensor (for stop lamp) ..................................... 52-34 Pressure switches ..........................................................72-47 Principle of cooling .........................................................72-19 Propeller Shaft .........................................................22-8, 23-3 Propeller shaft phase ........................................................ 23-3 Propeller shaft tightening torque ....................................... 23-4 Proportional relief valve (S/N 9001~9150) ....................42-101 Proportional relief valve (S/N 9151~) ............................42-103 Proportional relief valve operation ................................42-101 Proximity switch ............................................................62-107 Pumps & motors ...............................................................42-4 Purpose of flushing ...........................................................42-2

Q Quantum fault code information ..................................... 62-28

R Radiator (S/N 9001~9150) ................................................22-5 Radiator (S/N 9151~) ........................................................ 22-6 Rear Chassis ....................................................................12-5 Rear wiper ........................................................................ 72-6 Receiver dryer .......................................................72-45, 73-7 Recommended lubricants .................................................00-9 Recommended mixture of antifreeze ..............................00-10 Reducing valve ...............................................................42-56 Reducing Valve (for Orbitrol®) ........................................42-84 Reducing Valve (for Pilot Pressure) ............................... 42-24 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 Replacement interval pop-up .......................................... 62-80 Replacement interval set (timer reset) ............................62-79 Replacement Monitor .....................................................62-75 Replacement time check ................................................ 62-75 Resistance check mode ...............................................62-116 Reverse 1st speed power flow path ............................... 32-16 Reverse 2nd speed power flow path ..............................32-16 Reverse 3rd speed power flow path ............................... 32-17 Reversing fan control chart ...........................................42-111 Reversing fan motor (OPT) ..........................................42-109 Reversing fan motor function ........................................ 42-108 Reversing Fan Motor Line (OPT) .................................42-108 Ride Control (OPT) .........................................................42-52 Ride control circuit reducing valve setting pressures (OPT) ............................................................................43-7 Ride control function .......................................................42-52 Ride control hydraulic circuit ...........................................42-52 Ride control operation ....................................................42-53

Ride control system (OPT) ...............................................42-9 Ride control valve assembly (Accumulator circuit) .........42-58 Ride control valve assembly (Reducing valve circuit) .....42-55 Rotor part ........................................................................42-64 Running mode (ride control switch is ON) ......................42-54

S Safety precautions ............................................................00-2 Screw lock agent application procedure .........................00-19 Second propeller shaft alignment .....................................23-3 Second propeller shaft assembly ......................................22-9 Secondary Steering ......................................................42-113 Secondary steering function (OPT) ................................62-58 Secondary steering motor and pump ............................42-115 Secondary steering operation .......................................42-113 Selection of machine fault log and engine fault log ........62-82 Sensor assy ..................................................................62-111 Service Brake ....................................................... 52-14, 53-6 Service brake ....................................................................52-2 Service brake friction plate .............................................52-15 Service brake friction plate wear measurement ................53-7 Service brake operation ..................................................52-14 Service brake pedal stroke adjusting mechanism (S/N 9001~9014) .........................................................52-18 Service brake performance check ....................................53-6 Service brake piston .......................................................52-17 Service brake steel plate ................................................52-16 Shift lever ........................................................................72-12 Shift lever forward/reverse (F/R) position .......................62-15 Shift lever neutral (N) position ........................................62-15 Shift lever position ............................................................32-8 Shuttle valve ...................................................................42-59 Sight glass ......................................................................72-47 Solenoid specifications ...................................................52-33 Solenoid valve .................................................... 42-57, 42-59 Solenoid valve (for Autobrake circuit) .............................52-33 Solenoid valve assembly (1/2) ........................................42-90 Solenoid valve assembly (2/2) ........................................42-91 Solenoid valve mount .....................................................42-89 Solenoid valve operation ................................................52-28 Solenoid valve specifications ..........................................52-28 Specification Setting Monitor ........................................62-101 Specification setting monitor display .............................62-101 Standard Measurement Values for Performance Check .................................................03-3 Starter switch ..................................................................62-16 Steel plate: mm (in) .........................................................32-11 Steering and Transmission Shift Lever ...........................72-10 Steering circuit relief valve setting pressures ...................43-9 Steering cylinder .............................................................42-21 Steering Line Filter ..........................................................42-85 Steering pilot circuit and its operation .............................42-80 Steering speed and flow rate control ..............................42-68 Steering spool variable throttle .......................................42-74 Steering System .............................................................42-62 Steering system ................................................................42-8 Steering Valve (KVS32-A4.0/20) ....................................42-70 Steering valve flow control spool ....................................42-75 Steering valve main relief valve ......................................42-76 Steering valve operation .................................................42-72

Steering valve overload relief valve ................................ 42-78 Stop Valve ........................................................... 42-82, 43-17 Stop valve adjustment procedure ................................... 43-17 Stop valve function ......................................................... 42-83 Stop valve operation ....................................................... 42-83 Surge voltage and surge suppression diodes .............. 62-117 Switching from automatic to manual .............................. 62-46 Symbols ............................................................................ 00-3

T T/C and T/M Oil Circulation ............................................ 32-23 The operation condition of ELS ...................................... 42-92 Third propeller shaft assembly ....................................... 22-10 Tilt case .......................................................................... 72-11 Time lag measurement procedure ................................... 33-4 Tolerance ring ................................................................ 52-19 Torque Converter ............................................................. 32-2 Torque Converter (Lock-up) (Option) ............................... 32-3 Torque Converter and Transmission ................................ 92-3 Torque Converter Gear Pump ................................. 32-5, 32-6 Torque Converter structure .............................................. 32-2 Torque multiplication ........................................................ 32-2 Torque Proportioning Type Differential Gear (TPD) ....... 22-14 Transmission .................................................................... 32-8 Transmission Control Circuit and Monitor Circuit ........... 62-37 Troubleshooting using the gauge manifold .................... 72-64 Turn ................................................................................ 42-66

U Unit conversion and language selection ......................... 62-74 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 ............................................................... 12-7

V Valve part ....................................................................... 42-63 Valve Unit ......................................................................... 52-7 Viscous mount .................................................................. 12-6 Voltage relay .................................................................. 62-21

W Way of looking at connectors ......................................... 92-16 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 ................ 42-77 When the pressure is at the preset value or less ........... 42-76 While the ELS is not operating ....................................... 42-95 While the ELS is operating ............................................. 42-95 While the valve is not operating ..................................... 52-12 While the valve is operating ........................................... 52-13 While the valve is releasing ............................................ 52-13 Wiper motor ...................................................................... 72-7 Wiper mount ..................................................................... 72-6 Work procedure .............................................................. 72-53

Maintenance Log Date

Machine hours

Service performed

Date

Machine hours

Service performed

Date

Machine hours

Service performed

Date

Machine hours

Service performed

Notes

92-1 95ZV-2 Drawing & Diagrams

95ZV-2 Drawing & Diagrams Axle Assembly ......................................................................................................................... 92-2 Torque Converter and Transmission........................................................................................ 92-3 Hydraulic & Brake Circuit (S/N 9001~9250) ............................................................................ 92-4 Hydraulic & Brake Circuit (S/N 9251~) .................................................................................... 92-5 Brake Circuit ............................................................................................................................ 92-6 Electrical Wiring Diagram (1/3) (S/N 9001~9048) ................................................................... 92-7 Electrical Wiring Diagram (2/3) (S/N 9001~9048) ................................................................... 92-8 Electrical Wiring Diagram (3/3) (S/N 9001~9048) ................................................................... 92-9 Electrical Wiring Diagram (1/3) (S/N 9049~9250) ................................................................. 92-10 Electrical Wiring Diagram (2/3) (S/N 9049~9250) ................................................................. 92-11 Electrical Wiring Diagram (3/3) (S/N 9049~9250) ................................................................. 92-12 Electrical Wiring Diagram (1/3) (S/N 9251~) ......................................................................... 92-13 Electrical Wiring Diagram (2/3) (S/N 9251~) ......................................................................... 92-14 Electrical Wiring Diagram (3/3) (S/N 9251~) ......................................................................... 92-15 Electrical Wiring Diagram ...................................................................................................... 92-16 Electrical wiring diagram abbreviation chart .......................................................................... 92-18 Electrical Wiring Diagram (CAB)............................................................................................ 92-19 Electrical Connection Diagram (1/2) (S/N 9001~9250) ......................................................... 92-22 Electrical Connection Diagram (2/2) (S/N 9001~9250) ......................................................... 92-23 Electrical Connection Diagram (1/2) (S/N 9251~) ................................................................. 92-24 Electrical Connection Diagram (2/2) (S/N 9251~) ................................................................. 92-25 Electrical Wiring Diagram (Cabin Air Conditioner)................................................................. 92-26 Electrical Circuit Diagram (Cabin Air Conditioner)................................................................. 92-27 Equipment Operation Table (Cabin Air Conditioner).............................................................. 92-28 Electrical Equipment Layout .................................................................................................. 92-29 Electrical Equipment Layout (K-Lever) .................................................................................. 92-40 Outline of MODM (Machine Operation Diagnostic Module) Operation.................................. 92-41 MODM: Input/Output Monitor - Input/Output Signal Correspondence Table ......................... 92-50

92-2 95ZV-2 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.

(S/N 9001~9014)

48 49

1. Differential assembly 2. Axle housing assembly 3. Wheel hub 4. Spider (planetary carrier) 5. Cover 6. Axle shaft 7. Air bleeder screw 8. Sun gear 9. Disc gear 10. Planetary gear 11. Internal gear 12. Internal gear hub 13. Snap ring 14. Planetary pin 15. Spring pin 16. Wear ring 17. Wear ring 18. Piston 19. 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

A - Detail A 14

Brake oil inlet PT 3/8

50, 51

40 9 22 5 29 17 8 23 27 52 36 43

35 34 53

37, 38, 39

95V2E92001

28. Steel plate 29. Snap ring 30. Floating seal 31. D-ring 32. D-ring 33. O-ring 34. O-ring 35. Magnet plug 36. O-ring 37. Socket bolt 38. Spring 39. U-nut 40. Bolt 41. O-ring 42. Spacer 43. Ring 44. O-ring 45. Plug 46. Spring 47. Sleeve 48. Bushing 49. Socket bolt 50. Bolt 51. Bolt 52. Bolt 53. Socket bolt 54. Flange bolt

92-3 95ZV-2 Drawing & Diagrams Torque Converter and Transmission

Torque Converter and Transmission (Model: Kawasaki PT315E01~PT315E04) (Model: Kawasaki PT315L01~PT315L04) (Lock-up) 26

PT315E02-0214~

28 9 1 3 2

4 6

7 11

PT315E02-0215~ PT315L03-0101~(Lock-up) PT315E02-0215~ PT315L03-0101~(Lock-up)

PT315L04-0101~ Torque converter (Lock-up) 5

21 13

12 14

PT315E04-0101~ PT315L04-0101~(Lock-up)

16 17 23

22 K95V2E92021

1. Pump impeller 2. Turbine impeller 3. Stator 4. Turbine shaft 5. Stator shaft (Fixed) 6. Drive cover 7. Driven gear 8. P.T.O. drive gear 9. P.T.O. gear 10. Torque converter gear pump 11. Torque converter output gear 12. Clutch input gear 13. Transmission input shaft 14. High range clutch 15. Reverse clutch 16. Low range clutch 17. 3rd speed clutch 18. 2nd speed clutch 19. 1st speed clutch 20. Clutch output gear (Helical) 21. Output gear (Helical type) 22. Output shaft 23. Output flange (3rd propeller shaft side) 24. Output flange (2nd propeller shaft side) 25. Modulator valve unit 26. Clutch solenoid valve assembly 27. Clutch valve assembly 28. Lock-up clutch 29. Lock-up piston

92-4 95ZV-2 Drawing & Diagrams Hydraulic & Brake Circuit (S/N 9001~9250)

Hydraulic & Brake Circuit (S/N 9001~9250)

23.5 0.5 MPa 2 (240 5 kgf/cm ) (3,408 71 psi)

23.5 0.5 MPa (240 5 kgf/cm2) (3,408 71 psi)

Stop lamp turns on when pressure rises. 0.5 0.1 MPa (5 1 kgf/cm2) (74 14.5 psi)

20.6 0.5 MPa 2 (210 5 kgf/cm ) (2,986 71 psi)

24.5 +1.0 - 0 MPa 2 (250 +10 - 0 kgf/cm ) (3,555 +142 - 0 psi)

3.5 MPa 2 (36 kgf/cm ) (512 psi)

On when pressure drops. 3.9 0.5 MPa 2 (40 5 kgf/cm ) (567 71 psi)

20.6 0.5 MPa 2 (210 5 kgf/cm ) (2,986 71 psi) :

Max. pressure: 23.5 MPa 2 (240 kgf/cm ) (3,408 psi)

11.7 MPa 2 (120 kgf/cm ) (1,696 psi)

OFF when pressure rises. 0.4 0.002 MPa (4 0.02 kgf/cm2) (58 0.29 psi)

Capacity: 3.0 L Gas charging pressure: 2.94 0.1 MPa (30 1 kgf/cm2) (427 14 psi)

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)

3.5 MPa 2 (36 kgf/cm ) (512 psi)

0.3 0.06 MPa2 (3 0.6 kgf/cm ) (43.5 8.7 psi)

11.7 MPa (120 kgf/cm2) (1,696 psi)

0.1 0.02 MPa2 (1 0.2 kgf/cm ) (14 2.8 psi)

1.0 kPa 2 (0.01 kgf/cm ) (0.14 psi)

29.4 kPa (0.3 kgf/cm2) (4.3 psi)

09701-03261 K95V2E92022

1. Hydraulic pump (Steering) 2. Hydraulic pump (loading + pilot & brake) 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. Solenoid valve (for auto-brake) 30. — 31. — 32. Check valve 33. Accumulator 34. — 35. Solenoid valve (for parking brake) 36. — 37. Adapter, Tee (for auto-brake) 38. Reducing valve (pilot, parking brake, auto-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. Brake piston chamber (for parking) 56. — 57. — 58. — 59. — 60. — 61. Bleed screw 62. Relief valve 63. Check valve 64. Solenoid valve (for efficient loading system) 65. — 66. — 67. — 68. — 69. — 70. — 71. Fan motor 72. Proportional relief valve (for fan motor) 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)

92-5 95ZV-2 Drawing & Diagrams Hydraulic & Brake Circuit (S/N 9251~)

Hydraulic & Brake Circuit (S/N 9251~)

23.5 0.5 MPa 2 (240 5 kgf/cm ) (3,408 71 psi)

23.5 0.5 MPa (240 5 kgf/cm2) (3,408 71 psi)

Stop lamp turns on when pressure rises. 0.5 0.1 MPa (5 1 kgf/cm2) (74 14.5 psi)

20.6 0.5 MPa 2 (210 5 kgf/cm ) (2,986 71 psi)

24.5 +1.0 - 0 MPa 2 (250 +10 - 0 kgf/cm ) (3,555 +142 - 0 psi)

3.5 MPa 2 (36 kgf/cm ) (512 psi)

On when pressure drops. 3.9 0.5 MPa 2 (40 5 kgf/cm ) (567 71 psi)

20.6 0.5 MPa 2 (210 5 kgf/cm ) (2,986 71 psi) : Max. pressure: 23.5 MPa 2 (240 kgf/cm ) (3,408 psi)

11.7 MPa 2 (120 kgf/cm ) (1,696 psi)

Capacity: 3.0 L Gas charging pressure: 2.94 0.1 MPa (30 1 kgf/cm2) (427 14 psi)

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)

OFF when pressure rises. 0.4 0.002 MPa (4 0.02 kgf/cm2) (58 0.29 psi)

3.5 MPa 2 (36 kgf/cm ) (512 psi)

0.3 0.06 MPa2 (3 0.6 kgf/cm ) (43.5 8.7 psi)

11.7 MPa (120 kgf/cm2) (1,696 psi)

0.1 0.02 MPa2 (1 0.2 kgf/cm ) (14 2.8 psi)

1.0 kPa 2 (0.01 kgf/cm ) (0.14 psi)

29.4 kPa (0.3 kgf/cm2) (4.3 psi)

09701-04070 K95V2E92023

(for secondary steering) (for efficient loading system) 50. — 51. Pressure sensor (for declutch & stop lamp) 52. — 53. — 54. — 55. Brake piston chamber (for parking) 56. — 57. — 58. — 59. — 60. — 61. Bleed screw 62. Relief valve 63. Check valve 64. Solenoid valve (for efficient loading system) 65. — 66. — 67. — 68. — 69. — 70. — 71. Fan motor 72. Proportional relief valve (for fan motor) 73. Relief valve (for fan motor) 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)

92-6 95ZV-2 Drawing & Diagrams Brake Circuit

Brake Circuit 1. Hydraulic pump (Steering) 2. Hydraulic pump (loading + pilot & brake) 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. Solenoid valve (for auto-brake) 30. — 31. — 32. Check valve 33. Accumulator 34. — 35. Solenoid valve (for parking brake) 36. — 37. Adapter, Tee (for autobrake) 38. Reducing valve (pilot, parking brake, autobrake) 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. Brake piston chamber (for parking) 56. — 57. — 58. — 59. — 60. — 61. Bleed screw 62. — 63. — 64. — 65. — 66. — 67. — 68. — 69. — 70. — 71. — 72. — 73. — 74. — 75. — 76. — 77. — 78. — 79. — 80. — 81. Line filter 82. —

Stop lamp turns on when pressure rises. 0.5 0.1 MPa (5 1 kgf/cm2) (74 14.5 psi)

On when pressure drops. 3.9 0.5 MPa 2 (40 5 kgf/cm ) (567 71 psi)

Capacity: 3.0 L Gas charging pressure: 2.94 0.1 MPa (30 1 kgf/cm2) (427 14 psi)

Cut out: 11.8 0.5 MPa 2 (120 5 kgf/cm ) (1,706 71 psi) Cut in: 6.9 1.0 MPa (70 10 kgf/cm2) (995 142 psi)

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

0.3 0.06 MPa (3 0.6 kgf/cm2) (43.5 8.7 psi) 0.1 0.02 MPa2 (1 0.2 kgf/cm ) (14 2.8 psi)

1.0 kPa (0.01 kgf/cm2) (0.14 psi)

29.4 kPa (0.3 kgf/cm2) (4.3 psi)

09701-03261 95V2E92017

92-7 95ZV-2 Drawing & Diagrams Electrical Wiring Diagram (1/3) (S/N 9001~9048)

Electrical Wiring Diagram (1/3) (S/N 9001~9048)

HAZARD

3 4

(+)

8 GyG Gy LgY LgW S515 S519 S528 F903 753 749 173 102 WG LgW GyL Sb S513 H740 S527 S516 194 705 192 190

LgY A803 167 YO B001 176

8 RO RO BP B911 A815 G803 321 H109 323 RBr RBr BP B910 A814 G803 322 H119 323

8 Lg D103 013 GyW S823 200

5 Lg D103 013 GL S822 265

EG2 EG1 EG3

SS WTM TTM

3/4

1/2

EMP GND

1/4

GND

20 7

RB SbO YR YB YL YBr YG B601 S526 S511 S533 S522 S531 S523 410 411 412 413 414 C305 193 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

12 LY LG LO LW SbW S518 V304 S505 S508 B502 141 132 143 144 163 Lg GR D103 S529 013 135 1 6 1

SM H

GyB B S514 103 LgR GY WL S521 S520 S624 130 169 400

16 RY RBr RO F403 A102 A107 307 326 324 LgY BG RGy A007 H738 B101 167 720 B201

3 4

P RBr RO RW G703 A103 A106 F401 320 322 321 304

RB RY F601 F501 301 302

YV A401 231

8 RG RLg D113 C302 006 H106 RG RGy D113 A801 006 310

8 R RGy D109 C306 002 H138 R RGy D109 A801 002 310

1 YV T307 231 B

L C101 801 㧸 C102 802

HORN S/W TR

R D602 023 R D601 024 TL

8 5

COMBINATION S/W FOR LAMPS

F/R S/W SELECTION (EU STANDARD)

DECLUTCH

REAR WORKING LAMP

INSTRUMENT PANEL

1 2

GND

1 2

FRONT WORKING LAMP

EFFICIENT LOADING SYSTEM (ELS)

YSb S506 403

FUEL EFFICIENT MODE SELECTION

B YV S918 231

F801

SHIFT LEVER

L LgG D206 H137 005-b 162 GO SbW B S901 A712 164 163 1 3

RB A611 300

㧝

CAB

BW F003 271

BrG F002 255

4 GyY GyW BL H734 H724 H713 736 737 741 YV BLg BrW H715 H705 H725 734 735 733

C0 12 1

R G B O Y V

3 3

DATA LINK CONNECTOR DECLUTCH SENSOR

WP LgR PL BR BL 10 C5 H910 H913 H015 C802 H008 H011 B WG OL BrW BG H014 H013 H012 H007

LP F001 168

−

BY V S709 S707 100 114 LgR S727 166

BW BrG S813 S922 271 255 B LP S915 168

2 R R D108 D108 001 001 RB RB C403 B914 H129 301

(BLACK)

LIFT KICKOUT RELAY

BUZZER RELAY

LOWER KICKOUT RELAY

RL S510 330

EMERGENCY STEERING RELAY (EU:STANDARD)

4 SPEED INDICATOR RELAY

L YGy E706 E704 005-a 242 R B H804 243 1

(BLUE)

(BLACK)

CAB ALARM BUZZER

DOWNSHIFT BUTTON PILOT VALVE MAGNETS

4 YL YO H706 S2S H707 H716 S2L H708

AIR-SUS. 3

B 2

PG PW H733 H723 739 740 BrG BL H714 H713 738 741

OY D114 007

S2H W H709 6 D506

DIAG INC/DEC S/W

㧝 1

12 5

1 019 172 003 100 D609 S722 D110 H003 S709 RW V OR SbY Br 500 171 251 C307 S730 S826 H004 H016 YR PB SbY BrR Y 506 250 261 267 G302 S504 S501 C308 BrW LgL GB PL 182 221 266 S702 S801 S806 LgB GyB LgL 35 31

㧝

Br D110 003

1 Br

(BLUE) Br

BrR

G D107 010

BrB

910 D301 R 911 D402 R

912 D401 R 913 D901 R

914 D002 R 915 D001 R

3 1

LgSb X504 112

901 E201 W

D804 D802 H102 H112 R RB RW Y

C501 C510 BG BL

D803 D701 H111 C508 C504 C503 C502 C509 RG RL YR PL WG OL BrW BR

H6 BY R E701 V404 114 243 V SbR E702 E703 240 100

C404 C405 C406 C506 Sb GO WR WP

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 WY V PB YB VW RL P LgR BrB LgY 11

P R B909 D111 320 004 B 1

E L

BrW

B YGy LgR LP LLg S819 S605 S517 S507 151 150 149 140 LY LG LO LR LB LBr S518 S502 S505 S613 S601 S604 141 142 143 146 147 148

BY V S707 S709 114 100

HAZARD

E R

G V805

TURN SIGNAL

YSb S917 125

AIRCON UNIT

KICKOUT

6 325 308 181 311 A107 F404 S811 B108 RO RW BrY RLg 114 327 306 170 220 S707 A102 F403 S614 S723 BY RBr RY WR GyO 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

POSITIO -NER

FLOAT

SHIFT HOLD S/W (OPT)

3 2

(BLUE)

LG LW S502 S508 142 144 LG B A709 132 1

(BLACK)

BrR L G202 D205 272 005-a B L S610 273 1

BrB L G402 D205 257 005-a B BrB S611 258

(BLACK)

(BLUE)

Lg Lg D103 D103 013 013 LgSb LgBr G601 S609 112 104

(BLACK)

BACK LAMP (OPT)

LgW L A508 D205 102 005-a B LgW S612 101 1

(BLACK)

G G D107 D107 010 010 GW GL H127 B801 329 328 1

G L D102 D205 014 005-a RL SbP H710 S618 703 145

2 R R D108 D108 001 001 RY RY F402 B915 305 302

MCU FAULT RELAY

HORN RELAY

AIR TEMP. PROBE (MCU)

1 1

(BLUE)

BY G S707 S732 114 415

WY V PB YB VW P H920 H919 H918 H917 H916 H914

6 RW R H108 D108 308 001 RY RY RW A813 F504 B912 H118 305 304 3 1

(BLACK)

NEUTRAL RELAY

LO GW BY BrY Y RL 12 H901 H902 H903 H904 C801 D701

AIR PROBE (THAM)

(BLACK)

S914

2 Gy GyR S816 H721 750 751 B B

BR Y C509 C611

2 Sb SbP H704 S509 205 202 B B

WIDTH LAMP RELAY

1 168 T607 B LP 271 255 T706 T708 BW BrG

B 1

THROTTLE PEDAL 6

RB BrB LgY F604 H912 H911 300

Sb GO WR 6 H907 H908 H909

CAB (AIRCON) 4

HEAD LAMP RELAY

G WBr RLg O RGy RB B208 A611 D107 D604 B108 D610 520 300 010 022 521 020 PB PL OR OL OW OG H115 H125 D609 D608 D607 D606 500 506 019 018 017 016

2 SbY SbR H711 S608 209 208 B B

S2L S2H H708 H709 S720 S729 2

S2S H707

L B402 802 L B401 801

S921

LR LBr B S911 S904 126 128 LW B S912 120 LY LG LO S910 S903 S905 121 122 123

LLg

YO R

A002

CAN (RESISTOR)

DECLUTCH SET-UP

LIFT KICKOUT SET-UP/ LOWER KICKOUT SET-UP

257 T903 BrB

Hi-BEAM RELAY

250 H123 BrW

DECLUTCH CUT-OFF S/W

E/G OIL PRESS. S/W RELAY

272 T003 BrR

PARKING S/W

TORQUE SELECTION RELAY

B8 GW

E/G IDLE SELECTION RELAY

6 703 C201 C202 C203 747 F704 T406 T405 T404 T403 RL S2H S2L S2S YL 015 732 204 184 748 D101 A606 S534 S815 T402 WR BrW SbLg Sb YO 214 731 213 183 160 V205 A607 V210 S814 S716 GB BrB GL SbO Y 705 730 720 743 159 A503 A605 A802 V212 S708 WG BrR BG GY Y 40 36

5 1 V208 205 203 406 405 C002 F203 S615 S828 S817 BLg Sb SbW YB YR 734 738 C004 407 209 C001 G004 G001 S820 F103 YV BrG BL YL SbY V211 737 740 408 751 C003 C005 G002 S829 F302 BrW GyW PW YBr GyR 012 736 739 409 161 D105 C006 G003 S821 S715 BW GyY PG YG W 35 31

This page illustrates the transmission is in neutral and key switch is in OFF position.

95ZV2-09709-08383 EU 1/3 95V2E92018

92-8 95ZV-2 Drawing & Diagrams Electrical Wiring Diagram (2/3) (S/N 9001~9048)

Electrical Wiring Diagram (2/3) (S/N 9001~9048) 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

OPT B

A11

A12

A13

A14

A15

A16

A17

A18

A19

A20

A21

A22

A23

A24

A25

A27

A28

A29

A30

A31

A32

A10

A26

A33

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

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

B26

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

SPEEDOMETER DIVIDING RATIO ODOMETER SELECTION SELECTION

JPN PL P S803 S802 108 107 B

B PW S925 111

PB S916 110 1

PG S902 109 1

(BLUE)

(BLACK)

E12

E13

E14

E15

E16

E17

E18

E19

E20

E21

E22

E23

E24

E25

E27

E28

E29

E30

E31

E32

E33

E34

C10

C11

C12

C13

C14

C15

C16

C17

C18

C19

C20

C21

C22

C23

C24

C25

C26

YG YB LgR S2H SbY GyL G C703 C201 H114 H126 C901 S002 A603 166 171 180 415 116 401 G S2L BrW SbY GyO WL YL E003 C202 A602 H104 H116 H140 S004 234 402 172 220 707 117 L L W Y G D203 D204 H731 H726 D107 005-C 005-D 161 160 010 BR LgB L L B B BY Y V E002 H132 D201 D202 H736 236 221 005-A 005-B 159 7

C27

C28

C29

C30

C31

C32

C33

C34

D12.SL_A D13.SS_N D14.KD D15.INCH_S D16.OD_SW D17.SH D18.SS_SW D19.SS_F D20.TMP D21.INCH D22.KO_S D23.SC D24.AR D25.SM_SW D26.SS_R

D10

D11

D12

D13

D14

D15

D16

D17

D18

D19

D20

D21

D22

D23

D24

D25

D26

W3 W5

BW BG

WR WB

O WR

LW B

G D502 064

R B202 B207

R G702 004

WR L

R R5

BW H735 012

R H301 910

R H302 911 R H401 912

3 4 5 1 6 2 L L L L L L E008 S703 S704 S711 S712 E806 B504 005-A 005-B 005-C 005-D F702 005-b F902 T902 T002 005-a

WR RL

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 12

2 12

OSb Lg GB GW S530 D103 H730 S923 211 013 214 210 GY BrW GL B BLg GW H737 H725 H728 H705 S525 743 733 213 735 212

GB GB S603 S824 278 277 1

SLIP CONTROL

Lg LgL S825 S606 222 225 B LgY S834 223

EMERGENCY STEERING (EU : STANDARD) 4

2 GyW S833 260 B Lg D103 013 1

YGy V V402 H803 242 100 B SbR H802 240 L BY V403 H801 005-a 114

YGy V S709 S503 100 242 B SbR S827 240 L BY S707 D205 114 005-a

R R D602 D601

RS232C

R Y S812 S830 106 105

DIAG. S/W CONNECTION

RG RB 2 H018 H002

R H402 913

R H501 914 R H502 915

R H001

RL 1

1 4

DC-DC CONVERTOR (EC : STANDARD)

C612 H915 H017

BOUT

V902 V901 R R

V906 V804 V908 V909 V910 OG Y OL OR O 10 OG OW OL OR O C312 C311 C310 C309 C301 016 017 018 H105 020 WBr R R C303 B301 B302 022 023 024

OUT

G G501

L V904

Y D607

W D604 1

D0 V8

This page illustrates the transmission is in neutral and key switch is in OFF position.

V801 W

RIDE CONTROL S/W

REVERSAL FAN S/W

O 10 OL OR D608 D609 D610

OG D606 L V808

V GL S616 S709 810 100 GR BY S622 S707 811 114

MCU SELECTION

PRESS. INTENSIFYING

(EU:STANDARD)

1 YG YBr YB S623 S733 S617 115 116 119 YL YO B S725 S626 117 118

Note These switches/connectors are for factory use only.

W BW E202 E104 062 T407 WR G WR E107 E101 E106 065 064 063

A207 013 A307 A610 A706 E601 V204 X502 D1 X503

RG OY B102 T501 B107 007 G WR F703 H720 014 015

F/R SWITCH/ STICK STEERING

1 4

W D506 060 W H601 901

WR WR D501 D503 063 065 BW D504 062

E007 H120 T102 W102

FUSE BOX (CAB)

7 C304 F802 F803 G501 G802 S717 010

STARTER SWITCH

C701 C902 E801 114

001 8 R F406 F502 F503 F602 G F603

STARTER S/W

WRx2 WBx2

100 C702 E803 E004 H101 T101 W101

GW LB LLg BrG PW YW B002 F002 V206 E006 S201 E012 165 255 210 230 111 233 YL LP PB YSb YV YO G101 F001 S301 G901 A401 E005 124 168 110 125 231 232 B LR LY LW B703 B709 B706 121 126 120 GO PG LG LBr LO B503 S401 B702 B708 B701 164 109 122 128 123

FUSE BOX (MAIN)

003 G201 G301 G401 H103

R1 BR S2L B ACC R2 C

B BrR SbR YB YBr Y GyW LgY H113 E802 H702 H722 T202 E603 E501 251 240 406 408 105 260 223 YGy YL YG GL GyW GB Lg H210 H712 H732 A302 A202 V102 E503 151 407 409 265 200 277 222 BW SbO Sb YR BrY R Gy H107 T203 F003 H727 H717 F303 H701 181 106 271 183 184 750 405 GyB P PL LgL H135 H131 S102 S103 182 266 107 108

RL RG LR LW YR YW

E11

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

Note See Section 62 for the details of A/M selection switch. Others are for factory use only.

E10

E26

GR YB WL GyG YO T103 S003 A806 H136 S005 811 115 400 754 118 WR SbW GL YBr SbP RG H117 H703 T104 S001 F701 H139 170 203 810 119 145 331 SbR LgBr L BrB LgW LR F102 X501 T001 T901 F901 H204 208 104 273 258 101 146 BL LB GB LBr LgR LgL H205 V101 H206 H209 E502 E001 147 278 148 150 225 237

SbO LgW LgY GR OSb YBr YB SbLg RL A612 A502 A507 A701 V203 A618 A608 A616 H718 193 192 173 135 211 413 235 211 204 YG LgB GW LY Gy Gy LgR YL A708 A506 A807 A808 A617 A619 A604 V207 H201 749 169 130 412 414 224 212 0 YR Sb GyB GyG GyL LP RL H128 A615 A609 A504 A809 A505 A501 H208 T801 410 241 194 103 753 190 149 GB LG YGy LgL LO YSb LLg LW SbP H121 H202 E804 H122 A710 A901 H207 A711 F202 267 V303 242 261 H203 403 140 V302 202

A/M SELECTION

E31.TT_SE E32.OT_SE E33.OUT_RSE E34.ET_M

EU 3

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

95ZV2-09709-08383 EU 2/3 95V2E92019

92-9 95ZV-2 Drawing & Diagrams Electrical Wiring Diagram (3/3) (S/N 9001~9048)

BrY H107 181

K106

RBr

K103

303

K801

327

K802

BOOM ANGLE SENSOR

V L201

BrR L203

BrR K205 251

V K202 100 BY K203 114

1 B

−

LG H202 142

2 B

PL H125 506 B

−

LgL K204 261

−

LLg H207 140

−

SPPC

LgR H209 150

746 BO

PRESSURE SENSOR

S −

P0 STARTER

R N502 701

E/G WATER TEMP. SENSOR

1 B

FAN SPEED CONTROL SOL. VALVE

LgG H137 162

GL GB GR

BY V H101 H120 100 114 SbY H114 171

BY V H101 H120 100 114 SbY H104 172

GY W

M7 ALTERNATOR

G GR

YR H111

FUSIBLE LINK

BRAKE OIL PRESS. (MAIN)

WL M001 H140 706 707

BW N501 702 2

N3 BATTERY W N102 RELAY 900

WV N403 700

R H301 H302 H401 H402 H501 H502 910915

RGy R102

312

REAR WORKING LAMP

312

REAR WORKING LAMP

B 2

AIR HEATER N8 VOLTAGE RELAY

WG N801 704

R104

2 702 N702 BW 701 N703 R

015 708 N401 N402 WR WP B

4 4

R P002 701 BW P001 702

703 706 N701 N804 WL RL 705 N801 WG B 012 720 N601 N602 BW BG BW BG H735 H738 012 720 B WG H740 705 WL RL H710 M001 703 706

LICENSE LAMP

This page illustrates the transmission is in neutral and key switch is in OFF position.

RL RGy H128 H138 330 312 RB B H129 303

WG N704 N905 704 705

B WL N901 706

− 1

706 708 N901 P601 WL WP WL WP M701 M702 706 708 1

REAR COMBINATION LAMP (R. H)

R6 2

M0 3 3

REAR COMBINATION LAMP (L. H)

303

BACK UP ALARM

1 303 R501 RB B 330 R301 R401 R201 RL RGy

DIODE UNIT

330 R103 RL

RH BATTERY

3 3

R N502 3 701

RL N906 703

700 N301 WV 015 708 P601 P602 WR WP

1 B

R502

6 P707 P708 P717 031

RGy R102

BG N903 720

WR WP H720 M002 015 708

WP M002 708

W H601 P502 P503 901 081 085

BW N904 012

N6 HEATER RELAY

EMERGENCY STEERING MOTOR PUMP

24 25

+ −

GR P718 P728

W N303 900 4

− 2

W W N101 N101 081 085

PARKING SOLENOID 2

−

23 12

N7 MAGNETIC S/W

N1 31

4 5

22 11

R501

−

70A

R H804 243

EMERGENCY STEERING MOTOR PUMP

30A

10 3

EMERGENCY STEERING OIL PRESS. SENSOR

AIR CLEANER

ELECT. FAN CONDENSER

21 9

ECM

P746 P736 H709 S2H H707 P737 S2S H708 S2L

FUSIBLE LINK

+ −

BW N501 702

V YGy W101 100 H210 BY 151 W102 114

FUSE BOX (ECM)

16 26

R H804 243

COMPRESSOR CLUTCH (ECC)

15 25

RESISTOR

1 1

14 24

GROUND SPEED SENSOR

P4 J9

WATER LEVEL SENSOR

BY V H803 H801 100 114 SbR H802 240

2 LP H208 149

GyR H721

745 BO

2 Y Y H736 H726 159 160

LU (BLUE)

−

AUTO BRAKE SOLENOID

LgL L806 182

SbW H703 203

FUEL LEVEL SENSOR

B L802

LgB H132 221

SbY BrG GL H711 H714 H728 209 738 213 45

5 1

LO H203 143

RW Y L803 L804

LgL L401

GyG BY H136 H120 754 114

GyY Sb H734 H704 736 205 PG GyW W H733 H724 H731 739 737 161 PW SbLg GY H723 H718 H737 740 204 743

Sb H717 184

RIDE CONTROL SOLENOID (OPT)

BY GyL H120 H126 114 180

WR H117 170

T/M OIL TEMP. SENSOR

3/4 B

T/M OIL FILTER

BrW H719 732

LgL L401

E Y

−

LgL R801 R803

WASHER MOTOR

182 L002 LgL

1 BrR L302

LY H201 141

−

1/2 W

OR H105 019 PB H115 2 500

L903 B

BY L202

BY L303

1/8 G

X2 −

L902 L901 RW Y

V L301

1/4 R

L3 1

LBr H206 148 2

LgL H135 182

B K104

28 OR

6 B

RW Y H102 H112

Br K201 003 BrW B K206 250

−

K803

−

BUCKET LEVELER

JPN:CONNECT EU :DISCONNECT

COMBINATION LAMP

GyB H131 266 BY V H120 H101 114 100

−

LB H205 147

6 BL BL GY GY BrR H713 H713 N001 N001 H739 741 741 031 031 730 GB GR GY BrB N005 N001 H729 H730 214 035 031 731 B B GR YO YL N005 H716 H706 035 748 747 B B WR S2L S2S H720 P902 P903 015 B BLg BrW YV S2H H705 H725 H715 P901 735 733 734 50 46

GB H121 267

YR B H701 405 YB YG H702 H732 406 409 YL YBr H712 H722 407 408

GyO BY H116 H120 220 114

RW RY K108 K102 308 306 B

−

Br 2

LR H204 146

−

FRONT HEAD LAMP (OUTSIDE)

−

311

K105

J8 +

RLg

−

WORKING LAMP (INSIDE)

EFFICIENT LOADING SYSTEM (ELS) SOLENOID VALVE

HYD. OIL LEVEL S/W

GW K601

329 K107 GW

GW K702 K704

HORN (H)

EFFICIENT LOADING SYSTEM (ELS) OIL PRESS. SENSOR

HYD. OIL TEMP. SENSOR

T/M SOLENOID VALVE

2 B

W N101 901

GW K601

R N201 915 R N201 914

100 K202 L602 M202 M302

R N201 913 R N201 912

6 B

R N201 911 R N201 910

240 100 P403 P402 SbR V 114 X301 P401 P301 BY R

LBr J302 148 LLg J702 140

HORN (L)

BY V Br H120 H101 H103 114 100 003 LgL BrR BrW H122 H113 H123 261 251 250

LB J202 147 LP J902 149

311

K105

Br V BY L103 L201 L202 003 100 114 BrW BrR LgL L102 L203 L401 250 251 261

3 RLg

BY V W202 W201 114 100

LR LO J602 J102 143 146 YGy LgR W203 J002 151 150

LG J502 142

325 330 H109 H128 RO RL 303 331 H129 H139 RB RG

5 1

114 K203 L702 M502 M201 M602 M301 L601

LY J402 141 B

W P711 161 GyR P827 751 SbY P745 209 YR J801 405

WORKING LAMP (INSIDE)

BW GyY PG YG N904 P703 P714 J805 012 736 739 409 BrW GyW PW YBr P748 P713 P724 J804 733 737 740 408 YL YV BrG BL P747 P744 P709 J803 734 738 P710 407 BLg Sb SbW YB P749 P702 P741 J802 735 205 203 406 5

RW RY K108 K102 308 306 B

2 R B

FRONT HEAD LAMP (OUTSIDE)

R103 R602 R702 330

70A

327 330 H119 H128 RBr RL 303 331 H129 H139 RB RG

K503

36 Y WG BrR BG GY N905 P706 N903 P721 M901 705 730 720 743 159 GB BrB GL SbO Y P720 P716 P743 X101 M902 214 731 213 183 160 WR BrW SbLg Sb YO P602 P705 P723 X201 P727 P738 732 204 184 748 RL S2H S2L S2S YL N906 P701 P902 P903 P726 703 747 6 10 40

35 31 LgL LgB GyB P101 L603 L806 182 221 266 PL BrW LgL GB M803 K206 K204 L501 506 250 261 267 YR PB SbY BrR Y M802 M203 K205 L804 P201 500 171 251 OR SbY Br RW V M801 M303 K201 L803 019 172 003 5 1

70A

K502

36 WL RG RGy LgG GyG M701 R605 R102 M101 M601 707 R705 312 162 754 RB RL GW GyL K107 M501 329 180 BY RBr RY WR GyO K103 K102 X401 L701 R703 306 170 220 RO RW BrY RLg K101 K108 M401 K105 R603 308 181 311 10 6

SbO H727

325

40 303 K106 R104 R604 R704

K101

K501

327 306 325 L802 H119 H118 H109 B RBr RY RO 311 303 329 308 H106 H129 H127 H108 RLg RB GW RW

303

K106

RLg RB GW RW K401 K501 K601 K303 K901 K801 329 K003 B RBr RY RO K802 K302 K502 327 K002 325

JPN:CONNECT EU :DISCONNECT

COMBINATION LAMP

Electrical Wiring Diagram (3/3) (S/N 9001~9048)

LH BATTERY − +

95ZV2-09709-08383 EU 3/3 95V2E92020

92-10 95ZV-2 Drawing & Diagrams Electrical Wiring Diagram (1/3) (S/N 9049~9250)

Electrical Wiring Diagram (1/3) (S/N 9049~9250)

(+)

LgY A803 167 YO B001 176

8 RO RO BP B911 A815 G803 321 H109 323 RBr RBr BP B910 A814 G803 322 H119 323

8 Lg D103 013 GyW S823 200

EG2 EG1 EG3

WTM TTM

1/2

1/4

3/4

3 4

EMP GND

GND

20 7

12 B LY LG LO LW SbW B S518 V304 S505 S508 B502 141 132 143 144 163 Lg GR D103 S529 013 135 1 6 1

YL YBr YG RB SbO YR YB B601 S526 S511 S533 S522 S531 S523 410 411 412 413 414 C305 193 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

SM H

3 4

GyB B S514 103 LgR GY WL S521 S520 S624 130 169 400

RY RBr RO F403 A102 A107 307 326 324 LgY BG RGy A007 H738 B101 F002 720 B201

HORN S/W HU

YV A401 231

1 YV T307 231 B

L C101 801 L C102 802

B4 1

EMERGENCY STEERING RELAY (EU:STANDARD)

R RGy D109 C306 002 H138 R RGy D109 A801 002 310

1 R D602 023 R D601 024

COMBINATION S/W FOR LAMPS

RG RLg D113 C302 006 H106 RG RGy D113 A801 006 310

GyG Gy LgY LgW S515 S519 S528 F903 753 749 173 102 WG LgW GyL Sb S513 H740 S527 S516 194 705 192 190

8 Lg D103 013 GL S822 265

INSTRUMENT PANEL

F/R S/W SELECTION (EU STANDARD)

REAR WORKING LAMP

GND

HAZARD 3

DECLUTCH (JPN:DISCONNECT EU:CONNECT)

1 2

FRONT WORKING LAMP

EFFICIENT LOADING SYSTEM (ELS)

YSb S506 403

FUEL EFFICIENT MODE SELECTION

2 L YGy E706 E704 005-a 242 R B H804 243

B 4

YV S918 231

1 (BLACK)

1 F801

P RBr RO RW G703 A103 A106 F401 320 322 321 304

DECLUTCH CUT-OFF S/W

LR LBr B S911 S904 126 128 LW B S912 120 LY LG LO S910 S903 S905 121 122 123

BW F005 271

BrG F004 255

THROTTLE PEDAL 6

4 GyY GyW BL H734 H724 H713 736 737 741 YV BLg BrW H715 H705 H725 734 735 733

C0 12 1

R G B

4 4

O Y V

DATA LINK CONNECTOR DECLUTCH SENSOR

BR BL 10 WP LgR PL C5 H910 H913 H015 C802 H008 H011 WG OL BrW BG B H014 H013 H012 H007

−

V BY S709 S707 100 114 LgR S727 166

VOLTAGE RELAY

1 LO GW BY BrY Y RL 12 H901 H902 H903 H904 C801 D701

AIR PROBE (THAM)

6 RW R H108 D108 308 001 RY RY RW A813 F504 B912 H118 305 304 3 1

(BLACK)

R R D108 D108 001 001 RB RB C403 B914 H129 301 1

(BLUE)

R R D108 D108 001 001 RY RY F402 B915 305 302 (BLACK)

1 3

2 4

(BLACK)

Lg LB D103 S510 013 138 RL B H128 T801

WG WL H740 H140 705 707 B B

C9 4

(S/N ~9150)

3 3

G L D102 D205 014 005-a RL SbP H710 S618 703 145 4

(BLACK)

BrB L G402 D205 257 005-a B BrB S611 258 1

(BLUE)

Lg Lg D103 D103 013 013 LgSb LgBr G601 S609 112 104 1

(BLACK)

LgW L A508 D205 102 005-a B LgW S612 101

G G D107 D107 010 010 GW GL H127 B801 329 328 1

S2L H708

(BLACK)

DIAG INC/DEC S/W

AIR-SUS. 3

5 OY D114 007 1

2 PG PW H733 H723 739 740 BrG BL H714 H713 738 741

Br D110 003

1 1

FLOAT

SHIFT HOLD S/W (OPT)

POSITIO -NER

2 2 LgB LgR H132 H209 221 150 LgB LgR S702 S605 226 154

(BLUE)

YSb S917 125

BrR

BrW

1 6

910 D301 R 911 D402 R

1 912 D401 R 913 D901 R

E L

901 E201 W

G D107 010

C404 C405 C406 C506 Sb GO WR WP

LgSb X504 112

P R B909 D111 320 004 B 1

RL V604 330

2 BP G A101 D107 A108 010 B

D804 D802 H102 H112 R RB RW Y

9 C501 C510 BG BL

D803 D701 H111 C508 C504 C503 C502 C509 RG RL YR PL WG OL BrW BR 18

B 10

4 10

BY R E701 V404 114 243 SbR V E702 E703 240 100 2

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

1 914 D002 R 915 D001 R

HAZARD

YGy LgR LP LLg S819 V702 S517 S507 151 150 149 140 LY LG LO LR LB LBr S518 S502 S505 S613 S601 S604 141 142 143 146 147 148 1

BACK LAMP (OPT)

BrB

TURN SIGNAL

1 Br

AIRCON UNIT

G V805

Br D110 003

Br D110 003 1 (BLUE) Br

BY V S707 S709 114 100

KICKOUT

H8 7

12 2

CAB ALARM BUZZER

PILOT VALVE MAGNETS

S2H W H709 6 D506

1 (BLACK)

3 3

2 LG LW S502 S508 142 144 LG B A709 132

BrR L G202 D205 272 005-a B L S610 273

(BLACK)

DOWNSHIFT BUTTON

4 YL YO H706 S2S H707 H716

(BLUE)

1 019 172 003 100 D609 S722 D110 H003 S709 RW V OR SbY Br 500 171 251 C307 S730 S826 H004 H016 PB SbY BrR YR Y 506 250 261 267 C308 G302 S504 S501 PL BrW LgL GB 182 221 266 V703 S801 S806 LgB GyB LgL 35 31

4 SPEED INDICATOR RELAY

LOWER KICKOUT RELAY

226 154 V004 V001 LgB LgR 221 150 V003 V002 LgB LgR

LIFT KICKOUT RELAY

BUZZER RELAY

BrG YO S922 B001 255 176 BW LgY S813 A803 271 167 B LP S915 168

W1 6 325 308 181 311 A107 F404 S811 B108 RO RW BrY RLg 114 327 306 170 220 S707 A102 F403 S614 S723 BY RBr RY WR GyO 303 330 329 180 F604 V604 F804 S731 RB RL GW GyL V502 331 312 162 754 S724 S619 B208 B506 S625 WL RG RGy LgG GyG 40 36

MCU FAULT RELAY

HORN RELAY

LgB LgR V703 V702 221 150 LgB LgR V704 V701 226 154

NEUTRAL RELAY

168 T607 LP

1 BY G S707 S732 114 415

AIR TEMP. PROBE (MCU)

A G

BACK RELAY (OPT)

WY V PB YB VW P H920 H919 H918 H917 H916 H914 6

B 271 T706 BW 255 T708 BrG

BR Y C509 C611

1 (BLACK)

B 1

2 1

2 Gy GyR S816 H721 750 751 B B

272 T003 BrR

CAB

3 B

RB BrB LgY F604 H912 H911 300

2 LP F001 168

2 Sb SbP H704 S509 205 202 B B

Sb GO WR 6 H907 H908 H909

2 SbY SbR H711 S608 209 208 B B

CAB (AIRCON) 4

F1 4

G WBr RLg O RGy RB B208 A611 D107 D604 B108 D610 520 300 010 022 521 020 PB PL OR OL OW OG H115 H125 D609 D608 D607 D606 500 506 019 018 017 016

S2L S2H H708 H709 S720 S729 1

S2S H707

FUSE

RB A611 300

L B402 802 L B401 801

S914

6 L LgG D206 H137 005-b 162 GO SbW B S901 A712 164 163 1 3 4

S921

F003 A002

LLg

YO R

WIDTH LAMP RELAY

3 7

HEAD LAMP RELAY

8 B

Hi-BEAM RELAY

DECLUTCH SET-UP

PARKING S/W

257 T903 BrB

250 H123 BrW

E/G OIL PRESS. S/W RELAY

TORQUE SELECTION RELAY

E/G IDLE SELECTION RELAY

LIFT KICKOUT SET-UP/ LOWER KICKOUT SET-UP

B8 GW

SHIFT LEVER

RB RY F601 F501 301 302

6 703 C201 C202 C203 747 F704 T406 T405 T404 T403 RL S2H S2L S2S YL 015 732 204 184 748 D101 A606 S534 S815 T402 WR BrW SbLg Sb YO 214 731 213 183 160 V205 A607 V210 S814 S716 GB BrB GL SbO Y V503 730 720 743 159 A503 A605 A802 V212 S708 WG BrR BG GY Y 40 36

This page illustrates the transmission is in neutral and key switch is in OFF position.

95ZV2-09709-09360 EU 1/3

K95V2E92004

92-11 95ZV-2 Drawing & Diagrams Electrical Wiring Diagram (2/3) (S/N 9049~9250)

Electrical Wiring Diagram (2/3) (S/N 9049~9250) 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

OPT B

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

A10

A11

A12

A13

A14

A15

A16

A17

A18

A19

A20

A21

A22

A23

A24

A25

A26

A27

A28

A29

A30

A31

A32

A33

B10

B11

B12

B13

B14

B15

B16

B17

B18

B19

B21

B22

B23

B24

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

B25

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

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

E10

E11

E12

E13

E14

E15

E16

E17

E18

E19

E20

E21

E22

E23

E24

E25

E26

B26

E27

E28

E29

E30

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

E31.TT_SE E32.OT_SE E33.OUT_RSE E34.ET_M

E31

E32

E33

E34

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

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.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

C32

C33

D10

D11

D12

D13

D14

D15

D16

D17

D18

D19

D20

C34

D21

D22

D23

D24

D25

D26

(S/N 9151~)

AUTO/ FULL AUTO SELECTION

JPN PL P 2 S803 S802 108 107 B

F23 CHANGE POINT SELECTION

ODOMETER SELECTION

A/M SELECTION

B VG S925 157

PW S831 111

F34 CHANGE POINT SELECTION

PB S916 110

VY S913 158 1

PG S902 109 1

(BLUE)

(GREEN)

(BROWN)

GR YB WL GyG YO T103 S003 A806 H136 S005 811 115 400 754 118 WR SbW GL YBr SbP RG H117 H703 T104 S001 F701 H139 170 203 810 119 145 331 SbR LgBr L BrB LgW LR F102 X501 T001 T901 F901 H204 208 104 273 258 101 146 LB GB LBr LgR LgL BL H205 V101 H206 V701 E502 E001 147 278 148 154 225 237

RL SbO LgW LgY GR OSb YBr YB SbLg A612 A502 A507 A701 V203 A618 A608 A616 H718 193 192 173 135 211 413 235 211 204 LY Gy Gy LgR YL YG LgB GW A708 A506 A807 A808 A617 A619 A604 V207 H201 749 169 130 412 414 224 212 0 LB YR Sb GyB GyG GyL LP V602 A615 A609 A504 A809 A505 A501 H208 138 410 241 194 103 753 190 149 GB LG YGy LgL LO YSb LLg LW SbP H121 H202 E804 H122 A710 A901 H207 A711 F202 267 V303 242 261 H203 403 140 V302 202

(S/N 9151~)

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

YG YB S2H SbY GyL G C201 H114 H126 C901 S002 A603 171 180 415 116 401 G S2L BrW SbY GyO WL YL E003 C202 A602 H104 H116 H140 S004 234 402 172 220 707 117 L L W Y G D203 D204 H731 H726 D107 005-C 005-D 161 160 010 BR LgB L L B B BY Y V E002 V704 D201 D202 H736 236 226 005-A 005-B 159 1

100 C702 E803 E004 H101 T101 W101 9

(BLACK)

B BrR SbR YB YBr Y PW GyW LgY H113 E802 H702 H722 T202 W301 E603 E501 251 240 406 408 105 111 260 223 YGy YL YG GL GyW GB Lg H210 H712 H732 A302 A202 V102 E503 151 407 409 265 200 277 222 BW SbO Sb YR BrY R Gy H107 T203 F005 H727 H717 F303 H701 181 106 271 183 184 750 405 GyB P PL LgL H131 S102 S103 H135 266 107 108 182

LgR C703 166

C701 C902 E801 114

LLg BrG GW LB VG YW B002 F004 V206 E006 W401 E012 165 255 210 230 157 233 YL LP YV YO PB YSb G101 F001 S301 G901 A401 E005 124 168 110 125 231 232 B LY LW VY LR B703 B709 B706 W501 121 126 120 158 GO PG LG LBr LO B503 S401 B702 B708 B701 164 109 122 128 123 1

E007 H120 T102 W102

(S/N 9151~) S8

S9 S0

Note See Section 62 for the details of A/M selection switch. Others are for factory use only.

FUSE BOX (CAB)

003 G201 G301 G401 H103

R1 BR S2L B ACC R2 C

WRx2 WBx2 G

W3 W5 BW BG

WR WB

BW D504 062

2 5

O WR

G D502 064

LW B

R G702 004

WR O

BW H735 012

RG OY B102 T501 B107 007 WR G F703 H720 014 015

R H301 910

3 3

WR RL

OG D606

V801 W

3 8

FR SWITCH (EU : STANDARD)

6 B

YW E412

YW E308

F/R SWITCH/ STICK STEERING

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

2 12

OSb Lg GB GW S530 D103 H730 S923 211 013 214 210 GY BrW GL BLg GW B H737 H725 H728 H705 S525 743 733 213 735 212

GB GB S603 S824 278 277 1

SLIP CONTROL

Lg LgL S825 S606 222 225 B LgY S834 223

EMERGENCY STEERING (EU : STANDARD)

RIDE CONTROL S/W 2

GyW S833 260 B Lg D103 013 2

YGy V V402 H803 242 100 B SbR H802 240 L BY V403 H801 005-a 114

YGy V S709 S503 100 242 B SbR S827 240 L BY S707 D205 114 005-a

RL 1

RG RB H018 H002

R H402 913

R H501 914 R H502 915

R H001 1 4

RS232C

1 B

E/G WATER TEMP. SENSOR (FOR INSPECTION)

R Y S812 S830 106 105

DIAG. S/W CONNECTION

DC-DC CONVERTOR (EC : STANDARD)

C612 H915 H017

BOUT

OUT

G G501

L V904

Y D607

W D604 1

BY GyG S707 S625 114 754

Note These switches/connectors are for factory use only.

V902 V901 R R

D6 4

D0 V8

This page illustrates the transmission is in neutral and key switch is in OFF position.

OG OW OL OR O 10 C312 C311 C310 C309 C301 016 017 018 H105 020 WBr R R C303 B301 B302 022 023 024

REVERSAL FAN S/W

V906 V804 V908 V909 V910 Y OL OR O 10 6 OG 6

PRESS. INTENSIFYING

R R D602 D601

(EU:STANDARD)

O 10 OL OR D608 D609 D610

L V808

5 1 6 2 L L L L L L E008 S703 S704 S711 S712 E806 B504 005-A 005-B 005-C 005-D F702 005-b F902 T902 T002 005-a

GL V S616 S709 810 100 GR BY S622 S707 811 114

MCU SELECTION

6 BW W E104 E202 062 T407 WR G WR E107 E101 E106 065 064 063

R H302 911 R H401 912

A207 013 A307 A610 A706 E601 V204 V603 D1 X502 X503

R5 4

14 R B202 B207

YO E405

W D506 060 W H601 901

WR WR D501 D503 063 065

FR SWITCH (EU : STANDARD)

7 C304 F802 F803 G501 G802 S717 010

STARTER SWITCH

001 8 R F406 F502 F503 F602 G F603

STARTER S/W

1 YG YBr YB S623 S733 S617 115 116 119 YL B YO S725 S626 117 118

FUSE BOX (MAIN) RL RG LR LW YR YW

95ZV2-09709-09360 EU 2/3

K95V2E92005

92-12 95ZV-2 Drawing & Diagrams Electrical Wiring Diagram (3/3) (S/N 9049~9250)

Electrical Wiring Diagram (3/3) (S/N 9049~9250)

B W

BrY H107 181

K106

RBr

K103

303

K801

327

K802

BOOM ANGLE SENSOR

V L201

BrR L203

BrR L302

BrR K205 251

V K202 100 BY K203 114

1 B

−

LG H202 142

2 B

PL H125 506 B

−

LgL K204 261

−

LLg H207 140

−

746 BO

−

SPPC

LgR H209 150

1 B

PRESSURE SENSOR

S −

R N502 701

1 B

FAN SPEED CONTROL SOL. VALVE B

LgG H137 162

2 V BY H101 H120 100 114 SbY H114 171

GL GB GR

V BY H101 H120 100 114 SbY H104 172

GY W

M7 ALTERNATOR

G GR

YR H111

−

FUSIBLE LINK

N3 BATTERY RELAY

BRAKE OIL PRESS. (MAIN)

WP M002 708

WL M001 H140 706 707

WV N403 700

R H301 H302 H401 H402 H501 H502 910915

BW N501 702 2

W N102 900

RGy R102

REAR WORKING LAMP

312

REAR WORKING LAMP

B 2

1 B

330 R103 RL

R104

R502

BG N903 720 4

AIR HEATER

3 3

R N502 3 701

BACK UP ALARM 303

LICENSE LAMP

1 303 R501 RB B 330 R301 R401 R201 RL RGy

This page illustrates the transmission is in neutral and key switch is in OFF position.

2 2

RL RGy H128 H138 330 312 RB B H129 303

2 702 N702 BW 701 N703 R

015 708 N401 N402 WR WP B 2

4 4

R P002 701 BW P001 702

DIODE UNIT

WG N905 705

703 N701 RL 705 N704 B WG 012 720 N601 N602 BW BG BW BG H735 H738 012 720 WG B H740 705 WL RL H710 M001 703 706

− 1

706 708 N901 P601 WL WP 1

700 N301 WV 015 708 P601 P602 WR WP

RH BATTERY

4 RL N906 703

6 P707 P708 P717 031

312

WR WP H720 M002 015 708

W H601 P502 P503 901 081 085

BW N904 012

N6 HEATER RELAY

EMERGENCY STEERING MOTOR PUMP

P746 H709 S2H P737 H708 S2L

+ −

GR P718 P728

PARKING SOLENOID 2

W W N101 N101 081 085

W N303 900

− 2

RGy R102

24 25

N7 MAGNETIC S/W

70A

R501

−

N2 M3

R H804 243

EMERGENCY STEERING OIL PRESS. SENSOR FUSIBLE LINK

23 12

P736 H707 S2S

EMERGENCY STEERING MOTOR PUMP

30A

4 5

ECM

M1 2

+ −

BW N501 702

22 11

AIR CLEANER

ELECT. FAN CONDENSER

R H804 243

P0 STARTER

10 3

RESISTOR

V YGy W101 100 H210 BY 151 W102 114

21 9

2 7

GROUND SPEED SENSOR

P4 J9

WATER LEVEL SENSOR

V BY H803 H801 100 114 SbR H802 240

2 LP H208 149

GyR H721

E/G WATER TEMP. SENSOR

745 BO

2 Y Y H736 H726 159 160

(S/N ~9150)

(BLUE)

−

FUSE BOX (ECM)

LgB H132 221

SbW H703 203

10 6

COMPRESSOR CLUTCH (ECC)

SbY BrG GL H711 H714 H728 209 738 213 45

GyG BY H136 H120 754 114

FUEL LEVEL SENSOR

GyY Sb H734 H704 736 205 PG GyW W H733 H724 H731 739 737 161 PW SbLg GY H723 H718 H737 740 204 743

LO H203 143

AUTO BRAKE SOLENOID

LgL L806 182

BrW H719 732

Sb H717 184

B L802

BY GyL H120 H126 114 180

LgL L401

3/4 B

T/M OIL FILTER

RW Y L803 L804

RIDE CONTROL SOLENOID (OPT)

T/M OIL TEMP. SENSOR

E Y

WR H117 170

LgL L401

−

LgL R801 R803

1/2 W

LY H201 141

WASHER MOTOR

−

182 L002 LgL

BY L303

OR H105 019 PB H115 2 500

L903 B

BY L202

L902 L901 RW Y

V L301

1/8 G

X2 −

LBr H206 148

1/4 R

LgL H135 182

B K104

6 GY GY BrR BL BL H713 H713 N001 N001 H739 741 741 031 031 730 GR GY BrB GB N005 N001 H729 H730 214 035 031 731 B B GR YO YL N005 H716 H706 035 748 747 B B WR S2L S2S H720 P902 P903 015 B BLg BrW YV S2H H705 H725 H715 P901 735 733 734 50 46

28 OR

6 B

RW Y H102 H112

Br K201 003 BrW B K206 250

− −

K803

LB H205 147 2

BUCKET LEVELER

JPN:CONNECT EU :DISCONNECT

COMBINATION LAMP

−

GyB H131 266 BY V H120 H101 114 100

WL WP M701 M702 706 708 1

REAR COMBINATION LAMP (R. H)

R6 2

YR B H701 405 YB YG H702 H732 406 409 YL YBr H712 H722 407 408

GB H121 267

RW RY K108 K102 308 306 B

GyO BY H116 H120 220 114

−

Br 2

LR H204 146

3 3

REAR COMBINATION LAMP (L. H)

− −

FRONT HEAD LAMP (OUTSIDE)

311

K105

RLg

−

WORKING LAMP (INSIDE)

HYD. OIL LEVEL S/W

EFFICIENT LOADING SYSTEM (ELS) SOLENOID VALVE

329 K107 GW

GW K702 K704

HORN (H)

GW K601

HYD. OIL TEMP. SENSOR

2 B

GW K601

T/M SOLENOID VALVE

EFFICIENT LOADING SYSTEM (ELS) OIL PRESS. SENSOR

W N101 901

100 K202 L602 M202 M302

R N201 915 R N201 914

R N201 913 R N201 912

HORN (L)

BY V Br H120 H101 H103 114 100 003 LgL BrR BrW H122 H113 H123 261 251 250

R N201 911 R N201 910

240 100 P403 P402 SbR V 114 X301 P401 P301 BY R

LBr J302 148 LLg J702 140

LB J202 147 LP J902 149

311

K105

3 Br V BY L103 L201 L202 003 100 114 BrW BrR LgL L102 L203 L401 250 251 261

114 K203 L702 M502 M201 M602 M301 L601

BY V W202 W201 114 100

LO LR J602 J102 143 146 YGy LgR W203 J002 151 150

W P711 161 GyR P827 751 SbY P745 209 YR J801 405

325 330 H109 H128 RO RL 303 331 H129 H139 RB RG

3 RLg

5 1

6 LY LG J402 J502 141 142 B

WORKING LAMP (INSIDE)

327 330 H119 H128 RBr RL 303 331 H129 H139 RB RG

RW RY K108 K102 308 306 B

2 R B

FRONT HEAD LAMP (OUTSIDE)

R103 R602 R702 330

70A

31 LgB GyB LgL P101 L603 L806 182 221 266 PL BrW LgL GB M803 K206 K204 L501 506 250 261 267 YR PB SbY BrR Y M802 M203 K205 L804 P201 500 171 251 RW V OR SbY Br M801 M303 K201 L803 019 172 003 5 1

SbO H727

K503

70A

K502

325

36 WG BrR BG GY Y N905 P706 N903 P721 M901 705 730 720 743 159 Y GB BrB GL SbO P720 P716 P743 X101 M902 214 731 213 183 160 YO WR BrW SbLg Sb P602 P705 P723 X201 P727 P738 732 204 184 748 RL S2H S2L S2S YL N906 P901 P902 P903 P726 703 747 6 10 40

303 K106 R104 R604 R704

K101

K501

327 306 325 L802 H119 H118 H109 B RBr RY RO 311 303 329 308 H106 H129 H127 H108 RLg RB GW RW

303

(S/N ~9150) 40

K106

RLg RB GW RW K401 K501 K601 K303 K901 K801 329 K003 B RBr RY RO K802 K302 K502 327 K002 325

JPN:CONNECT EU :DISCONNECT

COMBINATION LAMP

LH BATTERY − +

95ZV2-09709-09360 EU 3/3

K95V2E92006

92-13 95ZV-2 Drawing & Diagrams Electrical Wiring Diagram (1/3) (S/N 9251~)

Electrical Wiring Diagram (1/3) (S/N 9251~) EFFICIENT LOADING SYSTEM (ELS)

2 5

3 4

5 7

RO B911

8 BP G803

5 321

323

A815 H109

A814 H119

324 325

326 327

8 8

EG2 EG1 EG3

WTM TTM

1/2

1/4

3/4

YR YB YL YBr YG S511 S533 S522 S531 S523

193

410

194

705

192

411

013

413

414

141

241

235

731

732

730

224

401

132

143

144

GND

SM H

GyB S514

GR S529

LgR GY WL S521 S520 S624

013

135

307

130

169

326 167

720

3 8

3 B

006

002

231

C302 H106 311 521

310

C306 H138

R RGy D109 A801 002

1 YV T307 231

F801

322

321

301

(S/N 9258~)

302

LIFT KICKOUT SET-UP/ LOWER KICKOUT SET-UP

LR LBr S911 S904

120 121

RB A611

123

300

BrG F004

271

010

022

521

500

019

506

018

017

GyY GyW BL H734 H724 H713

736

737

YV BLg BrW H715 H705 H725

734

735

V 2 S709

LgR S727

300

R G B

DECLUTCH SENSOR

166

BY S707

(S/N~9300)

VOLTAGE RELAY

1 V BY S709 S707

BACK RELAY

001

RG H139

RY RW F504 B912

RB B914

305

114

YO F003

1 BR Y C509 C611

YO H716

CONTROLLER FAULT RELAY

HORN RELAY

LIFT KICKOUT RELAY

BUZZER RELAY

FUSE

4 SPEED INDICATOR RELAY

LOWER KICKOUT RELAY

1A 2 4

167

LP S915

3 2

L G D102 D205

G G D107 D107

014

010

005-a

RL SbP H710 S618 703

329

3 102

005-a

LgW S612

328

LgW L A508 D205

010

GW GL H127 B801

145

L BrR G202 D205

LW LG S502 S508

257

005-a

272

005-a

142

144

BrB S611

L S610

LG A709

013

LgSb LgBr G601 S609 112

BrB L G402 D205

013

101

Lg Lg D103 D103

104

258

273

150

LgB LgR S702 S605 226

132

LgB LgR H132 H209 221

(BLACK)

(BLUE)

(BLACK)

(BLUE)

DOWNSHIFT BUTTON

154

WG WL H740 H140

YL H706 747

705

707

H128 T801 1

013

138

S2S H707

060

DIAG INC/DEC S/W

AIR-SUS.

S2L H708

S2H W H709 D506

330

(BLUE)

Lg LB D103 S510

OY D114

739

738

325

308

181

311

114

327

306

170

220

1 172

100

003

171

506

250

C308 PL

G302 S504 S501 BrW LgL GB

707

331

312

182

217

B208 B506 RGy LgG

329 162

003

BrR

S806 LgL 35

261

LgSb X504

221

266

142

143

146

G D107

149

147

148

1 914

D301 R

D401 R

D002 R

911

913

915

D402 R

D901 R

D001 R

G D107 010

330

240

C501 C510 BG BL

D803 D701 H111 C508 C504 C503 C502 C509 RG RL YR PL WG OL BrW BR

H7 V211 C002 10

6 703 C201 C202 C203 747 F704 T406 T405 T404 T403 RL S2H S2L S2S YL

243

SbR V E702 E703

901

E201 W

D804 D802 H102 H112 R RB RW Y

114

B 1

C404 C405 C406 C506 Sb GO WR WP

C606 C605 C604 C603 C602 D701 C601 C507 C402 C401 WY V PB YB VW RL P LgR BrB LgY 11

912

BP 323

3 A101 A108

004

C607 C608 C609 C610 LO GW BY BrY

010

BrB

140

B 1

BY R E701 V404 910

RL V604

112

015

732

204

184

748

D101 A606 S534 S815 T402 WR BrW SbLg Sb YO

100

214

3 V503 A503

T207 V703 S801 YSb LgB GyB

2 P R B909 D111 320

3 B 1

LY LG LB LO LBr LR S518 S502 S505 S613 S601 S604 141

267

150

E L

003

BrW

HAZARD

Br D110 1

1 (BLUE) Br

LP YGy LgR LLg S819 V702 S517 S507 151

100

251

C307 S730 S826 H004 H016 YR PB SbY BrR Y

180

330

Br D110

003

BACK LAMP (OPT)

G V805

H8 7

BY V S707 S709 114

D609 S722 D110 H003 S709 OR SbY Br RW V

F604 V604 F804 S731 RB RL GW GyL

303

Br D110 B

125

TURN SIGNAL

500

S707 A102 F403 S614 S723 BY RBr RY WR GyO

YSb S917

741

AIRCON UNIT

POSITIONER KICKOUT

019

A107 F404 S811 B108 RO RW BrY RLg

740

BrG BL H714 H713

007

2 6

PG PW H733 H723

FLOAT

SHIFT HOLD S/W (OPT)

(BLACK)

CAB ALARM BUZZER

PILOT VALVE MAGNETS

748

301

300 4 303

(BLACK)

306 307

C403 H129

302

V502 S724

305

A813 H118

(BLUE)

RY RY F402 B915

304

1 3

S619

(BLACK)

NEUTRAL RELAY

(S/N~9257)

415

BY G S707 S732

AIR TEMP. PROBE (CONTROLLER)

(BLACK)

AIR TEMP. PROBE (THAM)

001

166

Z504

001

LgR S727

(S/N 9258~)

001

271

100

308

(BLACK)

176

114

WY V PB YB VW P H920 H919 H918 H917 H916 H914

R R D108 D108

751

2 +

R R D108 D108

750

167

168

DECLUTCH SENSOR

BrG YO S922 B001

DATA LINK CONNECTOR

114

R D108

202

331

BW LgY S813 A803

7 LO GW BY BrY Y RL 12 H901 H902 H903 H904 C801 D701

T708 T601 BrG YO

255

100

(S/N 9301~)

6 WP LgR PL BR BL 10 C5 H910 H913 H015 C802 H008 H011 B WG OL BrW BG H014 H013 H012 H007

RW H108

205

176

255

O Y V

733

RB BrB LgY F604 H912 H911

741

167

Gy GyR S816 H721

208

T706 T608 BW LgY

016

T606 LP

Sb SbP H704 S509

209

168

B 271

SbY SbR H711 S608

245

THROTTLE PEDAL 6 12

3 LgY F002

020

4 Sb GO WR 6 H907 H908 H909

PB PL OR OL OW OG H115 H125 D609 D608 D607 D606 1

300

2 B

004

272

CAB (AIRCON)

WIDTH LAMP RELAY(LT)

RL R D111 S619

801

520

1 LP F001 168

RGy RB G WBr RLg O B208 A611 D107 D604 B108 D610

S2L S2H H708 H709 S720 S729

802

L B401

176

CAB

S2S H707

8 8

255

B0 L B402

BW F005

HEAD LAMP RELAY(LH)

Hi-BEAM RELAY(UL)

8 5

124

122

165

LY LG LO S910 S903 S905

LLg

162 163

S921

164

7 YO

005-b

GO SbW S901 A712

1 (BLACK)

257

LgG H137

LW S912

176

L D206

128

DECLUTCH CUT-OFF S/W

E/G OIL PRESS. S/W RELAY

T903 BrB

126

DECLUTCH SET-UP

250

TORQUE SELECTION RELAY

H123 BrW

R H804 4

A4 E/G IDLE SELECTION RELAY

BRAKE RELAY

F003

242

005-a 243

802

YV S918

RB RY F601 F501

304

YGy L E706 E704

C102

T003 BrR

G Y

801

S914

P RBr RO RW G703 A103 A106 F401 320

GY 328

PARKING S/W

231

9 GL

SECONDARY STEERING RELAY (EU:STANDARD)

312 520

310

SHIFT LEVER

5 YV A401

024

R D601 EL

L C101

023

R RGy D109

HORN S/W

RG RLg D113

006

403

R D602

YSb S506

310

B101 B201

COMBINATION S/W FOR LAMPS

RG RGy D113 A801

LgY BG RGy F002 H738

400

324

265

RY RBr RO F403 A102 A107

Lg D103

16 103

1 6

163

402

412

12 LY LG LO LW SbW S518 V304 S505 S508 B502

O RL BrB BrW BrR LgB YB BrW Lg D103 S512 S532 H729 H719 H739 S524 S734 S721

190

20 7 SbO S526

102

EMP GND

173

11 300

749

GL S822

(+)

753

013

GyW S823

GyG Gy LgY LgW S515 S519 S528 F903 WG LgW GyL Sb S513 H740 S527 S516

200

Lg D103

013

Lg D103

323

322

RBr RBr BP B910 G803 4

B601 C305

5 6

INSTRUMENT PANEL

2 3

F/R S/W SELECTION (EU STANDARD)

REAR WORKING LAMP

HAZARD

FRONT WORKING LAMP

GND

FUEL EFFICIENT MODE SELECTION

731

213

183

160

1 735

205

BLg

F203 T206 S828 S817 Sb SbW YB YR

734

738

218

406

407

405

209

C001 G004 YV BrG BL

S820 F103 YL SbY

733

408

737

740

751

V202 A607 V209 S814 S716 C005 G002 S829 F302 GL SbO GB BrB Y V208 BrW GyW PW YBr GyR 705 730 720 743 159 C003 012 736 739 409 161 D105 C006 G003 S821 S715 A605 A802 V207 S708 BW GyY PG YG Y WG BrR BG GY W 40 36 35 31

741

C004 G001

This page illustrates the transmission is in neutral and key switch is in OFF position. 95ZV2-09709-09932 EU 1/3

K95V2E92024

92-14 95ZV-2 Drawing & Diagrams Electrical Wiring Diagram (2/3) (S/N 9251~)

Electrical Wiring Diagram (2/3) (S/N 9251~)

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

OPT (BLACK) B

A12

A13

A14

A15

A16

A17

A18

A19

A20

A21

A22

A23

A24

A25

A27

A28

A29

A30

A31

A32

A11

A33

A34

B12.X_R B13.F_SO B14.B_SO B15.EG_SW2 B16.RIN1 B17.OUT_MD2 B18.N_R B19.BR_L B20.CAN_R1 B21.CAN_R2 B22.DOUT1 B23.OUT_FEW B24.MT B25.ET_SE B26.TXD1

B10

B11

B12

B13

B14

B15

B16

B17

B18

B19

B20

B21

B22

B23

B24

B25

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

(S/N ~9257)

B26

E31.TT_SE E32.OT_SE E33.OUT_RSE E34.ET_M

E11

E12

E13

E14

E15

E16

E17

E18

E19

E20

E21

E22

E23

E24

E25

E27

E28

E29

E30

E31

E32

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

E10

E26

RG H139

E33

E34

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

C10

C11

C12

C13

C14

C15

C16

C17

C18

C19

C20

C21

C22

C23

C24

C25

C26

C27

C28

C32

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

C29

C30

C31

C33

BrR SbR YB YBr H113 E802 H702 H722

PW W301

GyW LgY E603 E501

111

260

C34

D10

D11

D12

D13

D14

D15

D16

D17

D18

D19

D20

D21

D22

D23

D24

D25

D26

331

JAPAN

(S/N 9258~)

Note: See Section 62 for details.

AUTO/ FULL AUTO SELECTION

F23 CHANGE POINT SELECTION

F34 CHANGE POINT SELECTION

ODOMETER SELECTION

A/M SELECTION

PL P 2 S803 S802 108

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

(BLUE)

A10

A26

(WHITE)

EXPORT

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

A708 H201

PW S831

VG S925

111

157

158

110

(BLUE)

(GREEN)

(BROWN)

135

211

413

235

204

411

811

400

115

754

LgR C703

245

118

S2H SbY GyL G YB YG C201 H114 H126 C901 S002 A603

166

180

171

415

401

116

406

408

G S2L BrW SbY GyO WL YL E003 C202 A602 H104 H116 H140 S004

YGy YL YG GL GyW GB Lg H210 H712 H732 A302 A202 V102 E503

141

749

170

234

151

169

130

414

412

224

212

241

410

103

194

753

190

203

810

145

119

SbR LgBr BrB LgW LR L F102 X501 T001 T901 F901 H204

149

104

208

273

101

258

YGy LgL E804 H122

YSb LLg A901 H207

SbP F202

LB H205

GB LBr LgR LgL BL V101 H206 V701 E502 E001

267

142

242

143

403

144

202

147

278

261

140

148

154

225

220

172

L L D203 D204

146

GB H121

402

236

226

117

W Y G H731 H726 D107

005-C 005-D

161

BR LgB L L E002 V704 D201 D202

237

707

160

9 H202 V303

A710 H203

181

159

100

A711 V302

409

265

200

165

222

277

C701 E007 W102 C902 H120 W602 E801 T102

C702 E803 E004 9 H101 T101 W101

106

271

183

184

750

124

164

RL RG LR LW YR YW 1

G201 G301 G401 H103 RL

R1 R2

WRx2

B ACC C

WBx2

F406 F502 F503 F602 F603

063

14 OY T501

003

BW H735

006

004

G D502

062

064

WR RL

6 BW E104

910

911

062

060

R H401

WR G WR E107 E101 E106

912

065

064

V801 W

(S/N 9258~)

O 10 C301

017

018

019

020

WBr C303

R R B301 B302

022

023

GR BY S622 S707

118

811

114

RS232C

2 BY GyG S707 S625

100

754

E/G WATER TEMP. SENSOR (FOR INSPECTION)

SbW S615 203

R SbW YSb S812 H703 H133 5

106

218

217

NEW ECO SELECTION

R R

R H402

R H501

913

914

DC-DC CONVERTOR (EU : STANDARD)

R H502

R H001

915

1 4

C612 H915 H017

OUT

G G501

L V904

C309 H105

Y D607

W D604 1

D0 V8

FR SWITCH (EU : STANDARD) B

YW E412

237

YW E308

YW S926

233

236

234

100

232

GB GB S603 S824

230

L BY D205 S707 005-a

278

114

222

225

LgY S834

GyW S833

YGy V V402 H803

YGy V S709 S503 100

242

SbR H802

SbR S827

240

005-a

100

L BY V403 H801

Lg D103 013

242

260

223

277

Lg LgL S825 S606

SECONDARY STEERING (EU : STANDARD)

RIDE CONTROL S/W

REVERSAL FAN S/W 3

BL BR G V YO LB S607 S701 S719 S709 S919 S924

YO E306 B

PRESS. INTENSIFYING

F/R SWITCH/ STICK STEERING

232

233

810

232

RG RB 2 H018 H002

024

119

OG OW OL C312 C311 C310 016

V902 V901 R R

V906 V804 V908 V909 V910 OG Y OL OR O 10

005-a

R R D602 D601

(EU:STANDARD)

OL OR O 10 D608 D609 D610

OG D606 L V808

5 1 6 2 L L L L L L E008 S703 S704 S711 S712 E806 B504 005-A 005-B 005-C 005-D F702 005-b F902 T902 T002

063

3 3

E202 T407

YO E405

R H302

FR SWITCH (EU : STANDARD) 2

1 GL V S616 S709

116

YL YO S725 S626

R H301

A610 A706 E601 V203 V603 X502 X503

Z503

901

1 4

005

015

A207

W H601

007

013 A307

WR G F703 H720 014

1 115

Note: These switches/connectors are for factory use only. R

R G702

YB YG YBr S623 S733 S617

117

158

123

CONTROLLER SELECTION

128

001

O WR

060

065

BW D504

W D506

WR WR D501 D503

010

7 C304 B202 F802 B207 F803 002 G501 G802 S717

STARTER SWITCH

012

122

232

B102 B107

STARTER S/W

109

114

FUSE BOX (CAB)

120

126

182

108

233

LY LW VY LR B703 B709 B706 W501 121

231

266

107

157

405

125

GO PG LG LBr LO B503 S401 B702 B708 B701

FUSE BOX (MAIN) R5

230

110

LgL H135

210

168

GyB P PL H131 S102 S103

Note: See Section 62 for the details of A/M selection switch. Others are for factory use only.

255

YL LP PB YSb YV YO G101 F001 S301 G901 A401 E005

BrY R Gy BW SbO Sb YR H107 T205 F005 H727 H717 F303 H701

010

Y H736

005-A 005-B

407

LLg BrG GW LB VG YW B002 F004 V201 E006 W401 E012

223

WR SbW GL YBr SbP H117 T203 T104 S001 F701

(BLACK)

240

YG LgB GW Gy Gy LgR YL A506 A807 A808 A617 A619 A604 V212

109

251

138

PG S902

PB S916

VY S913

173

YR Sb GyB GyG GyL LP LB 0 V602 A615 A609 A504 A809 A505 A501 H208

107

192

193

RL Z502

GR YB WL GyG YO T103 S003 A806 W601 S005

SbO LgW LgY GR OSb YBr YB SbLg RL A612 A502 A507 A701 V204 A618 A608 A616 H718

114

211

013

214

GY BrW GL H737 H725 H728

BLg GW H705 S525

743

733

213

735

210 212

OSb Lg GB GW S530 D103 H730 S923

005-a

SLIP CONTROL

L BY S707 D205

114

This page illustrates the transmission is in neutral and key switch is in OFF position.

A 95ZV2-09709-09932 EU 2/3

K95V2E92025

92-15 95ZV-2 Drawing & Diagrams Electrical Wiring Diagram (3/3) (S/N 9251~)

K203 L702 M502 M201 L601 M301

306

500

RW BrY RLg K108 M401 K105 308

172

114

003

LR J101

LB J201

LBr J301

P403 P402 SbR V

143

146

147

148

114

YGy LgR W203 J002

LP J902

LLg J702

P401 BY

151

149

140

213

183

732

204

184

733

737

740

408

YL SbY J803 P745

734 735

747

205

218

LR H204

1 B

LB H205

147

408

1/8 G

LBr H206

148

V BY H803 H801

LY H201

1/2 W

E Y

3/4 B

240

LG H202

FUEL LEVEL SENSOR

J5 +

218

740

204

743

BLg BrW YV S2H H705 H725 H715 P901

SbY BrG GL H711 H714 H728

YSb M001

735

209

217

WR S2L S2S H720 P902 P903

733

734

738

213

745

159

746

Y Y H736 H726

8 2

(BLUE)

F B

BrR L203

BY L202

V L201

AUTO BRAKE SOLENOID

L002 LgL

V L303

BrR L302

BY L301

BrR K205 251

V K202 100 BY K203

PARKING SOLENOID

SPPC

LgR H209

R H804

243

J0 +

P746 P736 H709 S2H H707 P737 S2S H708 S2L

184

V YGy W101 100 H210 BY 151 W102

1 B

LgL K204

L4 1

261

JPN/EXP: OPT EU: STANDARD

701

T/M OIL TEMP. SENSOR

FAN SPEED CONTROL SOL. VALVE

FUSIBLE LINK

V BY H101 H120

100

SbY H104

171

172

S +

LgB H132

180

2 081

GR 035

WV N403

BRAKE OIL PRESSURE (MAIN)

WP M002

WL H140

708

707

330

312

031

W H601 P502 P503 901 081 085

R H301 H302 H401 H402 H501 H502

330

312

RB H129

This page illustrates the transmission is in neutral and key switch is in OFF position.

RL RGy H128 H138

303

705

708

015

N301 WV

910915

015

702

708

N401 N402 WR WP

N702 BW

N703 R

4 4

701 BW

P001

720

BW BG H735 H738 012

720

WG H740

M0 3

RL H710 6

DIODE UNIT N5

REAR COMBINATION LAMP (RH)

703

012

N601 N602 BW BG

708

N704 WG

705

702

708

217

705

R P002

P718 P728

YSb WP H133 M702

N701 RL

701

708

P601 P602 WR WP 1

1 703

1 700

WR WP H720 M002

LICENSE LAMP

RH BATTERY

WG N905

703

6 P707 P708 P717

303

R301 R201 2

R401 RL RGy

4 RL N906

015

P2 P1

900

W N303

085

W W N101 N101

221

N7 MAGNETIC S/W

900

700

1 BY GyL H120 H126

AIR HEATER R N502 3 701

217

R104

BACK UP ALARM

1 R501 RB

P741 P601 YSb WP

M7 ALTERNATOR

W N102

114

SbY H114

BW N501 702

GL GB GR

YR H111

N3 BATTERY RELAY

FUSIBLE LINK

70A

V BY H101 H120 114

720

N1 31

R103 RL

303

702

R N502

N2 M3

4 BG N903

012

N6 HEAER RELAY

30A

ELECT. FAN CONDENSER

BW N904

WATER LEVEL SENSOR

BW N501

FUSE BOX(ECM)

COMPRESSOR CLUTCH (ECc)

330

R502

SECONDARY STEERING MOTOR PUMP

114

AIR CLEANER

LgL L401

2 LgL R801 R803

70A

P0 STARTER

3 2

REAR WORKING LAMP

R501 +

T/M PRESS. SENSOR

312

RGy R102

1 1

REAR WORKING LAMP

Sb H717

312

RGy R102

CAN (RESISTOR)

150

B L802

LgL L401

ECM

RIDE CONTROL SOLENOID (OPT)

114

149

RW Y L803 L804

LP H208

751

GROUND SPEED SENSOR

114

182

140

L903 B

250

BOOM ANGLE SENSOR

LLg H207

L902 L901 RW Y

WAHSER MOTOR

24 25

GyR H721

13 14

500

SECONDARY STEERING OIL PRESS. SENSOR

W +

003

BrW K206

15 27

REAR COMBINATION LAMP (LH) R

Br K201

Br L

506

PB H115

23 12

PL H125

019

11 4

T/M OIL FILTER

1 6

RW Y H102 H112

143

B K104

70A

BUCKET LEVELER

OR H105

K803

162

170

182

LO H203

160

LgG H137

K802

WR H117

K801

327

1 B

LgL H135

327

303

6 B

K103

035

747

M9 1

161

GY H737

748

739

W H731

737

SbW PW SbLg H703 H723 H718

PG GyW H733 H724

731

GR YO YL N005 H716 H706

031

015

SbR H802

141

035

114

100

GR GY BrB N005 N001 H729

205

100

736

031

114

GyY Sb H734 H704

732

V BY H120 H101

407

1/4 R

BrW H719

031

214

409

YL YBr H712 H722

730

741

GB H730

YB YG H702 H732

BL GY GY BrR BL H713 H713 N001 N001 H739 741

405

6 YR H701

B 2

K106

405

182

RB RBr

406

GB H121 1

LgL L806

COMBINATION LAMP

P709 P710

331

741

209

YR BLg Sb SbW YB P749 P702 P725 J802 J801

28 OR

751

407

738

142

JPN/EXP: CONNECT EU: DISCONNECT

161

YV BrG P747 P744

748

RL S2H S2L S2S YL N906 P901 P902 P903 P726 703

409

BrW GyW PW YBr GyR P748 P713 P724 J804 P827

160

YO WR BrW SbLg Sb P705 P723 X201 P727 015

739

303

306

731

736

H129 H139 RB RG

914

012

267

181

912

214

P602 P738

901

BW GyY PG YG W N904 P703 P714 J805 P711

GL SbO Y GB BrB P720 P716 P743 X101 M902 W N101

146

GyB H131

BrY H107

114

910

159

331

R B

308

RW RY K108 K102

R N201

743

266 220

915

R N201

406

R N201

913

R N201

720

303

K9 GyO BY H116 H120

FRONT HEAD LAMP(OUTSIDE)

R N201

911

2 311

R N201

K105

RLg

X301 P301

L602 M202 M302

150

243

100 K202

WORKING LAMP (INSIDE)

100

LO J601

142

100

240

LG J501

141

6 LY J401

730

H129 H139 RB RG

GW K601

EFFICIENT LOADING SYSTEM (ELS) SOLENOID VALVE

HYD OIL LEVEL SWITCH

019

BY V W202 W201

251

RW OR SbY Br M801 M303 K201 L803

311

267

EFFICIENT LOADING SYSTEM (ELS) OIL PRESS. SENSOR

K107 GW

329

GW K702 K704

K7 HORN (H)

171

261

36 BG GY Y WG BrR N905 P706 N903 P721 M901 705

T/M SOLENOID VALVE

2 B

250

HYD OIL TEMP. SENSOR

B GW K601

BrW LgL GB K206 K204 L501

506

220

HORN (L)

181

K103 K101 R703 R603

250

170

266

330

327

221

325

261

PB SbY BrR Y YR M802 M203 K205 L804 P201

PL M803

180

114

003

250

251

GW GyL K107 M501

217

H109 H128 RO RL

100

RY WR GyO K102 X401 L701

182

325

308 329

306 327

303 311

325 306 327

H106 H129 H127 H108 RLg RB GW RW

RO K502

L802 H119 H118 H109 B RBr RY RO

308

114

LgL BrR BrW H122 H113 H123

261

RB RBr

325

BrW BrR LgL L102 L203 L401 251

YSb LgB GyB M001 P101 L603

162

330

35 LgL L806

312

329

R103 R602 R702

BY V Br H120 H101 H103

114

331

330

100

707

H119 H128 RBr RL

K105

306

003 311

WL RG RGy LgG M701 R102 M101

183

RLg

Br V BY L103 L201 L202

WORKING LAMP (INSIDE)

R605 R705 303 K106 R104 R604 R704

SbO H727

308

RW RY K108 K102

2 R B

FRONT HEAD LAMP(OUTSIDE)

K401 K901

K302 K002

329

K501 K801

K503

GW K601

K502

325

303

K101

K501

RBr K802

K303 K003

303

K106

311

RLg

JPN/EXP: CONNECT EU: DISCONNECT

COMBINATION LAMP

Electrical Wiring Diagram (3/3) (S/N 9251~)

N9 LH BATTERY

95ZV2-09709-09931 EU 3/3

K95V2E92009

92-16 95ZV-2 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

MCU

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

B10

B11

B12

B13

B14

B15

B16

B17

B18

B19

B20

B21

B22

B23

B24

B25

B26

E13

E14

E15

E16

E17

E18

E19

E20

E21

E22

E23

E24

E25

E27

E28

E29

E30

E31

E32

E33

E34

C701 E007 C902 K203 E801 T102 114 H724

100 C702 E803 E004 K202 T101 H708

C11

C12

C13

C14

C15

C16

C17

C18

C19

C20

C21

C22

C23

C24

C25

C27

C28

C29

C30

C31

C32

C33

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 G Y D203 D204 H743 H720 D107 005-C 005-D 161 160 010 V BR LgB L L B BY Y B E002 H751 D201 D202 H734 236 221 005-A 005-B 159

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

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

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

E12

Male connector S5

E11

LgR C703 166

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 BrB LgW LR L 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

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 1

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

Black (Female connector)

Female connector 115V2E92016

92-17 95ZV-2 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

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

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

36 BrR P743

Male connector

W PL GyY PG P701 P724 M803 P741

Y WY BrB BrY GyO P201 P744 M401 L701 M902

BrW GyW PW PB GyR P722 P711 P725 M802 P749

WR P739

OR SbY YV BrG BL P709 P702 P734 M801 P713

BL YO P734 P720

BLg Sb P723 P731 6

Y B

L D206

LgG H137

GyR Y P742 M901

S2H S2L S2S YL P901 P902 P903 P710 10

GO SbW S901 A712

Female connector

SbY SbY M303 M203 1

White (Male connector)

B 1

White (Male connector)

Black (Female connector)

90V2U92009

92-18 95ZV-2 Drawing & Diagrams Electrical wiring diagram abbreviation chart

Electrical wiring diagram abbreviation chart INSTRUMENT PANEL

INSTRUMENT PANEL

MCU

Radiator water level warning lamp

Parking brake lamp

A20

Auto brake lamp

Charge lamp

AUTO lamp

A21

Auto shift indicator lamp

Air cleaner clogging alarm

Auto brake lamp

A22

Fuel level lamp (1/2)

T/M oil temperature alarm

Meter (Speed/Tacho) +

A23

Fuel level lamp (E)

Engine water temperature alarm

Meter (Speed/Tacho) –

A24

S/S indicator lamp

B26

Communication TXD1

Engine oil pressure alarm

A25

Traction control selection

S/S solenoid valve R

Air cleaner clogging switch

Shift down switch

E/G coolant temperature switch (not used)

E/G speed sensor selection

Meter selection

—

E/G coolant temperature sensor (S/N 9001~9150) B25 E/G water temperature sensor (for inspection) (S/N 9151~)

Brake oil pressure alarm

Declutch lamp

A26

T/M oil filter warning lamp

Fan speed control solenoid valve

MCU error (failure alarm)

Preheating lamp

A27

Air cleaner warning lamp

Power supply +24 V

+24 V power supply

Work lamp

A28

Brake pressure warning lamp

Power supply +24 V

Efficient loading system oil pressure sensor

Parking switch

Auto/Manual selection

Specification change 1

Shift lever 2

Specification change 2

Shift lever R

Spare digital input

Shift lever 3

T/M oil temperature switch (not used)

Shift up switch

Secondary steering

Central alarm lamp

A29

Neutral indicator lamp

Power supply GND

—

D10

Shift lever 1

Reversal fan indication lamp

GND

GND (–)

A30

Traction control indicator lamp

Power supply GND

—

D11

Shift lever F

EG2

Engine warning lamp

—

A31

Fuel level lamp (1/4)

Power supply GND

C10

Spare digital input

D12

Shift lever A

EG1

Engine protection lamp

—

A32

Reversal fan indicator lamp

Power supply GND

C11

Hydraulic oil level switch

EG3

Engine stop lamp

High-beam lamp

A33

Fuel level lamp (3/4)

+5 V output

FR switch, S/S switch indication lamp

Turn signal (left) lamp

A34

E/G droop selection 2

E10

Tacho-graph E/G speed

WTM

Engine water temperature gauge (sensor)

Turn signal (right) lamp

H solenoid valve

E11

Power supply +24 V

C13

E12

Power supply +24 V

C14

TTM

T/M oil temperature gauge (sensor)

GND HM

— (+)

Instrument panel illumination

T/M oil filter clogging alarm — —

Fuel level lamp (F)

—

Reset switch (S/N 9001~9250)

D13

F34 change point selection (S/N 9151~)

Lower kickout set-up

D14

Downshift button

T/M oil filter clogging switch

D15

Declutch set up

New ECO mode selection (S/N 9251~)

—

Hour meter (–)

Pressure intensifying solenoid valve

E13

Communication CAN H1

C15

Radiator water level switch

D16

Odometer selection

Hour meter (+)

R solenoid valve

E14

E/G speed sensor 2 (not used)

C16

E/G oil pressure switch

D17

Shift hold switch

Modulation valve (SPCC)

E15

E/G ECM

C17

Fuel level F switch

D18

S/S shift selection switch S/S shift switch F

MCU A1

C12

Spare digital input (S/N 9001~9150)

Efficient loading system solenoid valve

Reversal fan solenoid valve

E16

Machine speed sensor

C18

Spare analog input

D19

S/S solenoid valve L

E17

Power supply

C19

T/M pressure sensor

D20

—

2nd speed solenoid valve

E/G idle selection

E18

Communication CAN L1

C20

Fuel level 1/2 switch

D21

Declutch switch

Secondary steering motor relay

Buzzer

E19

S/S potentiometer

C21

Fuel level 1/8 switch

D22

Kickout set up

3/4

Fuel level lamp (3/4)

Ride control solenoid valve

B10

Lower kickout relay

E20

Communication CAN L0

C22

Efficient loading system switch

D23

Traction control switch

1/2

Fuel level lamp (1/2)

3rd speed solenoid valve

B11

Lift kickout relay

E21

T/M oil temperature gauge

C23

E/G mode selection switch

D24

Armrest switch

1/4

Fuel level lamp (1/4)

Hour meter

B12

MCU fault relay

E22

Brake oil pressure sensor 2

C24

Pressure intensifying switch

EMP

Fuel level lamp (E)

T/C lock-up solenoid valve

B13

L solenoid valve

E23

Hydraulic oil temperature sensor

C25

Reversal fan (manual) switch

GND

GND (–)

4th speed indicator relay

B14

Auto brake solenoid valve

E24

Alternator

C26

Boom angle sensor

+ 24 V power supply

E/G torque selection

B15

E/G droop selection 1

E25

Communication RXD1

—

A10

Back-up lamp

B16

Communication RINI

E26

Tacho-graph machine speed

C27

Secondary steering oil pressure sensor

E27

Declutch sensor (brake oil pressure sensor)

C28

Fuel level 3/4 switch

C29

Fuel level 1/4 switch

—

A11

Fuel level lamp (F)

B17

—

A12

Steering oil pressure warning lamp

B18

—

A13

Radiator water level warning lamp

A14

Central warning lamp

B19

— Neutral relay Brake lamp (S/N ~9257)

E28

Spare analog input

Brake relay (S/N 9258~)

E29

Communication CAN H0

Neutral

–

GND (–)

A15

E/G coolant temperature warning lamp

B20

—

E30

Brake oil pressure sensor 1

1st speed indication

A16

T/M oil temperature warning lamp

B21

—

E31

T/M oil temperature sensor

2nd speed indication

A17

D solenoid valve

B22

E32

Air temperature probe

3rd speed indication

A18

1st speed solenoid valve

B23

4th speed indication

A19

E/G oil pressure warning lamp

B24

Communication DOUT1 — Meter output (Speed/Tacho)

E33 E34

— E/G coolant temperature gauge

C30

C31

Recall switch (S/N 9001~9250) New declutch selection (S/N 9251~) Lower kickout switch (S/N 9001~9150) Auto/Full auto selection (S/N 9151~)

C32

Spare digital input

C33

Ride control switch

C34

Auto fan reversal switch

Tire diameter selection (S/N 9001~9150) D25 F23 change point selection (S/N 9151~) D26

S/S shift switch R

92-19 95ZV-2 Drawing & Diagrams Electrical Wiring Diagram (CAB)

Electrical Wiring Diagram (CAB) Gy C101

P C102

Br B702

BrB B701

TURN LAMP

SPEAKER

WORKING LAMP (L) 1

RLg C302 B

10 SPEAKER (L)

WORKING LAMP (R)

WR B101

GB B115

WB B116

RLg C302

8 CIGAR LIGHTER

RY C103

DOOR SW

G C304

4 WIPER SWITCH (R)

RY C103

(OPT)

B 1

WIPER SWITCH (F) WHITE

GW B102

2 ROOM LAMP (OPT)

9 RADIO

BLACK

4 LY B606

(BLUE) PB 6 C307

OL PL 6 C310 C308

W YW L B901 B920 B605

Y OR B604 C309

S2L S2H B920 B901

B 1

O C301

No (FOR SPEAKER)

Y YW LY 6 B504 A801 A804 OR PB C309 C307

W 20 S2L B802 A802 C202 B502 S2H L B801 A803 C201 B503 1

INTERMITTENT WIPER RELAY

GB WB 16 B201 B301

L W B901 B920

S2S C203

GY A901 2

FRONT 5 WIPER MOTOR

R-

11 MODM

L-

GR OL A902 C310

REAR WIPER MOTOR M

CAN (RESISTER)

R+

RB GW WR C305 B202 B302

L+

B WBr G C303 C304

GR GY B401 B402

ACC+ B+

(BLUE)

ILL

OW C311

B 1

C301

B4 LW

10 SPEAKER (R)

RGy C306

REAR WORKING LAMP (OPT)

Br A401

BrB A402 1

DESCRIPTION

WORKING LAMP

ROOM LAMP

FRONT WIPER SWITCH

REAR WIPER SWITCH

FRONT WIPER MOTOR

INTERMITTENT WIPER RELAY

REAR WIPER MOTOR

CIGAR LIGHTER

RADIO

SPEAKER

MODM

CAN (RESISTOR)

Gy A301 1

C1 2 A302 P A203 3 A103 RY

C3 1

2 S2L S2H B920 B901

B602 B603 B404 12 A806 A906 B505 A905 C501 PB PL OR OL OW B113 A201 B907 A501 B103 A603 B112 A101 A702 RGy RB G WBr RLg O

S2S B803 6

(FOR TURN LAMP)(OPT)

CAN (RESISTOR)

1 V2CAB-09709-08343 EXP

TO FLOOR

K115V2E92004

92-20 95ZV-2 Drawing & Diagrams Electrical Wiring Diagram (CAB)

ROPS CAB S/N 0101~0161 Working lamp (front)

(A2) (A6)

(A3)

Room lamp

(A4) (A3) (A5) Wiper motor (rear) Speaker

(B3)

(B4) Cigar socket

Wiper S/W (rear)(A9) (A7)

(A1)

Wiper S/W (front)(A8)

Car radio

Speaker

(B2)

(C5)

(B1) Relay wiper intermittent Working lamp (rear) Wiper motor (front) (B6)

(B5) MODM Speaker (option) (B9)

(C2) (C3) CAN (B8)

(C1) To floor board

(C4)

K95V2E92026

92-21 95ZV-2 Drawing & Diagrams Electrical Wiring Diagram (CAB)

ROPS CAB S/N 0162~0196

ROPS CAB S/N 0197~

Working lamp (front)

(S/N 0169~) 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)

(A2) (B3)

(A6)

Room lamp

Speaker

Room lamp

(B3)

(A6)

(A2)

Speaker (B2)

Wiper motor (rear)

(B2)

Speaker (S/N ~0212)

(A1)

(B4)

(B4) Speaker Cigar socket

Cigar socket

Wiper S/W (rear)(A9) Wiper S/W (front)(A8)

(S/N 0169~)

Wiper S/W (rear)(A9)

(S/N ~0212)

Wiper S/W (front)(A8) (A7)

(A9)

(A7)

(A1)

MODM

(A8)

(A9) (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) 95ZV2 EU ROPS

K95V2E92031

92-22 95ZV-2 Drawing & Diagrams Electrical Connection Diagram (1/2) (S/N 9001~9250)

Electrical Connection Diagram (1/2) (S/N 9001~9250) STARTER S/W B

(L)

(005-B)

(L)

(005-A)

ACC’

BR ACC R1 R2

(005) L2

PREHEAT

TO PARKING S/W

30A

OFF ON

F10

(900) [W5]

12V

L x4 (005-A~005-D)

ACC’

12V

100

30A

E05

BATTERY

LBr (128) F N R

BATTERY RELAY

(013) (Lg)

23A

STARTER 70A

(014) G1.25

LR (126)

WV (700)

(063) 1.25 WR F13

F14

(064) G1.25 15A

F12

(062) BW

LW (120) LO (123) LG (122)

B C

LY (121)

[R5]x6 (910~915)

E17

E03 E04 E11 E12 B18 B12

(708) WP

(015)

E06

E24

MAGNETIC S/W 5 [R ] (701)

B11

D04

B10

(702) [BW5]

YO (232)

S/S SHIFT S/W F VOLTAGE

YW (233)

S/S SHIFT S/W R

A03 D05

B13

D03

B01

D10

(013) (Lg)

(705) (WG)

LB (230)

LG (122)

SHIFT UP S/W

LY (121)

(YL) (124)

DOWNSHIFT S/W

YSb (125)

SHIFT HOLD S/W

(005-a) ES (L)

LP (168)

DECLUTCH SET-UP

M2 M1

100

SECONDARY STEERING PUMP LIFT KICKOUT SECONDARY SET-UP STEERING PUMP LOWER KICKOUT SET-UP

PREHEAT LAMP (720) (BG) 15

(GW)(210)

SLIP CONTROL S/W

M M

BrG (255) BW (271)

(GB) (277)

PRESS. INC. S/W

Lg (222)

REVERSAL FAN S/W

ACC’

LgY (223)

(Y) (105)

RECALL S/W RESET S/W

(R) (106) LLg (165) GO (164) GyW (200)

TO PILOT LAMP

GL (265)

MACHINE

CAB 30

20A

10A

(013) (Lg) YO (176)

15A

10A

15A

20A

15A

10A

15A

10A

(GyW ) (260)

F13

DECLUTCH S/W ON

PARKING SOL (162) LgG

DECLUTCH

Gy (750) BrY (181) LgL (182)

PARKING S/W

YGy (242)

LOWER KICKOUT RELAY

EMERGENCY STEERING MOTOR RELAY COIL

YR (405) YB (406)

FUEL LEVEL 3/4

YL (407)

FUEL LEVEL 1/2

YBr (408)

FUEL LEVEL 1/4

R SOLENOID VALVE

(141) LY

Sb (184)

RADIATOR WATER LEVEL S/W FUEL LEVEL F

H SOLENOID VALVE

(148) LBR

SbO (183)

T/M OIL FILTER S/W

F SOLENOID VALVE

(147) LB

YG (409)

FUEL LEVEL 1/8

1ST SPEED SOLENOID VALVE

(142) LG

2nd SPEED SOLENOID VALVE

(LO)

D07

(144) LW

A08

D17 D15 D23 D22 C13

A17 B14 A07 A04 A01 B03

C24 C25 C34

C30 C12

B05

B07

D21 D01

4th INDICATOR RELAY

LP (149)

D SOLENOID VALVE BRAKE SOLENOID VALVE

LLg (140)

LU SOLENOID VALVE RIDE CONTROL SOLENOID VALVE

LgL (261) GB (267)

EFFICIENT LOADING SYSTEM SELECTION SOLENOID VALVE

GB (278)

PRESS. INC. SOLENOID VALVE

LgL (225)

REVERSAL FAN SOLENOID VALVE

(150) LgR

E02

(226) LgB

G (234)

A29 C16 C11

A14 A28 A19

C06

A15

A27

(LgR) (130) (GR ) (135) (GyB ) (103) (LbY) (173) (GY) (749) (GyG) (753) (GyL) (190) (LgW) (192) (O ) (241)

C29

A24

C21

A11

A22

E09(+5V)

A23

(SbO) (193) (Sb)

T/M OIL FILTER WARNING LAMP RADIATOR COOLANT LEVEL WARNING LAMP AUTO BRAKE INDICATOR LAMP

(194)

(GY) (169) (OSb) (211) (RL)

SLIP CONTROL INDICATOR LAMP

(235)

REVERSAL FAN INDICATOR LAMP

(LgB) (224)

S/S INDICATOR LAMP

(YR) (410) (YB)

(411)

(YL)

(412)

(YBr)

(413)

FUEL LEVEL F FUEL LEVEL 3/4 FUEL LEVEL 1/2 FUEL LEVEL 1/4 FUEL LEVEL E

(YG) (414)

E19 B09

LgBr (104)

BUZZER

C26 E34

E27

E21

SbY (172) E22

B24

T/M PRESS. SENSOR

(YB) (401)

E/G COOLANT TEMP. GAUGE

(BrW) (402)

T/M OIL TEMP. GAUGE

(400) (WL)

METER OUTPUT (TACHOMETER)

YGy (151) C19

EFFICIENT LOADING SYSTEM OIL PRESS. SENSOR

GyB (266)

EMERGENCY STEERING PRESS. SENSOR

SbR (240) GyG (754)

E/G COOLANT TEMP. SENSOR

GyL (180)

T/M OIL TEMP. SENSOR

(G) (415)

OUTSIDE AIR TEMP. SENSOR

GyO (220)

HYD. OIL TEMP. SENSOR

E10

C01

C27 B25

E26

Y (160)

ECM(11)

W (161) Y (159)

(420) OSb (+)

(−)

(421) OB (+)

(−)

TACHOGRAPH E/G SPEED

TACHOGRAPH GROUND SPEED

(S/N ~9150)

E31

A06

E32 B08 E23 A09

S/S SOLENOID VALVE L (221) LgB

E07

B15

E16

A34

E15

A25

E08 A10

FAN SPEED CONTROL SOLENOID VALVE

B19 F13

A21

A32

SbY (171) E30

E/G SPEED SENSOR

C23

C33

BRAKE OIL PRESS. SENSOR 1 BRAKE OIL PRESS. SENSOR 2

S/S SOLENOID VALVE R

C22

C20

DECLUTCH SENSOR

GROUND SPEED SENSOR

A20 A30

C28

A31

BY (114)

(236) BR (237) BL

C17

A13

S/S POTENTIOMETER

T/M CONTROL SOLENOID VALVE

1A E01

A26

A33

(LgR) (166)

WR (170)

(154) LgR

C15

BrR (251)

3rd SPEED SOLENOID VALVE

(LW)

D14

C14

BOOM ANGLE SENSOR

4S (132)(LG)

(143) LO

D06

A12 (005-b) (L)

LIFT KICKOUT RELAY

(146) LR

(LG) D24

A16 E

OFF

ECM

E/G OIL PRESS S/W

AIR CLEANER CLOGGING S/W

(163) (SbW)

OFF ON

HYD. OIL LEVEL S/W

(LgY) (167)

MCU FAILURE RELAY

D18

B06

AIR HEATER

(012) BW HEATER RELAY

A02

C31 (S/N ~9150)

LOWER KICKOUT S/W

AUTO FAN REVERSAL S/W

(273)

NEUTRAL RELAY

V (100)

SHIFT DOWN S/W

ALTERNATOR

A18

A05

(707) WL1.25

YV (231)

S/S SHIFT SELECTION S/W ARMREST S/W

70A

(LY )

(707) WL

CHARGE LAMP

BrB (258)

D26

F13

LgW (101)

OPT

D12

D19

(SbP) (145)

B04

WG (705) RELAY

RL1.25 (703)

D11

MCU

(065) F15 WR1.25

R1 BR B AC R2 C

WL (707)

ECM (38)

SHIFT LEVER

(060) (901) 5 W [W ]

MCU

(081) (085) W W

(012) BW

G (010)

START

YSb (403) SbR

(208)

SbP

(202)

SbW (203) SbLg (204) (GW) (212)

(LB ) (138) (RG) (331)

HOUR METER DRIVE E/G IDLE SELECTION

E/G TORQUE SELECTION

TC ECM(41)

E/G DROOP SELECTION 1

ECM(23)

E/G DROOP SELECTION 2 SLIP CONTROL SELECTION

TO BACK-UP LAMP TO BRAKE LAMP

(013) (Lg)

(100) V

(E09) E P (107)

SPECIFICATION SWITCH 1 SPECIFICATION SWITCH 2

PL (108) PW (111)

AUTO/FULL AUTO SELECTION

(S/N 9151~)

PG (109)

A/M SELECTION

VG (157)

F23 CHANGE POINT SELECTION F34 CHANGE POINT SELECTION

VY (158) PB (110)

ODOMETER SELECTION SPEED SENSOR SELECTION METER SELECTION

C02 C03

(OUT_FEW)B23 (OUT_RES)E33 (RXD0)E25 (TXD0)B26 (OUT_MD2)B17

YB YG YL YO YBr

(115) (116) (117) (118) (119)

C31

D16 D08

MCU PROGRAM REWRITE

D02 (RIN1)B16

GL (810)

(DOUT1)B22

GR (811)

D25 D13

(S/N 9151~) +5V FEW RESET RXD TXD MD2 GND

RS232C

(CANH0)E29

S2H

(CANL0)E20

S2L

D09

CAN

S2S

SPARE

15A

30A

10A

15A

10A

7.5

10A

7.5

15A

7.5

20A

10A

FUEL EFFICIENT MODE S/W

MAIN MCU EFFICIENT LOADING SYSTEM S/W

This page illustrates the transmission is in neutral and key switch is in OFF position.

RIDE CONTROL S/W X

MCU FAILURE

(LgW) (102)

(LgSb) (112)

WARNING BUZZER

95ZV2-09708-06160 EU 1/2

K95V2E92012

92-23 95ZV-2 Drawing & Diagrams Electrical Connection Diagram (2/2) (S/N 9001~9250)

Electrical Connection Diagram (2/2) (S/N 9001~9250) ACC'

ACC'

1.25

R (001)

RB (301)

Br (003)

BrW (250)

10A

EL RY (302)

BrB

(257)

BrR

(272)

(035) GR

F35

(015) WR

BS F15

MACHINE WIDTH LAMP

RB (303)

OY (007)

10A

LICENSE LAMP

AIR-SUS COMPRESSER

ACC'

WARNING

OR (019)

10A

(161) W

COMBINATION S/W

YV (734) BLg (735)

GyY (736)

(307) (RY)

HIGH BEAM PL

(306) RY

RIGHT HEADLIGHT (H)

(GW)

(P)

E 48 47

(751) GyR

E/G OIL PRESS.

DEC (741) BL

F16

FRONT WORKING LIGHT

OG (016)

TC E

FRONT WORKING LIGHT

R (002) RGy (312)

REAR WORKING LIGHT

TO FRONT WORKING LIGHT

(521) RLg

TO REAR WORKING LIGHT

(520) RGy

TO REAR CAB RGy (520) WORKING LIGHT RL (330)

CAB WORKING LIGHT

(A34)

ROOM LAMP

G(010)

F10

BACK-UP LAMP

(B15)

CAB REAR WORKING LIGHT CAB REAR WORKING LIGHT

REAR WORKING LIGHT

LB (138)

CAB WORKING LIGHT

(PL) (BR) (BrW ) (WY )

A/M SERVO MOTOR

(WR)

MAM

(OL) (GO )

RIGHT VENT SELECTION SERVO MOTOR

(SB )

MV1

(Y )

OUTSIDE AIR SENSOR(THAM)

11 34 35

(PL) (BrR)

SbL (204)

(GL ) (213) (GB ) (214)

MV2

(WP ) (VW )

CAN

S2S

ACM B

37 36

S2H

(060) W

MV3

(BG ) (PB )

INSIDE/OUTSIDE AIR SELECTION SERVO MOTOR

(V )

MRF

(LgR ) (BL ) SP CD (LGW )

S2L

F29

S2S

20A

(Y0 ) (748)

F27

F28

DATA LINK CONNECTOR

10A

RY2

(YL ) (747)

RY1.25

DEF SELECTION SERVO MOTOR

(YB )

LEFT VENT SELECTION SERVO MOTOR

(BrB )

SP HL

S2L

Sb (205)

S2H

SbY (209)

(LgY )

SbW (203)

(WG )

WATER TEMP. SENSOR(THW)

WORKING LIGHT PL

1.25

TO MCU

PG (739) PW (740)

WIPER S/W

TO CAB RLg (521) WORKING LIGHT

15A

REAR WORKING LIGHT S/W

B S1 S2 WASH

(BY )

RESISTOR

INC/DEC S/W INC (m)

R WIPER GR (508)

RLg (311)

FRONT WORKING LIGHT S/W

M (507) GY

WASHER MOTOR (506)

BLOW-OFF THERMISTOR(THF)

DIAGNOSTIC S/W

LEFT HEADLIGHT (L)

(310) (RGy)

15A

OL (018)

(746) BO

INSOLATION(SS) SENSOR BrG (738)

RIGHT HEADLIGHT (L)

(308) RW RG (006)

GyW (737)

IDLE

WIPER MOTOR

F18

LEFT HEADLIGHT (H)

LW (505)

(305) UL RY

1.25

WASHER MOTOR (500)

(BR)

(304) RW

(RB)

BrW (733)

OFF IDLE

5 3 INTER2 MITTENT 6 WIPER 4 RELAY

(BrY)

NIGHT ILLUMINATION

(745) BO

IDLE S/W

3 27

INSIDE AIR SENSOR (THI)

F WIPER

(504) LY

TO RADIO AIRCON

(E15)

THROTTLE PEDAL

L (503) (501)Y WIPER S/W (502)W S2 S3 B WASH Sint S1

(LO )

5 GY (743)

WIPER MONITOR

F19

F26 (RL)

(732) MAINTENANCE (BrW)

INSTRUMENT PANEL LIGHTING

ACC' F13

ACC'

(013) (LG)

STOP

REMOTE THROTTLE

THROTTLE OPENING SENSOR

(RB) (300)

(731) (BrB)

2 38

TAIL LAMP TAIL LAMP

(730) (BrR)

FLOAT

FOR OPT LAMP

17 (085) W

10A

FOR OPT LAMP

7 8

BOOM KICKOUT

(031) GY

F31 10A

20A LH

(081) W

BUCKET LEVELER

AIRCON UNIT

COMBINATION S/W

RY1.25 RG

BLOWER MOTOR

1 BLC

G1.25

ECC

COMPRESSOR CLUTCH

EC 1.25

RB CD

1.25

MCD

1.25

RCD

CONDENSER MOTOR CH

ACC'

43 20

ECM

(A10)

BACK-UP LAMP

F20

O (020)

CIGARETTE LIGHTER

10A

BACK-UP ALARM RG (331)

TO MCU

MODM KEY

RIGHT BRAKE LAMP

GND

(B19) S2H

LEFT BRAKE LAMP F4

(004) R

CANH0 CANL0

S2L

CAN

S2S

15A

ACC'

B E L

FLASHER UNIT (WINKER)

(324) (RO)

B F10 W (060)

15A

RIGHT TURN SIGNAL PL

(320) P COMBINATION (325) S/W (321) RO RO TR (322) TB RBr TL (010) G (327) RBR

B E L

FLASHER UNIT (HAZARD)

CAB ACC'

RIGHT FRONT TURN SIGNAL RIGHT REAR TURN SIGNAL

CONVERTER ACC'

24V F22

LEFT FRONT TURN SIGNAL

(WBr) (022)

12V

CAB

(WBr) (022) OW (017)

LEFT REAR TURN SIGNAL LEFT TURN SIGNAL PL

(326) (RBR)

F10 ACC'

(323)BP (329) GW

HORN

(328) (GL)

HORN RELAY

RESISTOR

(010) G

This page illustrates the transmission is in neutral and key switch is in OFF position.

HORN S/W

TO RADIO/ROOM LAMP TO MCU (E17) E

95ZV2-09708-05672 EU 2/2 95V2E92025

92-24 95ZV-2 Drawing & Diagrams Electrical Connection Diagram (1/2) (S/N 9251~)

Electrical Connection Diagram (1/2) (S/N 9251~) STARTER S/W B BR ACC R1 R2 C

ACC’

PREHEAT OFF ON START

(005) L2

(L)

(005-b)

(L)

(005-a)

E04

E12

TO PARKING S/W

30A

(900) [W5]

(081) (085) W W

12V

G (010)

F10

E ACC’

12V

Lx4(005-A~005-D)

100

30A

E05

R1 BR B AC R2 C

WL (707)

ECM(38) (065) WR1.25 F15 5A

E24

E11 B18 B12

(708) WP

(015) WR

E17 E03

BATTERY (060) (901) W [W5]

E06

LR (126) LBr (128)

WV (700)

F N R

D11

B11

D04

B10

(SbP) (145) LgW (101) BrB

(258)

(273)

NEUTRAL RELAY

MCU FAILURE RELAY

LIFT KICKOUT RELAY LOWER KICKOUT RELAY

A15

(012) BW

SHIFT LEVER

BATTERY RELAY 1

STARTER

(013) (Lg)

2 3 A

LW (120) LO (123)

70A

(014) G1.25

(063) WR1.25 5A

F14

F12

15A

(064) G1.25

F13

(062) BW

OPT

LG (122)

100

[R5]x6 (910~915)

LY (121)

[R5]

VOLTAGE RELAY

[BW5]

(701)

WG (705)

RL1.25 (703)

A03 B13 D12 D05 D03

B01 B04

D10 A18

MAGNETIC (702) S/W

F/R S/W

YO (232) YW (233)

SbO (183)

T/M OIL FILTER S/W YGy (242)

SECONDARY STEERING MOTOR RELAY COIL

(146) LR (147) LB (148) LBr

FUEL LEVEL F

H SOLENOID VALVE

FUEL LEVEL 3/4

R SOLENOID VALVE

(141) LY

1ST SPEED SOLENOID VALVE

Sb (184)

RADIATOR WATER LEVEL S/W

F SOLENOID VALVE

YR (405) YB (406) YL (407)

FUEL LEVEL 1/2

YBr (408)

FUEL LEVEL 1/4

YG (409)

FUEL LEVEL 1/8 D19 D26

(013) (Lg)

F13

(705) (WG)

(707) WL

CHARGE LAMP

S/S SHIFT SELECTION S/W I

A02

(142) LG

YV (231) LB (230)

(YL) (124)

DOWNSHIFT BUTTON PREHEAT LAMP

YSb (125)

SHIFT HOLD S/W (720) (BG)

(012) BW

HEATER RELAY

(005-a) (L)

SECONDARY STEERING PUMP SECONDARY STEERING PUMP

M M2

M B

ACC’

TO PILOT LAMP, BACK-UP LAMP

MACHINE 15 14 13

5A 5A

30 29 28

10A

11 10A

10 15A

20A

10A

15A

DECLUTCH

15A

10A

BW (271)

(GB) (277)

REVERSAL FAN S/W

Lg (222)

AUTO FAN REVERSAL S/W

LgY (223)

NEW DECLUTCH SELECTION NEW ECO: connection OLD ECO: opening

(R) (106)

GO (164) GyW (200)

(013) (Lg)

GL (265) (GyW) (260)

HYD. OIL LEVEL S/W

(163) (SbW)

OFF ON

AIR CLEANER CLOGGING S/W (005-b) (L)

PARKING S/W

ECM

15A

30A

10A

15A

10A

7.5

10A

7.5

15A

7.5

20A

10A

SPARE

E/G OIL PRESS S/W

DECLUTCH

DECLUTCH S/W

PARKING SOL. (162) LgG

D14 D17

FUEL EFFICIENT MODE S/W H

Gy (750) BrY (181) LgL (182)

A08

A17 B14

D23

A04

D22

A01

C13

B03 B06

B05

(100)

4TH INDICATOR RELAY

D SOLENOID VALVE

WR (170)

BRAKE SOLENOID VALVE LU SOLENOID VALVE

LgL (261)

RIDE CONTROL SOLENOID VALVE

GB (267)

EFFICIENT LOADING SYSTEM SELECTION SOLENOID VALVE

GB (278)

PRESSURE INTENSIFYING SOLENOID VALVE

LgL (225)

REVERSAL FAN SOLENOID VALVE (150) LgR

(154) LgR

(LgR) (166)

C20 A30

C29

A32

C21

A11

E09(+5V)

A22

E19

BRAKE OIL PRESS. SENSOR 2

E01

B07

A25

E34

YGy (151) C19 E21

EFFICIENT LOADING SYSTEM OIL PRESS. SENSOR

GyB (266)

SECONDARY STEERING PRESS. SENSOR

SbR (240)

C01 B24

GyG (754)

E/G COOLANT TEMP. SENSOR

GyL (180)

T/M OIL TEMP. SENSOR

(G) (415)

OUTSIDE AIR TEMP. SENSOR

GyO (220) BY (114) Y

MACHINE SPEED SENSOR S/S SOLENOID VALVE R 1A

E/G SPEED SENSOR

ECM(11)

(160)

W (161) Y

S/S SOLENOID VALVE L

(226) LgB

(159)

A06

B25 E31

B08

E32

A09

E23

B15 A34

E07 E16

1A F13 A21 A29 A14 A28

(LgR) (130) (GR) (135) (GyB) (103) (LgY) (173) (Gy)

(749)

(Sb)

(194)

(GY) (169)

AUTO BRAKE INDICATOR LAMP

(OSb) (211)

TRACTION CONTROL INDICATOR LAMP

(RL) (235)

REVERSAL FAN INDICATOR LAMP

(LgB) (224)

S/S INDICATOR LAMP

(YR) (410)

FUEL LEVEL F FUEL LEVEL 3/4 FUEL LEVEL 1/2

(YB) (411) (YL)

(412)

(YBr) (413)

FUEL LEVEL 1/4 FUEL LEVEL E

(YG) (414) LgBr (104) (GW) (212)

BUZZER RELAY

TRACTION CONTROL SELECTION

(YB) (401)

E/G COOLANT TEMP. GAUGE

(BrW) (402)

T/M OIL TEMP. GAUGE

(400) (WL)

METER OUTPUT (TACHOMETER)

A10

YSb

(403)

SbR (208) SbP

(202)

SbW (203) SbLg (204)

(LB)

(138)

(331)

(245)

HOUR METER DRIVE E/G IDLE SELECTION

B19

ECM(25/41) ECM(23)

TO BRAKE LAMP BR

(S/N (S/N ~9257) ~5368) (S/N 9258~) 5369~) BRAKE RELAY

E (100) V

(E09)

AUTO SHIFT INDICATOR LAMP

NEUTRAL INDICATOR LAMP

E/G OIL PRESS. WARNING LAMP

TO BACK-UP LAMP RELAY

E08

(013) (Lg)

CENTRAL WARNING LAMP BRAKE OIL PRESS. WARNING LAMP

E/G TORQUE SELECTION E/G DROOP SELECTION 1 (NEW ECO/OLD ECO) E/G DROOP SELECTION 2

FAN SPEED CONTROL SOLENOID VALVE

C33 C16

(241)

E15

B19 (221) LgB

(O)

(SbO) (193)

C27

E02

E/G COOLANT TEMP. WARNING LAMP T/M OIL TEMP. WARNING LAMP AIR CLEANER WARNING LAMP STEERING OIL PRESS. WARNING LAMP T/M OIL FILTER WARNING LAMP RADIATOR COOLANT LEVEL WARNING LAMP

(GyL) (190) (LgW) (192)

T/M PRESS. S/W

HYD. OIL TEMP. SENSOR

(237) BL

B09

(GyG) (753)

E27

SbY (172) E22

SPPC SOLENOID VALVE

(236) BR

A23

C26

SbY (171) E30

C23

C06

DECLUTCH SENSOR BRAKE OIL PRESS. SENSOR 1

LLg (140)

D01

C11

A20

A31 BrR (251)

LP (149)

C12

C22

(234)

3RD SPEED SOLENOID VALVE

(144) LW

C34

A19 F5

(143) LO

C24

D21

A13

C28

A33

S/S POTENTIOMETER

(LW)

A07

C25

A26

BOOM ANGLE SENSOR

D15

C30

NEW ECO MODE SELECTION

(LgY) (167)

OFF

BrG (255)

YO (176)

20A

LIFT KICKOUT SET-UP LOWER KICKOUT SET-UP

F13

20A

12 15A

(GW) (210)

LLg (165)

CAB

TRACTION CONTROL S/W

PRESSURE INTENSIFYING S/W

A05

D24

100

LP (168)

DECLUTCH SET-UP

AIR HEATER 15

D18

A12

C17

A24

2ND SPEED SOLENOID VALVE

4S (132)(LG)

(LG)

D06 D07

C15

(LO)

ARMREST S/W

ALTERNATOR

LY (121)

SHIFT DOWN S/W

(707) WL1.25 R

70A

SHIFT UP S/W

A27

(LY)

NR LG (122)

A16

C14

SPECIFICATION SWITCH 1

C02

SPECIFICATION SWITCH 2 AUTO/FULL AUTO SELECTION

C03 PW (111) PG (109)

A/M SELECTION F23 CHANGE POINT SELECTION

VG (157) VY (158)

F34 CHANGE POINT SELECTION ODMETER SELECTION SPEED SENSOR SELECTION

PB (110)

YB YG YL YO YBr

(RIN1)B16

D13

(DOUT1)B22

D16

+5V FEW RESET RXD TXD MD2 GND

MCU PROGRAM REWRITE

D25

GL (810)

S2H S2L S2S

(CANH0)E29 (CANL0)E20

MAIN MCU

RS232C

GR (811)

D09

(115) (116) (117) (118) (119)

C31 D02

D08

METER SELECTION

(OUT_FEW)B23 (OUT_RES)E33 (RXD0)E25 (TXD0)B26 (OUT_MD2)B17

CAN

EFFICIENT LOADING SYSTEM S/W

Option in

RIDE CONTROL S/W X

MCU FAILURE WARNING BUZZER

(LgW)

(102)

(LgSb)

(112)

(FM) E

95ZV2-09708-06532A USA 1/2

K95V2U92011

92-25 95ZV-2 Drawing & Diagrams Electrical Connection Diagram (2/2) (S/N 9251~)

Electrical Connection Diagram (2/2) (S/N 9251~) E (001) R1.25

ACC’

COMBINATION S/W

20A LH UL

RB (301) RY (302) RW (304)

E Br

(003)

BrB

(257)

BOOM KICKOUT

10A

(081) W

17 (085) W

HU BrR

(272)

(035) GR

F35 10A

FLOAT

EL HL

(031) GY

F31 10A

(730) (BrR)

STOP

(731) (BrB)

WARNING

ACC’

(013) (Lg)

F13 F26

(015) WR

F15

(732) MAINTENANCE (BrW)

(161) W

(E15)

NIGHT ILLUMINATION

LT BrW (250)

BUCKET LEVELER

FOR OPT LAMP

REMOTE THROTTLE

5 GY (743)

FOR OPT LAMP

7 6 19

MACHINE WIDTH LAMP

RB (303)

BrW (733) YV (734) BLg (735)

TAIL LAMP F7

OY (007)

AIR-SUS COMPRESSER

10A

INSTRUMENT PANEL LIGHTING

(RB) (300)

GyY (736)

IDLE

(020)

(613) (GW)

S2H S2L S2S

CAN

E 48 47

(751) GyR

(305) UL RY

(306) RY

RIGHT HEADLIGHT (H)

(006) RG1.25

15A

RLg (311)

CAB WORKING LIGHT

RGy (312)

CAB REAR WORKING LIGHT CAB REAR WORKING LIGHT

RGy (520)

(Lg) (013)

WIPER MOTOR

F19

REAR WORKING LIGHT

OR (019)

10A RGy (520)

(501) Y (502)W

TO REAR CAB WORKING LIGHT

RL (330)

BACK-UP LAMP

RIGHT BRAKE LAMP

(S/N 9258~) (S/N 5369~)

(616) (Y)

OUTSIDE AIR SENSOR (THAM)

(617) (PL) (618) (BrR)

40 13

FLASHER UNIT (HAZARD)

36 14

SbY (209)

Sb (205)

34 35

SbW (218)

SbW (203)

YSb (217)

(A34)

SbLg (204)

(GL) (213)

(WP) (628) (VW) (629)

RESISTOR

1 23

CAN

S2S

ACM

B (060)

37 36

S2H S2L S2S (747)

(Y0)

(748)

F29

20A

41 23

F27

DATA LINK CONNECTOR

(029) R2

(637) RY2

(027) RG

(641) YR

(PB) (632)

INSIDE/OUTSIDE AIR SELECTION SERVO MOTOR

(V) (633)

MRF

(LgR) (634) (BL) (635) SPCD (636) (LgW)

F28

M RY1.25 (637)

BLOWER MOTOR

1 BLC

G1.25 (640)

ECC

COMPRESSOR CLUTCH

EC (028)

10A

G A

MV3

(BG) (631)

(637) RY1.25

(YL)

DEF SELECTION SERVO MOTOR

(YB) (630)

SPHL

SbW (203)

MV2

3 16

LEFT VENT SELECTION SERVO MOTOR

(BrB) (627)

S2H

(LgY) (626)

(642)

1.25

RW CD

MCD

(643) 1.25

RCD

CONDENSER MOTOR

ACC’

43 20

R WIPER GR (508)

B S1 S2 WASH

WIPER S/W RIGHT TURN SIGNAL PL

F22

RIGHT FRONT TURN SIGNAL

RIGHT REAR TURN SIGNAL

(WBr) (022)

RADIO RELAY

CIGAR SOCKET RELAY

ACC’

LEFT FRONT TURN SIGNAL

(327) RBr

(010) G

MV1

(WG) (625)

Option in

FLASHER UNIT (WINKER)

(320) COMBINATION (325) P RO S/W (321) RO TR (322) TB RBr TL F10

RIGHT VENT SELECTION SERVO MOTOR

(Sb) (624)

(507) GY

WASHER MOTOR (506)

(324) (RO)

15A

(OL) (622) (GO) (623)

YW (505) 5

OL (018)

15A

(060) W

MAM

WIPER MOTOR

F18

LEFT BRAKE LAMP

OLD ECO (B15)

A/M SERVO MOTOR

ECM

WIPER S/W

INTER2 MITTENT 6 WIPER 4 RELAY

(B19)

WASHER MOTOR (500)

BACK-UP ALARM (331) RG

TO MCU

B E L

NEW ECO (B15)

(WY) (620) (WR) (621)

F WIPER

L (503)

(504) LY

BACK-UP LAMP

(S/N ~9257) (S/N ~5368)

(BrW) (619)

S2 S3 WASH B Sint S1

ACC’

(GB) (214)

REAR WORKING LIGHT

REAR WORKING LIGHT S/W

(004) F4 R

15A

F13

ROOM LAMP

RLg (521) TO CAB WORKING LIGHT

(002) R1.25

(615)(BY)

(741) BL

RLg (521)

TO REAR WORKING LIGHT

FRONT WORKING LIGHT

PW (740)

DEC

CAB WORKING LIGHT

FRONT WORKING LIGHT

FRONT WORKING LIGHT S/W F2

TO FRONT WORKING LIGHT

WORKING LIGHT PL

PG (739)

(m)

G (010)

F10

LEFT HEADLIGHT (L)

(310) (RGy)

(PL) (617) (BR) (612)

WATER TEMP. SENSOR (THW)

S2L

INC/DEC S/W INC

RESISTOR

RIGHT HEADLIGHT (L)

(308) RW F6

BrG (738)

LEFT HEADLIGHT (H)

BLOW-OFF THERMISTOR (THF) E/G OIL PRESS.

GND

CANH0 CANL0

DIAGNOSTIC S/W

MODM KEY

2 21

INSOLATION SENSOR (SS)

TO AIRCON

HIGH BEAM PL

(614) (P)

10A

(307) (RY)

(300) (RB)

(746) BO

IDLE S/W OFF IDLE

GyW (737) F20

3 27

INSIDE AIR SENSOR (THI)

THROTTLE OPENING SENSOR

TAIL LAMP

(611) (BrY)

(612) (BR)

(610) (LO)

(745) BO

THROTTLE PEDAL MACHINE WIDTH LAMP

(026)

LICENSE LAMP

(RL)

AIRCON UNIT

ACC’

LEFT REAR TURN SIGNAL LEFT TURN SIGNAL PL

(326) (RBr)

B (060) W2

DC-DC CONVERTER (531) + 15A

B E L

I N

O U T

HORN

B7 A8 B8

(510) Gy (511) GyB

RADIO

A7 P1.25 (514)

(323) BP

(329) GW

B1 B2

(532) W2

(512) WR (513) WB

CIGARETTE SOCKET (12V)

(328) (GL)

HORN RELAY

HORN S/W

TO RADIO/ROOM LAMP TO MCU (E17)

E CAB E

(FM)

95ZV2-09708-06532A USA 2/2

K95V2U92012

92-26 95ZV-2 Drawing & Diagrams Electrical Wiring Diagram (Cabin Air Conditioner)

Electrical Wiring Diagram (Cabin Air Conditioner) Control panel

Illumination power supply

24V(BR')

Fuse box 26

F26

RB A401 RL B408

RG B409

RB B417

R B418

Outside air sensor (THAM)

Condenser relay (MB)

Compressor clutch relay (RLEC)

Condenser HI relay (RLCH)

RB BrY B417 B307

RG BrY B409 B307

Y B B415 B410

RW RL B416 B408

YR RL B407 B408

5A YB LgY VW A403 A604 A605

B BR A501 A509

BrR Y BY P GW WP WG OL A102 A611 A609 A606 A608 A506 A502 A503

BG RL RB LgR PL BrW A612 A401 A507 A101 A504 A505 A508

BL A510

Sb GO PB V WY WR LO BrY BrB A402 A404 A405 A603 A602 A601 A406 A607 A610

F27 5A F28

10A

F29

Insolation sensor (SS)

BR Y A509 A611

20A

B LgW B410 D104 1

(Black)

A4 1

Sb GO WR B304 B303 B302

RB LgY BrB A220 A210 A305

RB BrB LgY A801 B312 B311

WP BL BR PL LgR A308 A211 A303 A304 A311

PB V P VW YB WY A313 A218 A219 A207 A206 A205

WY V PB YB VW P B320 B319 B318 B317 B316 B314 1

Y R RB RW A704 A703 B101 B102

LO GW BY BrY Y RL B310 B309 B308 B307 A901 B315

Sb GO WR WP A404 A405 A406 A506

BrY BY GW LO B503 C601 C501 C903 B603 LgY BrB LgR P RL VW YB PB V WY C107 C106 D103 D201 C901 C203 C202 C407 C406 B807

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

WP WR GO Sb C201 B806 B907 B906

WY V PB YB VW RL P LgR BrB LgY A601 A602 A603 A604 A605 A612 A606 A507 A402 A403

Floor harness

Y BrY BY GW LO RL A306 A315 A202 A314 A312 A203

1 LO GW BY BrY A607 A608 A609 A610

WP LgR PL BR BL B301 B313 B406 A902 B411 B402 B WG OL BrW BG B401 B405 B404 B403 B412

BG BrW B OL WG A301 A302 A309 A310 A212 5

10 3

B D101 1

BL BG C702 C405

Y RW RB R B704 B502 B504 C904

B801 B901 C103 C205

B702 B703 C701

BrW OL WG B805 B905 C105

C403 C502 C602 D202

YR B602

B803 B903 C101 C204 C401

RG B604

Def selection servo motor (MV3) 9

B501 B601 D102

Air mixing servo motor (MAM)

Vent selection servo motor (MV1)

Front vent selection servo motor (MV2)

Inside/outside air selection servo motor (MRF) 7

WP VW YB C203 C202 C201

Connector between floor and rear

BR C205

PL C204

C3 3

Rear harness

C307 C306 C305 VW YB WP

Electric blower condenser

1 1 3

B B410

WY WR BrW B320 B302 B403

PL B406

RW B416

BR B402

GO Sb OL B303 B304 B404 1

PL B406

LgY BrB WG B311 B312 B405

BR B402

PB V BG B318 B319 B412

VW YB WP B316 B317 B301

BR PL B402 B406

PL B406

C303 C301 BR PL

Y B415

BR B402

PL B406

High/low pressure SW SP HL

Inside air sensor (THI)

Compressor clutch (ECC)

Blower main relay (RLBM)

BLC

Water temperature sensor (THW)

Blow-off thermistor (THF)

Blower motor (MB)

SP CD 4

1 4

3 2

RY BL G B C801 C802 B411 B410

WR GO Sb A204 A208 A209

YR B407

BrR PL A316 A303

C7 BR GW B402 B309

BR BY B402 B308 1

RL B408 B B401

2 G C704 D302

LgW B701

RY RL D301 B315

RY C703 1

LgR B313

R LO B418 B310

G C801

BR B402

RY C902

P B314 1

95ZVE72020

92-27 95ZV-2 Drawing & Diagrams Electrical Circuit Diagram (Cabin Air Conditioner)

Electrical Circuit Diagram (Cabin Air Conditioner) SW K 1

10A

FU B

FU A

20A

5A LIGHT SW SIGNAL

M RF

M V3

9 1.25RY

9 2RY

M CD

1.25RY

FRE

9 2RY

M REC

RL BM

SP CD

RL CD

25 15 26 22

28 15 29 22

225W M V 3A

80W

1.25G

3 1

2 +B 6

2G 2G

10 4

RL EC

DEF

GND

RL BM

FOOT

RL EC

RL CD

FU EC

FU CD

GND

39 5

M V 3B

25 35

SV 3

M RFA

S RF

M RFB

9 BLC B 3

RL CH BLC F

BAT

BLC

2 11

AC M

11 8

1 01

28 G

4 R CD

7 RL CH

0.5B

22 B P

17 TH AM

EC C

14 17

TH W

20 TH I

27 15

4 23

21 30

31 M AMB

33 M V 1B

S AM

M AMA

36 36

35 M V 1A

S V1

37 M V 2A

38 M V 2B

S V2

S SD

TH F

40W

37 15 38 22 GND

FACE

34 22 35 15

SHUT

GND

31 22 32 15

FOOT

FACE

Mhot

Mcool

GND

22 01

0.5B

SP HL

01 0.5B

0.5B

M AM

ACM

Air conditioner control amplifier

M AM

Air mixing servo motor

RL CH

Condenser HI relay

BAT

Battery

Blower motor

RL EC

Compressor clutch relay

BLC

BLC (blower linear controller)

M CD

Condenser motor

S SD

Solar insolation sensor

Diode 1

M RF

Inside/outside air servo motor

SPCD

Condenser speed change pressure switch

Diode 2

M V1

Vent servo motor

SPHL

Refrigerant high/low pressure switch

ECC

Compressor clutch

M V2

Front vent servo motor

SWK

Key switch

FU A

Air conditioner fuse

M V3

Defroster selection servo motor

TH AM

Outside air thermistor

FU B

Blower motor fuse

R CD

Condenser motor speed change resistor TH F

FU CD

Condenser motor fuse

RL BM

Blower main relay

TH I

Inside air thermistor

FU EC

Compressor clutch fuse

RL CD

Condenser relay

TH W

Water temperature thermistor

M V1

M V2

Dotted lines indicate the wiring on the machine side.

Frost prevention thermistor

95ZVE72019

92-28 95ZV-2 Drawing & Diagrams Equipment Operation Table (Cabin Air Conditioner)

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

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

Automatic control

↑

Normal

↑

Frost cut

↑

High pressure cut

↑

Low pressure cut

↑

High pressure error

↑

Normal

↑

32 (90ºF)

Before engine is warmed Water temperature < 25ºC

↑

Before/after engine is warmed Water temperature > 55ºC

↑

35 (95ºF) ~0

18.5 (65ºF) ~ 31.5 (90ºF)

Automatic control

Set value

Mode just before OFF is displayed.

Nothing is displayed.

↑

Air mixing Blow-off

Major functional parts Inside outside air

Blower motor

BLC

Compressor (clutch)

Set value

or X

(Hi or Lo)

Automatic control

HI ~ Lo

↑

OFF

↑

FACE

OFF High air blow

(Lo)

High pressure < 1,226 kPa (12.5 kgf/cm2) (178 psi)

Evaporator frost prevention control

Condenser clogging, etc.

Gas leak, etc.

High/low pressure cut, etc.

Outside air < 0 → Fixed to "foot" and compressor disabled

Prevention of cold air blow at low temperature

Set value: 32 → High air blow

or X

Set value

(Hi or Lo) X

or X

↑

FACE/FOOT

↑

or X

↑

FOOT

↑

or X

↑

FOOT/DEF

↑

or X

↑

DEF

↑

or X

↑

Automatic control

↑

or X

↑

or X

↑

or X

↑

Mode manual

Outside air

Inside/outside air manual Inside air

(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

Set value: 18 → High air blow High pressure > 1,520 kPa (15.5 kgf/cm2) (220 psi)

Hi ～ Lo

OFF

Remarks

(Hi) X

Condenser motor

Outside air > 30 → Fixed to "face" (Hi or Lo) Set value: 18 → High air blow

or X

High air blow

Blower manual

Manual (Fully automatic mode is released.)

Relay LCD

92-29 95ZV-2 Drawing & Diagrams Electrical Equipment Layout

Electrical Equipment Layout Front chassis

Bucket leveler (L1)

Ground

Left turn signal

Ground

Right turn Head lamp signal (K3)

Head lamp (K0)

To horn

Horn

Boom angle sensor (L3) (K1/K2) Front chassis ground

For ride control (opt) To rear chassis To rear chassis

Top view

95ZV2-03256-00061 EU 95V2E92011a

92-30 95ZV-2 Drawing & Diagrams Electrical Equipment Layout

Front chassis

Combination lamp (option)

Not used Head lamp (K5) Working lamp

(K1) (K3)

(K2)

(K4)

Ride control (option) (L4)

Bucket leveler (L1) (K7)

(L2) (K6)

(S/N 9060~) Working lamp

Horn Head lamp Combination lamp (option) (K9)

(K0)

(K8)

Boom angle sensor (L3)

K95V2E92030

92-31 95ZV-2 Drawing & Diagrams Electrical Equipment Layout Rear chassis

Oil filter (X1) Efficient loading system oil pressure sensor (L6)

Connectors (H3~H7)

Efficient loading system solenoid valve (L5) Hydraulic oil temperature sensor (L7)

Brake oil pressure sensor (M2/M3)

To front

A-A To front

Auto brake solenoid valve (X4)

Hydraulic oil level switch (M4)

To floor A A

Parking brake solenoid valve (M1)

Rear to floor ground

Fuel level sensor (J8) To floor

Connector (H1)

Transmission oil temperature sensor (M5)

To floor ground

Washer tank (M8)

To floor ground

Speed sensor (automatic gear) (M9)

Transmission solenoid valve (J1~J7)

Air cleaner (L0) Electrical fan condenser (L9)

Starter motor

Ground Engine water temperature sensor (M6)(S/N ~9150) Rear chassis ground

Ground

Starter (E) to engine body

Engine ground Air heater

Proportional relief valve (S/N 9151~)

Rear chassis ground

Fusible link (N1/N2)

Alternator ground

Fuse box (ECM) ECM (P8) (31 poles)

Air conditioner compressor

Proportional relief valve (S/N 9151~)

(S/N 9151~)

ECM (P7) (50 poles) Alternator (M7)

Battery ground

To rear grill

Engine relay

To combination lamp

Water level switch (X2)

To rear grill

Top view

To combination lamp

RH 95ZV2-03257-00143 EU 1/2 K95V2E92027

92-32 95ZV-2 Drawing & Diagrams Electrical Equipment Layout Rear chassis

(Red tape) 100 Red

Starter 15 BK

(Red tape)

Fusible link

70A 30A

70A

5 Red White & Green

70A

Battery relay (N3)

Heater relay (N6)

Air 15 BK heater 5 White 20 BK

White & Violet

5 Red x 6

20 BK

Ground

5 BK & White Red & Blue

To fusible link

20 BK G Terminal B Terminal

0.85 White & Blue 1.25 White & Blue To rear chassis harness 5 Bk & R Terminal 0.85 White White I Terminal & Peach C Terminal

To magnetic switch

5 Red

B Terminal 100 Red

(S/N ~9150)

BK & White

Fuse box (ECM)

5 White White x 2

1.25 White & Blue

Magnetic switch (N7)

20 Red

To battery relay To engine body

Voltage relay (N8)

BK & Green

100 BK White & Green

BK BK

White & Blue

Engine ground

Alternator wiring

Starter motor wiring

BK To ECM

(S/N 9005~)

( + Mark) 3 poles (P5)

6 poles (N0)

100 Red

2 poles

5 White

6 poles

Diode unit (N4)

To rear chassis harness

To To rear alternator chassis (B) harness

To battery (+)

To rear chassis harness

To heater Rear chassis harness To starter (B Terminal) To battery (+) Rear chassis harness To alternator (B Terminal)

Engine relay unit wiring

Wiring in engine relay box (S/N ~9150) Rear working lamp

Rear working lamp

To ECM

To heater

Modulator valve

+ Mark: Connected to red cable Mark: Connected to black cable

Rear working lamp connection Oil flow rate sensor (X5) Rear chassis harness

Transmission harness To rear chassis harness

Radiator guard wiring

Transmission solenoid wiring

To starter (B Terminal)

To battery (+) Rear chassis harness To alternator (B Terminal)

Wiring in engine relay box (S/N 9151~)

95ZV2-03255-01341 EU 2/2

K95V2E92013

92-33 95ZV-2 Drawing & Diagrams Electrical Equipment Layout

Rear chassis

Working lamp

Air compressor

(S/N ~9150)

Working lamp

(S/N ~5250) E/G water temperature sensor (M6)

Back up alarm

Combination lamp (R2)

(R4)

Fan control solenoid (P1)

License lamp (option)

(R6)

(R3) (R5) A/C condenser (L9) Alternator

Combination lamp -

(L0)

(L8) To floor board

Battery

Air cleaner

(S/N 9001~9015, S/N 9151~)

(R7) (R1)

T/C oil temperature sensor (M5)

Water level sensor (X2)

ELS oil pressure sensor (L6)

ELS solenoid valve (L5)

Brake oil main pressure S/W (M2/M3)

Washer motor (M8)

Hydraulic oil temperature sensor (L7) (K1/K2)

To front chassis

(X4) Hydraulic oil level S/W (M4)

(M1) Parking brake solenoid

Auto brake solenoid + Battery K95V2E92020

92-34 95ZV-2 Drawing & Diagrams Electrical Equipment Layout

Rear chassis (S/N 9001~9150)

Rear chassis (S/N 9151~)

Magnetic S/W (N7)

Battery relay (N3)

Magnetic S/W

(N7)

(S/N 9002~)

Starter motor (P0)

Heater relay (N6)

Battery relay (N3)

Starter motor (P0) (N4) Air heater

Air heater

Fuse box

(N4)

Diode unit

Heater relay (N6)

Voltage relay (N8) Fuel level sensor (J8) Fusible link

(S/N ~9048)

Fuse box

Fuel level sensor (J8)

(P6)

Diode unit

(P6)

(N5/N9) Fusible link

(P8)

(N2)

ECM

(N5/N9)

(P9)

(P8)

(N2)

(P7)

(N1)

(P7)

(N1)

Resistor

(P9)

ECM

Resistor

(J1

Lock up (J7)

(J1

(W1/H2)

(W1/H2) (H

Lock up (J7)

)

(H7)

)

(X1) Pressure sensor (X5)

To floor board

(H7)

(X1) Pressure sensor (X5)

To floor board (M9)

(M9)

Speed sensor (for auto-shift) T/M oil filter

Speed sensor (for auto-shift)

T/M solenoid valve

T/M oil filter

K95V2E92019

92-35 95ZV-2 Drawing & Diagrams Electrical Equipment Layout Floor board

(Floor to rear ground)

To rear ground To control box Red tape

Accelerator pedal (C0)

Green tape Blue tape

Air temperature probe (MCU) (C9)

To rear

Air temperature probe (air conditioner) (C8)

Hazard

Front working lamp

Fuel efficient mode change

Rear working lamp

Efficient loading system Declutch selector (S/N ~9150)

(Floor ground)

Yellow tape

Selection switch for shift lever or F/R switch

Declutch switch (B0)

Operation switch connection

To operation stand

To rear

Declutch sensor

Top view Horn switch (B8) Combination switch (B9) Instrument panel, switch Shift lever (B7)

To instrument panel, switch

Parking switch (B5)

Front

95ZV2-03255-01250 EU 1/2

K95V2E92014

92-36 95ZV-2 Drawing & Diagrams Electrical Equipment Layout Floor board (Control box, S/N 9001~9250) To declutch set-up switch, lift kickout / lower kickout set-up switch

Declutch set-up switch Remote kickout / lower kickout set-up switch

(S/N 9049~) To floor harness Fuse unit (V7)

Buzzer (G6)

Relay unit

Fuse box (cab) Fuse box (main)

Switch wiring in control box Circuit protector (E3/E4) (S/N ~9004)

Details of A (S/N 9049~) A

Declutch set-up switch (T6) Remote kickout / lower kickout set-up switch (T7)

Buzzer (G6)

6 poles white connector (S/N 9049~) RS232C 4 poles white connector RS232C

2 poles green connector F23 change point selection 2 poles blue connector Auto/full auto selection

3 poles white connector Diagnostic switch connection

4 poles black connector

MCU 2 poles blue connector (S/N ~9048) Speedometer dividing ratio selection

Front (S/N 9098~)

2 poles white connector Odometer selection

2 poles brown connector F34 change point selection

2 poles black connector A/M selection

Back-up lamp (opt) (S/N 9049~) 4 poles black connector

4 poles blue connector

3 poles blue connector (opt)

(Ground) Red tape

Starter switch (E1/E2)

To downshift button Data link connector (T4)

To pilot valve

4 poles white connector Flasher unit Shift hold switch (opt)

4 poles white connector Diagnostic increment / decrement switch To air-sus, air conditioner unit

4 poles blue connector Voltage relay (S/N 9049~)

Power (option) directed to battery

6 poles white connector

Relay unit wiring details

95ZV2-03255-00650 EU 2/2

K95V2E92028

92-37 95ZV-2 Drawing & Diagrams Electrical Equipment Layout Floor board (Control box, S/N 9251~)

To declutch set-up switch, lift kickout / lower kickout set-up switch Declutch set-up switch Remote kickout / lower kickout set-up switch

To floor harness

Relay unit Fuse box (cab) Fuse box (main)

Switch wiring in control box 2 poles black connector E/G water temp. sensor (for inspection) 6 poles white connector Controller selection 4 poles white connector RS232C 8 poles white connector New FE mode selection 2 poles blue connector Auto/full auto selection 2 poles green connector F23 change point selection 2 poles brown connector F34 change point selection 2 poles white connector Odometer selection 2 poles black connector A/M selection 3 poles blue connector Specification selection

Declutch set-up switch (T6) Remote kickout / lower kickout set-up switch (T7)

Buzzer (G6)

Front Back-up lamp (opt)

4 poles black connector

4 poles blue connector MCU

(Ground)

Red tape

Starter switch (E1/E2)

Data link connector (T4)

Brake relay (S/N 9258~)

To downshift button

4 poles blue connector Voltage relay

To pilot valve 4 poles white connector Flasher unit

4 poles white connector Diagnostic increment / decrement switch To air-sus

Shift hold switch (opt) Power (option) directed to battery

6 poles white connector

Relay unit wiring details

To air conditioner unit 95ZV2-03255-01250 EU 2/2

K95V2E92029

92-38 95ZV-2 Drawing & Diagrams Electrical Equipment Layout

Floor board (S/N 9001~9048)

Horn S/W (B8) (S/N 9001~9038) Rear working lamp S/W Front working lamp S/W (B1)

Combination S/W

Option Parking S/W (B5)

Operation stand

(B2)

Declutch S/W

(B9)

ELS S/W

)

Shift lever (B7)

(A0)

Fuel efficient mode S/W Hazard S/W (A2) (A1)

(A3)

MCU (S5~S9)

Fuse box (cab) (D6~D0) Fuse box (main) (D1~D5)

DATA LINK connector Air suspension (T5)

Starter S/W

(T4) Buzzer

Downshift button (G1)

Diagnostic inc/dec S/W (G0)

Spec. (S1) Speed meter (S2) Odometer (S3)

Pilot valve (G6) (E2)

(E1) Kickout set-up S/W (T7)

(G2~G4) Outside air Throttle pedal thermo sensor (air conditioner) Outside temp. sensor (controller) (C8)

Declutch set-up S/W (T6)

A/M S/W (S4)

Electrical unit

(C9) (C0)

To rear chassis (H2) To Cab

Declutch cut-off S/W (B0)

Declutch sensor (C7)

)

To rear chassis

(H7) (H1) K95V2E92032

92-39 95ZV-2 Drawing & Diagrams Electrical Equipment Layout

Horn S/W (B8)

F/R S/W selection

Floor board (S/N 9049~)

Front working lamp S/W

Rear working lamp S/W Spare power

(B1)

(T3) Combination S/W (S/N ~9150) Operation stand

(B2)

Parking S/W

Declutch S/W Shift lever

ELS S/W Fuel efficient mode S/W

(A0) (B5)

)

(B7) (A2)

(A1)

(W6) E/G water temp. sensor (for inspection) (S/N 9151~) (S0)

Declutch set-up S/W (T6)

(A3)

Hazard S/W

(B9)

Kickout set-up S/W (T7)

(T1)

(F0)

(T2)

Fuse box (cab) (D6~D0) To aircon unit Fuse box (main) (D1~D5)

Outside temp. sensor (controller)

Air suspension (T5)

Starter S/W

Downshift button Pilot valve

(E1)

/H (H9

MCU (S5~S9) Buzzer

(T4)

(G6)

Diagnostic inc/dec S/W (G0)

Fuse unit (V7)

(E2)

(C9)

DATA LINK connector

Electrical unit Outside air thermo sensor (air conditioner)

(G2~G4)

(G1)

(W3~W5) (S/N 9151~)

(C8) (G9) Shift hold S/W (option)

(S3) Odometer (S4) A/M S/W

(C0) (S1) Spec. Throttle pedal Power

To T/M solenoid (H2)

To rear chassis (H

Declutch cut-off S/W (B0)

)

Secondary steering (E8) F/R S/W & stick steering (E0)

To Cab (C1~C3)

(C7)

(C4~C6)

Declutch sensor

(E6) Ride control S/W

(H7) (E5) Reversal fan S/W

To rear chassis

To cab (aircon)

(H1)

K95V2E92018

92-40 95ZV-2 Drawing & Diagrams Electrical Equipment Layout (K-Lever)

Electrical Equipment Layout (K-Lever) Horn switch

(S/N 5124~) K-Lever switch

Solenoid valve

2 1 3

Armrest switch

Downshift button

Horn switch

Horn relay

3 7

Joy stick

Fuse unit

2 4

1 2 3 4

W LR

(Black)

805 806 P P 809 810 P P

(Black)

800 P B

803 P

808 P

B B

804 P

R R G L

808 P 802 807 P P

801 P

G L R R

Y B

G G GW GL

E0 B

YV 12

807 B R 801 P P 810 809 804 803 802 800 P P P P P P

Standard harness

806 P

SOL. B

805 P

Standard harness

SOL. A

1 6

BL BR G V

YO LB

L BY

E0 Connector SPPC(L)

SPPC(R)

Horn switch Standard harness

To K-Lever

Bucket control lever

Hoist control lever

Solenoid valve K-Lever switch

K-Lever

A-A (Fuse unit)

E0 connector for F/R switch opt. or K-Lever connector

(S/N 5124~) Horn relay

Downshift button 3

4 SOL.B(L) Connect 806 wire

SOL.A(R) Connect 805 wire

Horn relay To horn switch To downshift button Ground

Solenoid valve

To K-Lever

R R G L

2 G L R R G G GW GL

Standard floor harness

B-detail 1 1 K-Lever Wire color: black, red, pink

Solenoid valve

Control box detail

Armrest angle switch

Lever (potentiometer)

K-Lever detail

To control box

To solenoid valve

1. Cable assembly 2. Cable assembly 3. Cable assembly 4. Fuse unit Note Refer to the electrical connection diagram for the K-Lever electrical connection diagram. For adjusting the speed of the K-Lever, refer to the K-Lever section on "MODM Parameter Setting Monitor" page 62-92. 95ZV2_03030-29292A 95V2U92023

92-41 95ZV-2 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)

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

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

92-42 95ZV-2 Drawing & Diagrams Outline of MODM (Machine Operation Diagnostic Module) Operation

Power On (MODM Software Version) 3sec. displayed

Main Menu Language Selection Specification Setting Monitor

Dutch

English (Initial Screen) Information Monitor

3 sec

Active Error

Active Error Language Selection

2 sec change No Change

Japanese

Press any button Replacing Time Comming

Replace Pop Up

Replacement Monitor Press any button Dutch

Press any button:

Fault Log Monitor

(

Inout/Output Monitor

)

English

Parameter Setting Monitor

Specification Selection Monitor

Information Monitor

80V2U92020

92-43 95ZV-2 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

)

Reset

Outside Temperature

80V2U92008

92-44 95ZV-2 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

Timer Reset

2 sec Change No Change Fuel Filter

2 sec

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

(

)

2 sec Change No Change Engine Oil

2 sec Timer Reset 2 sec Change No Change

Transmission & Torque Conveter Oil

80V2U92009

92-45 95ZV-2 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

)

Maximum Engine Fault Log Clear Fault Log

Note When pressing the [ ] button to clear a fault code, password entry is required on the 95ZV-2 S/N 9254 and thereafter.

2 seconds or more: Return after clear Return without clear

Machine Fault Log 1

Engine Fault Log 1

80V2U92010

92-46 95ZV-2 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

DI Port 7

DI Port 1 (Initial Screen for I/O Monitor)

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

)

DO Port 6

DO Port 1

Output Signal Screen

Cooling Fan Current Output

80V2U92011

92-47 95ZV-2 Drawing & Diagrams Outline of MODM (Machine Operation Diagnostic Module) Operation

Parameter Setting Monitor Calendar

Deceleration Pervention Setting 1 (Initial Screen for Parameter Setting)

Power Control (Vni) Setting 2

2 sec

Lower Kick Out Parameter Setting

Input/Output Monitor

2 sec Change No Change Deceleration Prevention Setting 2

2 sec

Lift Kick Out Specification Selection Monitor

Parameter Setting 2 sec Change No Change 2 sec

Ride Control Setting 1

2 sec

Calendar Parameter Setting

Parameter Setting 2 sec Change No Change

2 sec Change No Change 2 sec

Ride Control Setting 2

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 - TACHOGRAPH DIV1 - TACHOGRAPH DIV2 - EMG STEERING ON - EMG STEERING OFF - K-LEVER V1 - K-LEVER V2 - K-LEVER Vmax - K-LEVER i1 - K-LEVER i2 - K-LEVER imax

- TRACTION CONTROL F1 - TRACTION CONTROL DSsc - TRACTION CONTROL Isc - TRACTION CONTROL ti - TRACTION CONTROL SCv - TRACTION CONTROL SCeg - TRACTION CONTROL SCi - TRACTION CONTROL SCt - T/M CUT OFF IS - 2 STAGE DSon - POWER CONTROL TWni

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

Subtraciting 1 to the value where the cursor is. (9

Power Control (Vni) Setting 2

80V2U92012

92-48 95ZV-2 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. (

To confirm the change, press this button for 2 seconds or more. Password OK 2 sec

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 - Emergency 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

80V2U92013

92-49 95ZV-2 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. (

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

2 sec Change No Change

2 sec

Specification Item 4

Specification Selection

2 sec Change No Change - Ride control - Emergency 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 80V2U92014

92-50 95ZV-2 Drawing & Diagrams MODM: Input/Output Monitor - Input/Output Signal Correspondence Table

MODM: Input/Output Monitor - Input/Output Signal Correspondence Table 0

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

Opt 2

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