KCM WHEEL LOADER 115ZV-2 SHOP MANUAL 93216-00462 - PDF DOWNLOAD by www.heydownloads.com

115ZV-2

93216-00462

SHOP MANUAL General Information Function & Structure

Printed in Japan (K) （ヨーロッパ用）

93216-00462

February 2017

SHOP MANUAL WHEEL LOADER

115ZV-2 General Information Standard Measurement Values for Performance Check Function & Structure Check & Adjustment Powered by CUMMINS QSK19 Engine Serial No. 11C5-9001 and up

93216-00462 February 2017

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

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

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

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

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

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

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

CONTENTS 00 General Information ......................................................................................................................................... 00-1 How to Use Manual ........................................................................................................................................... 00-2 Safety precautions ...................................................................................................................................... 00-2 Symbols ...................................................................................................................................................... 00-3 Outline ............................................................................................................................................................... 00-4 Layout of main components ........................................................................................................................ 00-4 Inspection and maintenance table .............................................................................................................. 00-5 Recommended lubricants ........................................................................................................................... 00-8 Coolant ....................................................................................................................................................... 00-9 Lubrication chart ....................................................................................................................................... 00-10 Weight of main components ......................................................................................................................00-11 Bolt tightening torque ................................................................................................................................ 00-12 Hose band tightening torque ..................................................................................................................... 00-16 Liquid gasket and screw lock agent .......................................................................................................... 00-17 Cautions regarding welding repair service ................................................................................................ 00-19 03 Measurement for Performance Check ............................................................................................................. 03-1 Cautions on Safety ............................................................................................................................................ 03-2 Standard Measurement Values for Performance Check ................................................................................... 03-3 12 Function & Structure Chassis Group ................................................................................................................ 12-1 Front Chassis .................................................................................................................................................... 12-2 Loading linkage ........................................................................................................................................... 12-2 Loading linkage pin ..................................................................................................................................... 12-4 Rear Chassis .................................................................................................................................................... 12-5 Fuel tank ..................................................................................................................................................... 12-5 Floor board mount ....................................................................................................................................... 12-6 Center Pin ......................................................................................................................................................... 12-7 Upper center pin ......................................................................................................................................... 12-7 Lower center pin ......................................................................................................................................... 12-8 Dust seal ..................................................................................................................................................... 12-9 13 Check & Adjustment Chassis Group ................................................................................................................ 13-1 Linkage Pin ....................................................................................................................................................... 13-2 Liner ............................................................................................................................................................ 13-2

Center Pin ......................................................................................................................................................... 13-6 Adjusting shim ............................................................................................................................................. 13-6 Installing bearing cover ............................................................................................................................... 13-6 Installing bearing outer ring ......................................................................................................................... 13-7 22 Function & Structure Power Group .................................................................................................................. 22-1 Power Line ........................................................................................................................................................ 22-2 Engine / Transmission ....................................................................................................................................... 22-3 Engine / transmission mount ....................................................................................................................... 22-3 Radiator (S/N 9001~9050) ................................................................................................................................ 22-4 Radiator mount ............................................................................................................................................ 22-5 Radiator (S/N 9051~) ........................................................................................................................................ 22-6 Propeller Shaft .................................................................................................................................................. 22-8 First propeller shaft assembly ..................................................................................................................... 22-9 Second propeller shaft assembly .............................................................................................................. 22-10 Third propeller shaft assembly .................................................................................................................. 22-11 Axle Assembly ................................................................................................................................................. 22-12 Axle Support .................................................................................................................................................... 22-14 Differential Gear .............................................................................................................................................. 22-16 Conventional type ..................................................................................................................................... 22-16 Function of differential gear ....................................................................................................................... 22-19 Operation of differential gear ..................................................................................................................... 22-19 Limited Slip Differential (option) (S/N 9054~) .................................................................................................. 22-21 23 Check & Adjustment Power Group ................................................................................................................... 23-1 Engine ............................................................................................................................................................... 23-2 Measuring engine speed ............................................................................................................................. 23-2 Measuring engine oil pressure .................................................................................................................... 23-2 Propeller Shaft .................................................................................................................................................. 23-3 Propeller shaft phase .................................................................................................................................. 23-3 Second propeller shaft alignment ................................................................................................................ 23-3 Propeller shaft tightening torque ................................................................................................................. 23-4 Axle ................................................................................................................................................................... 23-5 Axle nut tightening procedure ..................................................................................................................... 23-5 Differential gear adjustment procedure ....................................................................................................... 23-6

32 Function & Structure Torque Converter and Transmission Group ................................................................... 32-1 Torque Converter .............................................................................................................................................. 32-2 Torque converter structure .......................................................................................................................... 32-3 Power flow path .......................................................................................................................................... 32-3 Torque multiplication ................................................................................................................................... 32-3 Torque Converter (Lock-up) (Option) ................................................................................................................ 32-4 Lock-up clutch structure .............................................................................................................................. 32-5 Lock-up clutch function (only forward) ........................................................................................................ 32-5 Torque Converter Gear Pump ........................................................................................................................... 32-7 Gear pump specifications ........................................................................................................................... 32-7 Transmission ..................................................................................................................................................... 32-8 Clutch combination ..................................................................................................................................... 32-9 Planetary gear ............................................................................................................................................. 32-9 Shift lever position ....................................................................................................................................... 32-9 Downshift button operation ......................................................................................................................... 32-9 Gear train and number of teeth ................................................................................................................. 32-10 Clutch Pack ..................................................................................................................................................... 32-14 Power Flow Path in the Transmission ............................................................................................................. 32-15 Hydraulic System Diagram ............................................................................................................................. 32-19 Hydraulic Circuit Diagram ............................................................................................................................... 32-20 Oil Flow ........................................................................................................................................................... 32-22 Oil flow in the torque converter line ........................................................................................................... 32-22 Oil flow in the transmission line ................................................................................................................. 32-22 T/C and T/M Oil Circulation ............................................................................................................................. 32-24 Modulator Valve Unit ....................................................................................................................................... 32-25 Interior schematic (simple explanation) .................................................................................................... 32-27 Modulation Mechanism ............................................................................................................................. 32-28 Modulator valve operation ......................................................................................................................... 32-29 Control Valve Assembly .................................................................................................................................. 32-31 Clutch solenoid valve assembly ................................................................................................................ 32-33 Clutch valve assembly .............................................................................................................................. 32-36 Accumulator assembly .............................................................................................................................. 32-37 Direct charge valve ................................................................................................................................... 32-38 Lock-up clutch solenoid valve ................................................................................................................... 32-39

33 Check & Adjustment Torque Converter and Transmission Group ................................................................... 33-1 Clutch Oil Pressure and Time Lag .................................................................................................................... 33-2 Measuring clutch oil pressure ..................................................................................................................... 33-2 42 Function & Structure Hydraulic Group .............................................................................................................. 42-1 Flushing Hydraulic Circuit ................................................................................................................................. 42-2 Purpose of flushing ..................................................................................................................................... 42-2 Cautions on Hydraulic Parts Replacement ....................................................................................................... 42-3 Hydraulic Circuit Symbols ................................................................................................................................. 42-4 Hydraulic lines ............................................................................................................................................. 42-4 Pumps & motors .......................................................................................................................................... 42-4 Cylinders ..................................................................................................................................................... 42-4 Operation methods ...................................................................................................................................... 42-5 Pressure control valve ................................................................................................................................. 42-5 Flow control valve ....................................................................................................................................... 42-5 Directional control valve .............................................................................................................................. 42-6 Check valve ................................................................................................................................................. 42-6 Miscellaneous hydraulic symbols ................................................................................................................ 42-7 Hydraulic System Operation ............................................................................................................................. 42-8 Hydraulic system operation outline ............................................................................................................. 42-8 Layout of Hydraulic Units ................................................................................................................................ 42-10 Hydraulic Tank ................................................................................................................................................. 42-11 Hydraulic Tank (S/N 9001~9150) .............................................................................................................. 42-11 Hydraulic Tank (S/N 9151~) ...................................................................................................................... 42-13 Hydraulic tank specifications ..................................................................................................................... 42-15 Hydraulic oil level check ............................................................................................................................ 42-16 Hydraulic Pump ............................................................................................................................................... 42-17 Loading and pilot and brake pump ............................................................................................................ 42-17 Pump specifications .................................................................................................................................. 42-17 Steering pump ........................................................................................................................................... 42-18 Steering pump specifications .................................................................................................................... 42-18 Hydraulic pump principle ........................................................................................................................... 42-19 Hydraulic pump wear plate ........................................................................................................................ 42-20 Hydraulic pump bushing lubrication .......................................................................................................... 42-20

Hydraulic Cylinder ........................................................................................................................................... 42-21 Boom cylinder ........................................................................................................................................... 42-21 Bucket cylinder .......................................................................................................................................... 42-21 Steering cylinder ....................................................................................................................................... 42-22 Hydraulic cylinder specifications ............................................................................................................... 42-23 Loading System .............................................................................................................................................. 42-24 Reducing Valve (for Pilot Pressure) ................................................................................................................ 42-25 Pilot valve (S/N 9001~9100) ........................................................................................................................... 42-26 Pilot valve (S/N 9101~9105) ........................................................................................................................... 42-31 Pilot valve (S/N 9106~) ................................................................................................................................... 42-36 Multiple Control Valve (KML35A/2T103) ......................................................................................................... 42-41 Multiple control valve specifications .......................................................................................................... 42-42 Multiple control valve main relief valve ..................................................................................................... 42-43 Multiple control valve overload relief valve (with make-up function) ......................................................... 42-45 Multiple control valve make-up valve ........................................................................................................ 42-46 Multiple control valve bucket spool ........................................................................................................... 42-47 Multiple control valve boom spool ............................................................................................................. 42-49 Adapter (Orifice) .............................................................................................................................................. 42-52 Ride Control (OPT) ......................................................................................................................................... 42-53 Ride control hydraulic circuit ..................................................................................................................... 42-53 Ride control operation ............................................................................................................................... 42-54 Ride control valve assembly (Reducing valve circuit) ............................................................................... 42-56 Ride control valve assembly (Accumulator circuit) ................................................................................... 42-59 Accumulator (for ride control) .................................................................................................................... 42-62 Steering System .............................................................................................................................................. 42-63 Orbitrol® .......................................................................................................................................................... 42-64 Orbitrol® structure ..................................................................................................................................... 42-64 Orbitrol® specifications .............................................................................................................................. 42-65 Orbitrol® operation .................................................................................................................................... 42-66 Orbitrol® feed-back mechanism operation ................................................................................................ 42-68 Steering speed and flow rate control ........................................................................................................ 42-69 Hydraulic pump oil amount and steering force .......................................................................................... 42-69 Orbit rotor operation principle ................................................................................................................... 42-70

Steering Valve (KVS32-A4.0/21) ..................................................................................................................... 42-71 Steering valve operation ........................................................................................................................... 42-73 Steering spool variable throttle .................................................................................................................. 42-75 Steering valve flow control spool ............................................................................................................... 42-76 Steering valve main relief valve ................................................................................................................ 42-77 Steering valve overload relief valve .......................................................................................................... 42-79 Steering pilot circuit and its operation ....................................................................................................... 42-81 Stop Valve ....................................................................................................................................................... 42-83 Stop valve function .................................................................................................................................... 42-84 Stop valve operation ................................................................................................................................. 42-84 Reducing Valve (for Orbitrol®) ......................................................................................................................... 42-85 Steering Line Filter .......................................................................................................................................... 42-86 Efficient Loading System ................................................................................................................................. 42-87 Efficient loading system outline ................................................................................................................. 42-87 Mounting of the ELS valve ........................................................................................................................ 42-88 Mounting of the variable kickout sensor .................................................................................................... 42-89 Efficient loading system operation ............................................................................................................ 42-90 Fan Motor System ........................................................................................................................................... 42-91 Mounting of fan motor ............................................................................................................................... 42-91 Fan Motor Line ................................................................................................................................................ 42-92 Hydraulic circuit (fan motor normal rotation) ............................................................................................. 42-94 Proportional relief valve (S/N 9001~9050) ................................................................................................ 42-96 Proportional relief valve (S/N 9051~) ........................................................................................................ 42-98 Fan motor ................................................................................................................................................ 42-100 Reversing Fan Motor Line (OPT) .................................................................................................................. 42-103 Reversing fan motor function .................................................................................................................. 42-103 Hydraulic circuit (Reverse rotation) ......................................................................................................... 42-107 Secondary Steering ....................................................................................................................................... 42-108 Secondary steering circuit ....................................................................................................................... 42-108 43 Check & Adjustment Hydraulic Group .............................................................................................................. 43-1 Loading/Steering Circuit Relief Valve/Ride Control Circuit Reducing Valve (OPT) ........................................... 43-2 Loading circuit relief valve setting pressures .............................................................................................. 43-2 Ride control circuit reducing valve setting pressures (OPT) ....................................................................... 43-7 Steering circuit relief valve setting pressures .............................................................................................. 43-9

Hydraulic Cylinder ........................................................................................................................................... 43-14 Cylinder natural drift .................................................................................................................................. 43-14 Stop Valve ....................................................................................................................................................... 43-16 Stop valve adjustment procedure ............................................................................................................. 43-16 52 Function & Structure Brake Group ................................................................................................................... 52-1 Brake System Outline ....................................................................................................................................... 52-2 Service brake .............................................................................................................................................. 52-2 Parking brake .............................................................................................................................................. 52-2 Adjustment of axle internal pressure ........................................................................................................... 52-2 Brake Units Layout ............................................................................................................................................ 52-3 Unloader Valve .................................................................................................................................................. 52-4 Unloader valve operation ............................................................................................................................ 52-6 Valve Unit .......................................................................................................................................................... 52-7 Accumulator ...................................................................................................................................................... 52-9 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 disc ......................................................................................................................... 52-15 Service brake steel plate ........................................................................................................................... 52-16 Service brake piston ................................................................................................................................. 52-17 Service brake pedal stroke adjusting mechanism ..................................................................................... 52-18 Brake circuit air bleeding procedure ......................................................................................................... 52-20 Parking Brake ................................................................................................................................................. 52-22 Parking brake operation ............................................................................................................................ 52-25 Parking brake friction disc ......................................................................................................................... 52-28 Parking brake steel plate .......................................................................................................................... 52-28 Parking brake solenoid valve .................................................................................................................... 52-29 Parking Brake Manual Release ...................................................................................................................... 52-30 Brake Circuit Check Valve ............................................................................................................................... 52-32

Auto Brake ...................................................................................................................................................... 52-33 Auto brake circuit ...................................................................................................................................... 52-33 Auto brake operation set value ................................................................................................................. 52-33 Reducing valve (for Autobrake circuit) ...................................................................................................... 52-34 Solenoid valve (for Autobrake circuit) ....................................................................................................... 52-35 Pressure Sensor (for stop lamp and declutch) ................................................................................................ 52-36 Pressure sensor (for declutch) .................................................................................................................. 52-36 Pressure sensor (for stop lamp) ................................................................................................................ 52-36 53 Check & Adjustment Brake Group ................................................................................................................... 53-1 Brake Circuit Oil Pressure ................................................................................................................................. 53-2 Unloader valve setting pressure .................................................................................................................. 53-2 Brake valve oil pressure .............................................................................................................................. 53-4 Service Brake .................................................................................................................................................... 53-6 Service brake performance check ............................................................................................................... 53-6 Service brake friction plate wear measurement .......................................................................................... 53-7 Cautions on installing brake discs ............................................................................................................... 53-8 Parking Brake .................................................................................................................................................... 53-9 Parking brake performance check .............................................................................................................. 53-9 62 Function & Structure Electrical Group .............................................................................................................. 62-1 How to Use Electrical Wiring Diagram .............................................................................................................. 62-2 Utilisation des schémas des câblages électriques (FRANÇAIS) ...................................................................... 62-3 Verwendung des elektrischen Schaltplans (DEUTSCH) ................................................................................... 62-4 Modalità di utilizzo dello schema dei collegamenti elettrici (ITALIANO) ............................................................ 62-5 Cómo utilizar un Diagrama de Alambrado Eléctrico (ESPAÑOL) ..................................................................... 62-6 Como Utilizar o Diagrama de Ligações Eléctricas (PORTUGUÊS) .................................................................. 62-7 Electrical Cable Color Codes ............................................................................................................................ 62-8 Electrical Circuit Symbols .................................................................................................................................. 62-9 Sensor Mount .................................................................................................................................................. 62-10 Fuse ................................................................................................................................................................ 62-11 Fuse box ................................................................................................................................................... 62-11 Fusible link ................................................................................................................................................ 62-12

Engine Start Circuit ......................................................................................................................................... 62-13 Engine start circuit diagram ...................................................................................................................... 62-13 Neutral starter ........................................................................................................................................... 62-14 Starter switch ............................................................................................................................................ 62-15 Battery relay .............................................................................................................................................. 62-16 Alternator I terminal wire ........................................................................................................................... 62-17 Diode unit .................................................................................................................................................. 62-17 Neutral relay .............................................................................................................................................. 62-18 Magnetic switch ........................................................................................................................................ 62-19 Voltage relay ............................................................................................................................................. 62-20 Power Generating/Charging Circuit ................................................................................................................ 62-21 Alternator .................................................................................................................................................. 62-21 ECM (Engine Controller) ................................................................................................................................. 62-22 Function of ECM ....................................................................................................................................... 62-22 Connection diagram .................................................................................................................................. 62-22 Monitor lamp test ...................................................................................................................................... 62-23 Failure diagnosis ....................................................................................................................................... 62-24 Quantum fault code information ................................................................................................................ 62-27 Accelerator pedal ...................................................................................................................................... 62-33 Transmission Control Circuit and Monitor Circuit ............................................................................................ 62-36 Machine control unit (MCU) ...................................................................................................................... 62-36 MCU connection diagram (S/N 9001~9200) ............................................................................................. 62-38 MCU connection diagram (S/N 9201~) ..................................................................................................... 62-40 Machine control unit (MCU) function ......................................................................................................... 62-42 Modulator valve operation ......................................................................................................................... 62-49 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 ................................................................................................................... 62-65 Gauge circuit ............................................................................................................................................. 62-67 Fuel gauge circuit ...................................................................................................................................... 62-69

MODM ............................................................................................................................................................. 62-70 MODM function ......................................................................................................................................... 62-70 Monitor Changeover .................................................................................................................................. 62-70 Information Monitor ................................................................................................................................... 62-73 Replacement Monitor ................................................................................................................................ 62-77 Fault Log Monitor ...................................................................................................................................... 62-83 Input/Output Monitor ................................................................................................................................. 62-90 Parameter Setting Monitor ........................................................................................................................ 62-94 Specification Setting Monitor ................................................................................................................... 62-103 Electrical Detent Circuit ................................................................................................................................. 62-109 Bucket leveler .......................................................................................................................................... 62-109 Detent solenoid ....................................................................................................................................... 62-110 Lift kickout & lower kickout .......................................................................................................................62-111 Sensor assy ............................................................................................................................................ 62-112 Detent solenoid ....................................................................................................................................... 62-114 Preset height adjustment ........................................................................................................................ 62-114 Diode ............................................................................................................................................................. 62-115 Diode check method ............................................................................................................................... 62-116 Caution for diode check method ............................................................................................................. 62-116 Surge voltage and surge suppression diodes ......................................................................................... 62-118 72 Function & Structure Operator Station Group .................................................................................................. 72-1 Cabin ................................................................................................................................................................. 72-2 Glass ........................................................................................................................................................... 72-4 Wiper mount ................................................................................................................................................ 72-7 Wiper motor ................................................................................................................................................. 72-8 Operator Seat .................................................................................................................................................. 72-10 Steering and Transmission Shift Lever ............................................................................................................ 72-11 Tilt case ..................................................................................................................................................... 72-12 Column shaft ............................................................................................................................................. 72-13 Shift lever .................................................................................................................................................. 72-13

Air Conditioner ................................................................................................................................................ 72-14 Air conditioner components ...................................................................................................................... 72-14 Denso air conditioner structure ................................................................................................................. 72-15 Function of cooling mechanism ................................................................................................................ 72-20 Cooling circuit ........................................................................................................................................... 72-23 Electrical circuit ......................................................................................................................................... 72-24 Air conditioner functions of components ................................................................................................... 72-25 Charge of refrigerant ................................................................................................................................. 72-53 Troubleshooting .............................................................................................................................................. 72-70 Air conditioner ........................................................................................................................................... 72-70 73 Check & Adjustment Operator Station Group .................................................................................................. 73-1 Air Conditioner .................................................................................................................................................. 73-2 Adjustment of lubricating oil quantity when components of air conditioner are replaced ............................ 73-2 Adjustment of air gap (between hub and rotor) in compressor magnetic clutch ......................................... 73-5 Compressor V-belt adjustment .................................................................................................................... 73-6 Parts to be replaced periodically ................................................................................................................. 73-8 92 Drawing & Diagrams ........................................................................................................................................ 92-1 Axle Assembly .................................................................................................................................................. 92-2 Torque Converter and Transmission ................................................................................................................. 92-4 Hydraulic & Brake Circuit .................................................................................................................................. 92-5 Brake Circuit ..................................................................................................................................................... 92-6 Electrical Wiring Diagram (1/3) (S/N 9001~9006) ............................................................................................. 92-7 Electrical Wiring Diagram (2/3) (S/N 9001~9006) ............................................................................................. 92-8 Electrical Wiring Diagram (3/3) (S/N 9001~9006) ............................................................................................. 92-9 Electrical Wiring Diagram (1/3) (S/N 9007~9050) ........................................................................................... 92-10 Electrical Wiring Diagram (2/3) (S/N 9007~9050) ............................................................................................92-11 Electrical Wiring Diagram (3/3) (S/N 9007~9050) ........................................................................................... 92-12 Electrical Wiring Diagram (1/3) (S/N 9051~9100) ........................................................................................... 92-13 Electrical Wiring Diagram (2/3) (S/N 9051~9100) ........................................................................................... 92-14 Electrical Wiring Diagram (3/3) (S/N 9051~9100) ........................................................................................... 92-15 Electrical Wiring Diagram (1/3) (S/N 9101~9200) ........................................................................................... 92-16 Electrical Wiring Diagram (2/3) (S/N 9101~9200) ........................................................................................... 92-17 Electrical Wiring Diagram (3/3) (S/N 9101~9200) ........................................................................................... 92-18 Electrical Wiring Diagram (1/3) (S/N 9201~) ................................................................................................... 92-19 Electrical Wiring Diagram (2/3) (S/N 9201~) ................................................................................................... 92-20

Electrical Wiring Diagram (3/3) (S/N 9201~) ................................................................................................... 92-21 Electrical Wiring Diagram ................................................................................................................................ 92-22 Way of looking at connectors .................................................................................................................... 92-22 Electrical wiring diagram abbreviation chart .................................................................................................... 92-24 Electrical Wiring Diagram (CAB) ..................................................................................................................... 92-26 Electrical Wiring Diagram (Cabin Air Conditioner) .......................................................................................... 92-28 Electrical Circuit Diagram (Cabin Air Conditioner) .......................................................................................... 92-29 Equipment Operation Table (Cabin Air Conditioner) ....................................................................................... 92-30 Electrical Connection Diagram (1/2) (S/N 9001~9050) ................................................................................... 92-31 Electrical Connection Diagram (2/2) (S/N 9001~9050) ................................................................................... 92-32 Electrical Connection Diagram (1/2) (S/N 9051~9100) ................................................................................... 92-33 Electrical Connection Diagram (2/2) (S/N 9051~9100) ................................................................................... 92-34 Electrical Connection Diagram (1/2) (S/N 9101~9200) ................................................................................... 92-35 Electrical Connection Diagram (2/2) (S/N 9101~9200) ................................................................................... 92-36 Electrical Connection Diagram (1/2) (S/N 9201~) ........................................................................................... 92-37 Electrical Connection Diagram (2/2) (S/N 9201~) ........................................................................................... 92-38 Electrical Equipment Layout ............................................................................................................................ 92-39 Outline of MODM (Machine Operation Diagnostic Module) Operation ........................................................... 92-48 MODM: Input/Output Monitor - Input/Output Signal Correspondence Table ................................................... 92-57 Traction Control Switch Mount ........................................................................................................................ 92-58

115ZV-2 FS EU 00-1 00 General Information

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

115ZV-2 FS EU 00-2 00 General Information How to Use Manual

How to Use Manual Safety precautions

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

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

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

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

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

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

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

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

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

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

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

115ZV-2 FS EU 00-3 00 General Information How to Use Manual

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

Item

Description

Reference

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

Weight

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

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

Coating

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

Oil or water supply

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

Drainage

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

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

Abbreviation To save space, abbreviations are used in sentences. To understand the contents of this manual, refer to the following abbreviation list. Additional abbreviations are listed on page 92-24. 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

115ZV-2 FS EU 00-4 00 General Information Outline

Outline Layout of main components

6 7

9 2

115V2E00001

1. Engine assembly (Cummins QSK19) 2. Torque converter assy 3. Transmission 4. Hydraulic pump 5. Multiple (loader) control valve 6. Steering valve 7. Pilot valve (for loading) (right side) 8. Transmission control valve

9. Air cleaner 10. Muffler 11. Radiator 12. Hydraulic oil cooler (air-to-oil type) 13. T/C oil cooler (lower tank of radiator) 14. T/C oil cooler (installed on E/G) 15. Charge air cooler

16. Efficient loading system (ELS) valve 17. Front axle assembly 18. Rear axle assembly 19. 1st propeller shaft 20. 2nd propeller shaft 21. 3rd propeller shaft 22. Parking brake 23. Fan motor

115ZV-2 FS EU 00-5 00 General Information Outline

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

IMPORTANT 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

2000

When Required

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

Clean Crankcase Breather Tube Adjust Belt Tension Engine Replace Engine Oil and Oil Filter Cartridge Check and Adjust Injection Timing Check Engine Compression Pressure Check Injection Pressure Replace Fuel Tank Breather Clean Fuel Tank Check and Adjust Valve Lash Clearance Check Vibration Damper Clean Crankcase Breather Clean or Replace Air Cleaner Element Clean Radiator / Air cooler / Hydraulic oil cooler Fins Replace Ether Cylinder Clean or Replace Air Cleaner Element Replace Coolant

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

Note: *1 applies to machines from S/N 9101 and thereafter. Refer to the Operation & Maintenance Manual for details.

115ZV-2 FS EU 00-6 00 General Information Outline : First time replacement or cleaning only Operating hours Section

Item for check 10

250

500

1000

Check Transmission Oil Level Transmission & Torque Converter

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

Axle system Greasing (Differential seals) Greasing (2nd Propeller Shaft Spline) Replace Differential Gear Oil Replace Planetary Gear Oil Greasing (1st Propeller Shaft)

Every 12000 hours

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 Oil Brake system

Clean Filter for Brake Line Replace Parking Brake Oil Check Service Brake Disk Wear Check Brake Accumulator 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 ~9150) Replace Filter in the Hydraulic Tank Breather Valve (S/N 9151~) Replace Bucket Teeth (option) Replace Cutting Edge (option)

2000

When Required

115ZV-2 FS EU 00-7 00 General Information Outline : First time replacement or cleaning only Operating hours Section

Item for check 10

250

500

1000

2000

Adjust and Check Rear View Mirrors ROPS (Roll Over Protective Structure) Greasing (Center Pin) Chassis Check Ride Control Accumulator (option) Check and/or Replace Seat Belt Check Windshield Washer Fluid Check Wiring Harnesses Check Horn Operation Electrical system

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

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

Walk-Around Inspection

Every 3 years or 6000 hours

When Required

115ZV-2 FS EU 00-8 00 General Information Outline

Recommended lubricants Refill capacity (Approximate)

Kind of Oil

Engine

66 liter

Engine oil (CH4 or CI4)

Transmission

90 liter

Engine oil (CD) or ATF

Hydraulic tank

1

3

225 liter

Hydraulic oil

Differential & Planetary

Front: 180 liter Rear: 180 liter

Engine oil (CD)

Parking brake

3 liter

Fuel tank

660 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, antifoam, anti-rust and anti-oxidation additive properties for heavy duty use. Use of the wrong viscosity of oil can cause improper operation of hydraulic functions or premature pump failure. 3. In a case that fire-resistant fluid is to be used in the hydraulic circuit, some hydraulic equipment must be replaced. Contact your Kawasaki dealer for service. Be sure to use ISO VG32 when the temperature is below -15ºC. When replacing the hydraulic oil ISO VG46 with ISO VG32, the brakes must be bled to fully circulate the new oil, or brake problems could occur. Contact your Kawasaki dealer for service.

Differential & Planetary

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

Lubricating Grease

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

115ZV-2 FS EU 00-9 00 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

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

Kinematic Viscosity mm2/s at 40ºC

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

Recommended mixture of antifreeze Expected Minimum Ambient -35ºC Temperature

-30ºC

-25ºC

-20ºC

-15ºC

72.8

80.6

88.3

96.1

103.8

Pure Water

(liter)

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

Antifreeze

(liter)

82.2

74.4

66.7

58.9

51.2

Mixture Ratio (%)

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

- 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.

115ZV-2 FS EU 00-10 00 General Information Outline

Lubrication chart

DIFF & GEAR BOX

EVERY 12000Hr

HYD. TANK

EVERY 2000Hr

BUCKET LINK SYSTEM G G

TRANSMISSION DIFF G TO PILLOW UNIT G CENTER PIN G TO

DIFF

EVERY 1000Hr

ENGINE OIL PAN EO

AXLE SUPPORT

EVERY 250Hr

EVERY 50Hr

G CENTER PIN

EVERY 500Hr

EVERY DAY

G G

STEERING CYL.

PROPELLER SHAFT G SPLINE 2ND PROPELLER SHAFT

G 1ST & 3RD PROPELLER SHAFT

115ZV2-44794-23630EU

Grease point

G Multipurpose grease

HO Hydraulic oil

Check and add if necessary

GO Gear oil

TO Engine oil

Oil replacement

EO Engine oil

115ZV-2 FS EU 00-11 00 General Information Outline

Weight of main components Item Part name

Approx. weight (kg)

Approx. weight (lb)

Bucket

4,985

10,970

Boom

3,210

7,070

"Z" -Lever

515/pc

1,135/pc

Link (Bucket to Lever)

90/pc

200/pc

Screen board

175

385

Roof

155

Radiator guard

115/pc

250

Access panel

35/pc

80/pc

Unit name

Engine room

360

795

Excluding oil

Fuel tank

330

730

Excluding fuel

Floor board

285

630

Including ope. board, instrument panel and control box

Cab

270

600

Soft cab

ROPS

Deck

950

2,090

Left side

105

230

With handrail

Right side

175

With handrail

Center Front chassis

80 8,360

Rear chassis

4,300

9,460

2,150

4,730

Engine

1,980

4,360

Excluding oil

1,960

With air cooler, hyd. cooler and duct. Excluding water and oil

890

Torque converter

440

970

Excluding oil

Transmission

1,310

2,880

Excluding oil

First propeller shaft

Second propeller shaft

130

290

Third propeller shaft

Front axle assembly

2,970

6,530

Excluding tires and oil

Rear axle assembly

2,940

6,470

Excluding tires and oil (Including axle support) Including parking brake

Front

745

1,640

Rear

560

1,235

Multiple control valve

100

220

Pilot valve

Steering valve

110

Orbitrol®

Differential

Other

35 3,800

Counter weight

Radiator assembly

Hydraulic system

RVT bucket

Hydraulic tank Chassis

Power line

Remarks

Gear pump

Switch

Main & pilot

Fan motor

Boom cylinder

520/pc

1,145/pc

Excluding oil

Bucket cylinder

245/pc

540/pc

Excluding oil

Steering cylinder

40/pc

90/pc

Excluding oil

Tire

1,580/pc

3,480/pc

With rim (35/65R33

Battery

65/pc

145/pc

)

115ZV-2 FS EU 00-12 00 General Information Outline

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

Metric thread

Nominal diameter

Pitch

8.8 (8T)

10.9 (11T)

(F) 1.25

132

(F) 1.25

142

206

(F) 1.5

152

221

216

314

(F) 1.5

226

330

299

436

(F) 1.5

324

476

417

608

(F) 1.5

451

662

559

814

(F) 1.5

598

878

721

1,030

M10

M12

M14

M16

M18

M20

M22

M24

M27

M30

Unified thread

Bolt strength

Nominal dimension

M33

5/16

(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

(F) 2.0

2,059

3,040

18 UNC

3/8

16 UNC

7/16

14 UNC

103

1/2

13 UNC

103

147

9/16

12 UNC

147

216

5/8

11 UNC

201

294

3/4

10 UNC

358

525

7/8

9 UNC

554

809

8 UNC

868

1,275

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

115ZV-2 FS EU 00-13 00 General Information Outline

(kgf-m) Bolt size Type

Metric thread

Nominal diameter

Pitch

8.8 (8T)

10.9 (11T)

2.7

3.9

5.4

7.8

(F) 1.25

5.6

8.2

M10

M12

M14

M16

M18

M20

M22

M24

M27

M30

Unified thread

Bolt strength

Nominal dimension

M33

5/16

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.

115ZV-2 FS EU 00-14 00 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

230

(F) 1.5

165

245

220

320

(F) 1.5

235

350

305

450

(F) 1.5

330

490

410

600

(F) 1.5

440

650

530

760

M10

M12

M14

M16

M18

M20

M22

M24

M27

M30

Unified thread

Bolt strength

Nominal dimension

M33

5/16

(F) 2.0

565

830

760

1,120

(F) 2.0

830

1,190

1,050

1,550

(F) 2.0

1,160

1,660

1,410

2,100

(F) 2.0

1,520

2,240

18 UNC

18.0

3/8

16 UNC

7/16

14 UNC

1/2

13 UNC

105

9/16

12 UNC

110

160

5/8

11 UNC

150

215

3/4

10 UNC

265

385

7/8

9 UNC

410

595

8 UNC

640

940

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

115ZV-2 FS EU 00-15 00 General Information Outline

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

Metric thread

Bolt strength

Nominal dimension

Pitch

0.8

1.25

M10

1.5

M12

1.75

M16

231

M20

2.5

441

M24

765

8.8 (8T)

(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

115ZV-2 FS EU 00-16 00 General Information Outline

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

Hose band

Tightening torque (N-m)

Tightening torque (kgf-cm)

Tightening torque (lb-ft)

69002-02200

1.6

1.2

2.9

Hose band

Tightening torque (N-m)

Tightening torque (kgf-cm)

Tightening torque (lb-ft)

69002-02200

1.6

1.2

2.9

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

16.5

7.9

18.5

9.5

20.5

12.7

24.5

15.9

29.9

19.0

30.0

25.4

38.0

69002-04400

31.8

45.8

69002-05200

38.1

52.1

69002-05700

50.8

67.8

69002-07100

60.5

76.0

69002-08200

75.5

93.0

69002-09500

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

16.5

18.5

20.5

22.0

24.5

26.0

29.0

30.5

32.0

34.0

39.5

41.5

46.0

48.0

54.0

70.5

73.0

69002-02700 69002-03100

69002-02300 69002-02700

69002-03100

69002-03800

69002-04400

69002-05200 69002-05700 69002-07600

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

Fix the band avoiding the beading.

2~3 mm Pipe

Hose Hose band

K50V200002

115ZV-2 FS EU 00-17 00 General Information Outline

Liquid gasket and screw lock agent To reassemble the disassembled parts, be sure to use the specified liquid gasket or screw lock agent or the equivalent according to the following lists: Code Liquid gasket

Screw lock agent

Manufacturer

Product name

AA01

Loctite

Plastic Gasket 568

AA02

Loctite®

Hydraulic sealant

AA03

Three Bond

Three Bond 1215

AB01

Loctite®

Loctite® 262

AB02

Three Bond

Three Bond 1327

AB03

Three Bond

Three Bond 1374

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

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

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

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

Manufacturer

AC01

Loctite®

Product name Loctite® 767 (Paste or spray)

115ZV-2 FS EU 00-18 00 General Information Outline

Screw lock agent application procedure

How to wind a seal tape

Through-hole Apply screw lock agent one or two lines on the male threads.

Seal tape Screw lock agent Leave 1~2 screw

65ZV00004a

65ZV00002

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

115ZV-2 FS EU 00-19 00 General Information Outline

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

Cautions 1. Turn the starter switch OFF.

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

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

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

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

115ZV-2 FS EU 00-20 00 General Information Outline 7. The weld spattered on the hydraulic cylinders and on the plated sections of pins will damage the cylinders and pins. There are other parts that may be damaged by the spatter; hydraulic units, harnesses, hydraulic hoses, and nylon tubes. Be sure to mask these units and parts before welding.

Hydraulic cylinder

Heat-resistant cloth Section to be welded

Hydraulic hose Nylon tube Harness

Remove and if necessary wrap Chassis

35A00005

Plated section (Mask this section.)

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

Pin section with pin temporarily inserted Pin

Plated section (Mask this section.) 35C00003

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

1m or more

Scrap material, etc.

Section to be welded

1m or more 35C00004

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

115ZV-2 FS EU 03-1 03 Measurement for Performance Check

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

115ZV-2 FS EU 03-2 03 Measurement for Performance Check Cautions on Safety

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

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

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

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

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

115ZV-2 FS EU 03-3 03 Measurement for Performance Check Standard Measurement Values for Performance Check

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

Item Measurement item

System

Engine speed (min-1) (rpm)

Engine

(S/N 9001~9100)

(S/N 9101~)

Transmission

Minimum no-load speed, Low Idle (LI)

925±50

Maximum no-load speed, High Idle (HI)

1,910±50

Maximum speed in torque converter stall mode

1,780±100

1,690±100

Maximum speed in multiple control valve relief mode

1,855±100

1,705±100

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

1,420 +150 - 100

1,375 +150 - 100

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

Fuel efficient mode

Normal

925±50

Maximum no-load speed, High Idle (HI)

1,910±50

1,700±50

Maximum speed in torque converter stall mode

1,780±100

1,690±100

Maximum speed in multiple control valve relief mode

1,850±100

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

1,420 +150 - 100

1,380 +150 - 100

Main pressure MPa (kgf/cm2) (psi)

Remarks

775 in hibernate mode

Idling (LI)

2.6±0.2 (27±2) (384±28)

Maximum (HI)

2.6±0.2 (27±2) (384±28)

Engine speed Clutch pressure MPa (kgf/cm2) (psi) Clutch time lag (sec)

Idling (LI)

2.1~2.5 (21.5~25.5) (305~363)

Maximum (HI)

2.1~2.5 (21.5~25.5) (305~363)

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

0.3±0.1

Before wheels move

115ZV-2 FS EU 03-4 03 Measurement for Performance Check Standard Measurement Values for Performance Check

Standard measurement values for performance check

Item Measurement item

System

Normal

Hydraulic line

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

Engine speed

Full steering time (sec)

Engine speed

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

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

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

Remarks

3 (1/8) or less

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

Boom rising time (no load) (sec)

Fuel efficient mode

25±3.0 -1

1,500 min (rpm)

10.5±1.0

Maximum (HI)

8.4±0.5

Idling (LI)

5.0±0.5

1,500 min-1 (rpm)

3.9±0.3

Full accelerated engine speed

3.9±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)

1,120 +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

900 +50 - 200

Run engine at lowest possible speed while setting

115ZV-2 FS EU 03-5 03 Measurement for Performance Check Standard Measurement Values for Performance Check

Standard measurement values for performance check

Item Measurement item

System

Shift lever position

2nd speed reverse

Engine speed

Maximum (HI)

Shift lever position

3rd speed reverse

Performance of service brake

Performance of parking brake Maximum (HI)

Off (Cut-out)

11.8±0.5 (120±5) (1,706±71)

On (Cut-in)

6.9±1.0 (70±10) (995±142)

Brake

Unloader valve setting pressure

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

Remarks

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

Same as above Engine speed

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

Fuel efficient mode

Normal

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

3.9±0.5 (40±5) (569±71) 1.3 (13) (185)

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.

at least 11 times

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

Declutch engagement (cm) (in)

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

15 (6) or less

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

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

115ZV-2 FS EU 03-6 03 Measurement for Performance Check

MEMO

115ZV-2 FS EU 12-1 12 Function & Structure Chassis Group

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

115ZV-2 FS EU 12-2 12 Function & Structure Chassis Group Front Chassis

Front Chassis Loading linkage

6 115ZV12001

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)

115ZV-2 FS EU 12-3 12 Function & Structure Chassis Group Front Chassis

Even contact both sides

5000 5040 mm

Hinge pin height at 300 bucket on ground

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

Note for setting roll-back stops: When installing roll-back stops, the stops must have a smooth radius and must contact boom on both sides. The cylinder must retain 3~5 mm of rod with in the cylinders so the piston does not hit the cylinder head.

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

(FM) 115V2E12001

115ZV-2 FS EU 12-4 12 Function & Structure Chassis Group Front Chassis

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

2. Boom - Lever

3. Boom - Boom cylinder

4. Front chassis - Boom

5. Bucket - Rod

6. Lever - Rod

7. Lever - Bucket cylinder

8. Bucket cylinder Front chassis

9. Boom cylinder Front chassis

10. Front chassis Steering cylinder

11. Steering cylinder Rear chassis

115V2E12002

115ZV-2 FS EU 12-5 12 Function & Structure Chassis Group Rear Chassis

Rear Chassis Fuel tank

9 7 A-Detail

4 9

1. Fuel tank 2. Fuel level sensor 3. Fuel tank filler assembly 4. Filter 5. Drain plug (S/N 9201~ Square socket head) 6. Inspection hole cover 7. Gasket (Rubber seal type) 8. Suction pipe 9. Fuel return pipe

115V2E12003

115ZV-2 FS EU 12-6 12 Function & Structure Chassis Group Rear Chassis

Floor board mount

Viscous mount

Floor board

2 1

3 4 115ZV12008

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.

70ZV12007

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

115ZV-2 FS EU 12-7 12 Function & Structure Chassis Group Center Pin

Center Pin Upper center pin

Upper

4 9, 10

5 Front chassis 6

11 2 Upper

8, 10

Rear chassis 115ZV12010

6 4 9, 10 7 3

Grease pipe

Split shim

2 5 8, 10 115V2E12004

1. Center pin 2. Plate 3. Bearing cover 4. Sleeve 5. Shim 6. Bearing assy 7. Dust seal 8. Bolt 9. Bolt 10. Washer 11. Bushing

115ZV-2 FS EU 12-8 12 Function & Structure Chassis Group Center Pin

Lower center pin

Lower

6 7

2 3 Front chassis

Rear chassis

Lower

115ZV12011

6, 7

Grease pipe

2 115V2E12005

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

115ZV-2 FS EU 12-9 12 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.

115ZV-2 FS EU 12-10 12 Function & Structure Chassis Group

MEMO

115ZV-2 FS EU 13-1 13 Check & Adjustment Chassis Group

13 Check & Adjustment Chassis Group Linkage Pin ............................................................. 13-2 Center Pin ............................................................... 13-6

115ZV-2 FS EU 13-2 13 Check & Adjustment Chassis Group Linkage Pin

Linkage Pin WARNING

CAUTION

Unexpected movement of the machine may cause an accident resulting in injury or death. Before starting adjustment work, be sure to observe the following items: - Park the machine on level ground. - Apply the parking brake. - Remove the starter key, and 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

115ZV12005

Adjustment portion

Liner hole diameter (mm)

110

121

101

121

Adjustment unnecessary

115ZV-2 FS EU 13-3 13 Check & Adjustment Chassis Group Linkage Pin

Bucket hinge pin section (#1) Boom

Bucket

Bushing

Hinge pin (#1)

Bolt

Dust seal

Shim

Seal retainer assy

Shim 95V2E13001

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

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

R142

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 115V2E13001

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)

115ZV-2 FS EU 13-4 13 Check & Adjustment Chassis Group Linkage Pin

Bucket link pin section (#2) Bucket Bushing

Link

* Bushing

Dust seal

Shim Seal ring assy 115V2E13002

How to assemble 1. Insert the bushings into the link boss and attach the seal ring assy to the bushing.

91 +10

80 -10

(When installing the dust seal to the seal ring assy, be sure to check the direction of the dust seal.) 2. Place the shim between the bucket boss and the seal ring assy so that the clearance between the link boss and the seal ring (* marked) is less than 1mm. Shim thickness: 1.0, 0.5 mm (0.039, 0.020 in) (2 kinds of shim thickness)

Shim

115V2E13003

3. Align the pin holes in the bucket and the link. Then, insert the pin.

115ZV-2 FS EU 13-5 13 Check & Adjustment Chassis Group Linkage Pin

Adjustment

95ZV12005

Adjust the clearance (*) to 1.2 mm or less for #3 ~ #8 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.

115ZV-2 FS EU 13-6 13 Check & Adjustment Chassis Group Center Pin

Center Pin Adjusting shim

The clearance between the front chassis and bearing cover (3) is 0.75±0.5 mm (0.03±0.02 in) before shim adjustment. 1

4 9, 10

Add shims (5) so that the clearance is 0.1±0.05 mm (0.004±0.002 in). After that, tighten bolt (9). 5

Front chassis 6

Torque for assembly: : Bolt (8): 662 N-m (67.5 kgf-m) (488 lb-ft) Bolt (9): 441 N-m (45.0 kgf-m) (326 lb-ft) (with lubricating oil (Engine oil or gear oil))

Installing bearing cover 11 2 Upper

8, 10

Rear chassis 115ZV12010

Front

Grease pipe

Upper

3 115V2E13004

6 4

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

9, 10 7 3

Grease pipe

Split shim

2 5 8, 10 115V2E12004

115ZV-2 FS EU 13-7 13 Check & Adjustment Chassis Group Center Pin

Installing bearing outer ring

6 7

Front

Rear

Center line

Split of outer bearing

3 2 3 Front chassis

Rear chassis

Lower

115ZV12011

6, 7

Grease pipe

2 115V2E12005

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

95ZV13003

115ZV-2 FS EU 13-8 13 Check & Adjustment Chassis Group

MEMO

115ZV-2 FS EU 22-1 22 Function & Structure Power Group

22 Function & Structure Power Group Power Line .............................................................. 22-2 Engine / Transmission............................................. 22-3 Radiator (S/N 9001~9050) ...................................... 22-4 Radiator (S/N 9051~) .............................................. 22-6 Propeller Shaft......................................................... 22-8 Axle Assembly......................................................... 22-12 Axle Support............................................................ 22-14 Differential Gear ...................................................... 22-16 Limited Slip Differential (option) (S/N 9054~) .......... 22-21

115ZV-2 FS EU 22-2 22 Function & Structure Power Group Power Line

Power Line

15 4

14 115V2E22001

1. Engine 2. Torque converter 3. Transmission 4. Radiator 5. 1st propeller shaft 6. 2nd propeller shaft 7. 3rd propeller shaft 8. Front axle differential gear 9. Rear axle differential gear 10. Parking brake 11. Air cleaner 12. Muffler 13. Hydraulic oil cooler 14. Torque converter oil cooler (bottom tank of radiator) 15. Charge air cooler

The power output from the engine is transmitted to the transmission through the torque converter and the first propeller shaft. 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 and an external air type hydraulic oil cooler. A parking brake is installed on the front differential gear.

115ZV-2 FS EU 22-3 22 Function & Structure Power Group Engine / Transmission

Engine / Transmission Engine / transmission mount

C D

E,F A

C T/C side

E/G side Spacer

4 1 2 3

E/G flywheel housing A-Detail

B-Detail

C-Detail

D-Detail

E-Detail

F-Detail

115V2E22002

1. Rubber cushion 2. Ring gear 3. O-ring 4. Plug

Bolts are used to connect the engine flywheel housing to the torque converter housing, and a spline ring coupling 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, torque converter and the transmission on the chassis.

115ZV-2 FS EU 22-4 22 Function & Structure Power Group Radiator (S/N 9001~9050)

Radiator (S/N 9001~9050)

Charge air cooler OUT

Coolant IN

Charge air cooler IN

B 1 B

3 D D

A C A

Hydraulic oil cooler OUT

Hydraulic oil cooler IN T/C oil cooler OUT

T/C oil cooler IN

Coolant OUT

115V2E22003

1. Radiator assembly 2. Radiator duct 3. Stay (Bracket)

4. Charge air cooler 5. Hydraulic oil cooler 6. T/C oil cooler

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

The torque converter oil cooler is in the radiator lower tank. When the coolant is hot, the thermostat opens and the coolant flows to the radiator. When the coolant is cold enough, the thermostat is completely closed and no coolant flows to the radiator. The air charge cooler is required to meet engine emission regulations.

115ZV-2 FS EU 22-5 22 Function & Structure Power Group Radiator (S/N 9001~9050)

Radiator mount 2 1

6 4 1

3 A-Detail

B-Detail

C-Detail

D-Detail K115V2U22005

1. Plate 2. Flange bolt 3. Nut 4. Plate 5. Bushing 6. Boss 7. Strip seal Capacity in radiator: 86 L (23 gal) Cooling water 14 L (3.7 gal) Hydraulic oil Torque converter oil 3 L (0.8 gal) x 2 pcs Dry weight

890 kg (1,960 lbs)

115ZV-2 FS EU 22-6 22 Function & Structure Power Group Radiator (S/N 9051~)

Radiator (S/N 9051~)

Charge air cooler OUT

Coolant IN

Charge air cooler IN

B 1 B

A C A

2 5 Hydraulic oil cooler OUT

Hydraulic oil cooler IN T/C oil cooler OUT

T/C oil cooler IN

Coolant OUT

K115V2U22006

1. Radiator assembly (with aluminum core) 2. Radiator duct 3. Stay (Bracket)

4. Charge air cooler 5. Hydraulic oil cooler 6. T/C oil cooler

115ZV-2 FS EU 22-7 22 Function & Structure Power Group Radiator (S/N 9051~)

Radiator mount

2 1

6 4 1

3 A-Detail

B-Detail

C-Detail K115V2U22007

1. Plate 2. Flange bolt 3. Nut 4. Plate 5. Bushing 6. Boss

Capacity in radiator: 98 L (26 gal) Cooling water 11 L (2.9 gal) Hydraulic oil Torque converter oil 2.4 L (0.6 gal) x 2 pcs Dry weight

570 kg (1,257 lbs)

115ZV-2 FS EU 22-8 22 Function & Structure Power Group Propeller Shaft

Propeller Shaft

1. 1st propeller shaft 2. 2nd propeller shaft 3. 3rd propeller shaft (fixed type) 4. Pillow block 5. Parking brake 6. Slip joint

115V2E22005

The engine power is transmitted to the torque converter, the first propeller shaft 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. A parking brake is installed on the front differential gear. The third propeller shaft is the fixed type with universal joints.

115ZV-2 FS EU 22-9 22 Function & Structure Power Group Propeller Shaft

First propeller shaft assembly Transmission – Torque converter

Grease nipple installation angle (a,b)

Z View Z

a 2

1 1

Every 12000 hours greasing

115V2U22002

1. Journal spider assy 2. Propeller shaft

115ZV-2 FS EU 22-10 22 Function & Structure Power Group Propeller Shaft

Second propeller shaft assembly Front differential – Transmission

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

a 45 Z

View Z

Every 12000 hours greasing

d 4 Every 2000 hours greasing

Front differential side

b 2

1 c Transmission side

1 Every 12000 hours greasing

a 115V2U22003

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

115ZV-2 FS EU 22-11 22 Function & Structure Power Group Propeller Shaft

Third propeller shaft assembly Transmission – Rear differential 1

2 b

Grease nipple installation angle (a,b)

1 a

View Z

1 1 b

Every 12000 hours greasing 115V2U22004

1. Journal spider assy 2. Propeller shaft

115ZV-2 FS EU 22-12 22 Function & Structure Power Group Axle Assembly

Axle Assembly

1 50 22

2 3 44 42

36 45

35 45

43 28

37 11

40 52

23 31

16 34

12 30 29

21 24

26 41 19

14 25 9

18 25 14

49 18

5 39

4 37

27 33

115V2E22009

115ZV-2 FS EU 22-13 22 Function & Structure Power Group Axle Assembly 1. Differential assembly 2. Axle housing assembly 3. Wheel hub 4. Spider 5. Cover 6. Axle shaft 7. Sun gear 8. Disc gear 9. Planetary gear 10. Internal gear 11. Internal gear hub 12. Snap ring 13. Planetary pin 14. Wear ring 15. Wear ring 16. Brake piston 17. Separation disc 18. Friction disc 19. Brake backing plate 20. Plate 21. Axle nut 22. Taper roller bearing (inner) 23. Taper roller bearing (outer) 24. Separation disc 25. Needle cage 26. Axle lock plate 27. Snap ring 28. Floating seal 29. D-ring 30. D-ring

31. O-ring 32. O-ring 33. O-ring 34. Socket bolt 35. Spring 36. U-nut 37. Magnet plug 38. Bolt 39. Socket bolt 40. Air bleeder screw 41. Spring pin 42. Ring 43. O-ring 44. Spring pin 45. Plug 46. Spring 47. Sleeve 48. Bushing 49. Socket bolt 50. Bolt 51. Bolt 52. Flange bolt

115ZV-2 FS EU 22-14 22 Function & Structure Power Group Axle Support

Axle Support Grease pipe connection port (PT1/8)

Grease pipe connection port (PT1/8)

Pin (Axle housing)

Axle housing

Front

16 9

4 15

6 10

238.1 0.8

A-A

Groove at bushing end

12 14

237.7 0.8

10 #10 Details

(S/N 9001~9053) (S/N 9054~) #8 Details

#11 Details

K115V2J22003

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

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

115ZV-2 FS EU 22-15 22 Function & Structure Power Group Axle Support

9 (S/N ~9002) 9 (S/N 9003~) Grease piping

2 10 7 12

6 7

9 (S/N 9003~) 9 (S/N ~9002)

5 4 Grease piping

11 15

Front

16 16

3 8 13 1

115V2E22011

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 ~9002) Elbow fitting (S/N 9003~) 10. Bushing 11. Bushing 12. Ring 13. Snap ring 14. Bolt 15. Bolt 16. Bolt

115ZV-2 FS EU 22-16 22 Function & Structure Power Group Differential Gear

Differential Gear Conventional type Front differential gear (S/N 9001~9050) 2

3 29

26 33 35

5 6

8 9

10 21

11 12 13

16 18 19

20 115V2E22012

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

115ZV-2 FS EU 22-17 22 Function & Structure Power Group Differential Gear Front differential gear (S/N 9051~9100)

3 36

K115V2U22002

Front differential gear (S/N 9101~)

3 36

K115V2U22003

1. Nut 2. Flange yoke 3. Oil seal 29. Piston assembly 36. Oil seal (Double lip) (S/N 9051~)

115ZV-2 FS EU 22-18 22 Function & Structure Power Group Differential Gear Rear differential gear 1

31 23

8 21 6 9

25 11 7

12 18

14 13

1. Nut 2. Flange yoke 3. Oil seal 4. Trunnion 5. Housing 6. Taper roller bearing 7. Taper roller bearing 8. Sleeve

9. Spiral gear set 10. Carrier assembly 11. Adjusting nut 12. Lock plate 13. Straight pin 14. Wear ring 15. Wear ring 16. Diff pinion

17. Side gear 18. Spider 19. Housing assy 20. Roller bearing 21. O-ring 22. O-ring 23. O-ring 24. Shim

K115V2U22004

25. O-ring 26. Bolt 27. Snap ring 28. Bolt 29. Bolt 30. Bolt 31. Oil seal (Double lip) (S/N 9051~)

115ZV-2 FS EU 22-19 22 Function & Structure Power Group Differential Gear

Function of differential gear

Operation of differential gear

Power transmission

Straight

2 3 4 4 5

115K22005

115ZV22013

1. The power output from the engine is transmitted to the front and rear axle through the torque converter and the transmission.

When moving in a straight direction, each wheel holds the same amount of torque.

2. The power is transmitted from pinion gear (1) to axle shaft (2) through bevel gear (5) and differential (4) in the axle housing. 3. Finally the power is transmitted to the planetary gears and tires to move the machine.

Therefore, pinion gears (4) in the differential assy do not turn. Torque from carrier (6) is transmitted to each wheel equally through pinion gears (4), side gears (3) and axle shafts (2).

115ZV-2 FS EU 22-20 22 Function & Structure Power Group Differential Gear

Turn

2 115ZV22014

When turning, the inside wheel needs more torque than the outside wheel because of the resistance on it. The outside wheel rotates faster than the inside wheel. Then, pinions (4) turn on side gears (3) and torque from carrier (6) is transmitted to each wheel through pinion gears (4), side gears (3) and axle shafts (2).

115ZV-2 FS EU 22-21 22 Function & Structure Power Group Limited Slip Differential (option) (S/N 9054~)

Limited Slip Differential (option) (S/N 9054~) LSD structure Differential assembly

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

Side gear Differential cage

3 1

Limited Slip Differential 3

3 2 4 1

K115V2U22008

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

115ZV-2 FS EU 22-22 22 Function & Structure Power Group Limited Slip Differential (option) (S/N 9054~)

LSD function

LSD operation Performance comparison between LSD and conventional differential Side gear moves to the left and pushes LSD clutch.

LSD Differential point 0.5 (bias ratio 2.0) Torque

Differential cage

ire et On

Axle shaft

Side gear

LSD clutch assembly

Differential pinion

0.1

in s sp

r the

e On

ge an

tire

n spi

Limited Slip Diff. Conventional Diff. ge g ran eratin p O D

A th e s in

g ran

Conventional Diff. point 1.0 (bias ratio 1.0)

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

0.5

0.9

Torque is transferred to the right and left tires evenly until the friction ratio between the right and left tires comes to 0.5:1. The result is that the LSD adds tractive effort.

A - Detail K115V2U22009

K115V2U22010

LSD (Limited-Slip Differential) is installed between the side gear and the differential cage, 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 following shows operation for the left tire.

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.

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.

A rotating driving force is transmitted from the differential cage via spider (cross shaft) to the differential pinion and the side gear.

115ZV-2 FS EU 23-1 23 Check & Adjustment Power Group

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

115ZV-2 FS EU 23-2 23 Check & Adjustment Power Group Engine

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

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

Measurement instrument - Pressure gauge

Install position 1. Location (A) 2. Measuring port: 9/16-18 UNF 3. Oil pressure gauge: 1.0 MPa (10 kgf/cm2) (150 psi)

Standard measurement value Engine speed

Service standard

925±50 min-1

0.14 MPa (1.4 kgf/cm2) (20 psi)

1,910±50 min-1

0.34~0.48 MPa (3.5~4.9 kgf/cm2) (50~70 psi)

[Engine coolant temperature 50ºC (120ºF)]

Measuring engine speed Measurement instrument - Tachometer

Standard measurement value Low idle (min-1): 925±50 High idle (min-1): 1,910±50

115V2E23001

115ZV-2 FS EU 23-3 23 Check & Adjustment Power Group Propeller Shaft

Propeller Shaft Propeller shaft phase

Third propeller shaft

Second propeller shaft

Front differential

Transmission

Rear differential

95ZV22007

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

Second propeller shaft alignment

Top view Differential side

(C)

(B)

(A)

Transmission side

Side view 95ZV22008

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

115ZV-2 FS EU 23-4 23 Check & Adjustment Power Group Propeller Shaft

Propeller shaft tightening torque

2nd propeller shaft

3rd propeller shaft

Front differential

Rear differential

Bolt

Washer

(S/N (S/N 9114~) 5159~)

1st propeller shaft

5 2nd propeller shaft

1st propeller shaft

3rd propeller shaft (FM) K115V2U23004

: 1. 221 N-m (22.5 kgf-m) (163 lb-ft) 2. 142 N-m (14.5 kgf-m) (105 lb-ft) 3. 441 N-m (44.9 kgf-m) (325 lb-ft) 4. 162 N-m (16.5 kgf-m) (119 lb-ft) 5. 220 N-m (22.4 kgf-m) (162 lb-ft) 6. 155 N-m (15.8 kgf-m) (114 lb-ft) 7. 417 N-m (42.5 kgf-m) (308 lb-ft)

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

115ZV-2 FS EU 23-5 23 Check & Adjustment Power Group Axle

Axle Axle nut tightening procedure

8 PT3/8 (Brake oil inlet)

4 2

115V2E23003

1. Tighten axle nut (6) with 3,923 N-m (400 kgf-m) (2,894 lb-ft) tightening torque to install taper roller bearings (7)(8). 2. Loosen axle nut (6).

: 1. 89.7 N-m (9.15 kgf-m) (66 lb-ft) 2. 721 N-m (73.5 kgf-m) (532 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 3,923 N-m (400 kgfm) (2,894 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) 353~392 N (36~40 kgf) (79~88 lbs)  This is "breakaway" force. The force required to start the wheel turning. Note Use jig to install the floating seal to the axle assembly.

115ZV-2 FS EU 23-6 23 Check & Adjustment Power Group Axle

Differential gear adjustment procedure (S/N 9001~9050) 1

2 10

5 3 115V2E23004

: 1. 1,030 N-m (105 kgf-m) (760 lb-ft) 2. 314 N-m (32.0 kgf-m) (232 lb-ft) 3. 1,130 N-m (115 kgf-m) (832 lb-ft) 4. 52.5 N-m (5.35 kgf-m) (39 lb-ft) 5. 314 N-m (32.0 kgf-m) (232 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)

115ZV-2 FS EU 23-7 23 Check & Adjustment Power Group Axle

Preload adjustment

Front differential gear (S/N 9051~9100)

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

Standard preload 7

Front differential: 24.5~29 N (2.5~3 kgf) (6~7 lbf) Rear differential: 39~49 N (4~5 kgf) (9~11 lbf)

9 11

If the preload is out of the above range, replace spacer (10) to adjust the preload to the specified range. K115V2U23001

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

Front differential gear (S/N 9101~)

Note There are 20 types of spacers from 29.10 mm (1.146 in) to 29.48 mm (1.161 in) in increments of 0.02 mm (0.0007 in). Thicker spacers reduce preload; thinner spacers increase preload.

9 11

K115V2U23002

Rear differential gear

K115V2U23003

115ZV-2 FS EU 23-8 23 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 9051~) (double lip) 9 (S/N ~9050) (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.

115ZV-2 FS EU 23-9 23 Check & Adjustment Power Group Axle

Adjusting tooth contact Tooth contact

Possible cause

Adjusting method

Correct

Ring gear is too close to the drive pinion

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

Ring gear is too far from the drive pinion

Do the reverse adjusting as B.

Drive pinion is too close to the ring gear.

Increase the thickness of shim at the part of bearing cage being installed and 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.

115ZV-2 FS EU 23-10 23 Check & Adjustment Power Group Axle Three types of tooth contact shown below are acceptable as the best tooth contact. Tooth contact position and length (rate) 10 1

Pattern A

5 TOP

HEEL 4~5

Pitch line TOE

BOTTOM 10 2

Pattern B

4 TOP

HEEL

Pitch line

4~5

TOE BOTTOM 10 3

Pattern C

TOP TOE

HEEL 4~5

Pitch line BOTTOM

Service parts After adjusting the tooth contact and backlash in our factory, we 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.

115ZV-2 FS EU 32-1 32 Function & Structure Torque Converter and Transmission Group

32 Function & Structure Torque Converter and Transmission Group Torque Converter .................................................... 32-2 Torque Converter (Lock-up) (Option) ...................... 32-4 Torque Converter Gear Pump ................................. 32-7 Transmission ........................................................... 32-8 Clutch Pack ............................................................. 32-14 Power Flow Path in the Transmission ..................... 32-15 Hydraulic System Diagram...................................... 32-19 Hydraulic Circuit Diagram........................................ 32-20 Oil Flow ................................................................... 32-22 T/C and T/M Oil Circulation ..................................... 32-24 Modulator Valve Unit ............................................... 32-25 Control Valve Assembly .......................................... 32-31

115ZV-2 FS EU 32-2 32 Function & Structure Torque Converter and Transmission Group Torque Converter

Torque Converter 9

4 115V2E32001

1. Pump impeller 2. Turbine impeller 3. Stator 4. Turbine shaft 5. Stator shaft (Fixed) 6. Drive cover

7. Ring gear 8. P.T.O. drive gear 9. P.T.O. driven gear 10. P.T.O. driven gear 11. Output flange

115ZV-2 FS EU 32-3 32 Function & Structure Torque Converter and Transmission Group Torque Converter

Torque converter structure

Torque multiplication

Output

Torque ratio (t)

Input

1 S P

0.5 Speed ratio (e)

1.0

95ZV32002

115ZV32002

The torque converter is between the engine and transmission, and consists of three impellers as shown in the figure. The three impellers are pump (P), turbine (T), and stator (S) impellers.

If the engine speed/pump impeller speed stays the same but the turbine impeller speed is reduced due to the transmission load-output torque is increased. This is "torque multiplication". Heat is also generated.

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.

Turbine impeller speed (min – 1 ) (rpm) Speed ratio(e)= -----------------------------------------------------------------------------------------------Pump impeller speed (min – 1 ) (rpm)

115ZV-2 FS EU 32-4 32 Function & Structure Torque Converter and Transmission Group Torque Converter (Lock-up) (Option)

Torque Converter (Lock-up) (Option)

Oil from Lock-up solenoid valve

T S

1 2 3

115V2E32024

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

115ZV-2 FS EU 32-5 32 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

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

115V2E32028

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 lock-up 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.

115ZV-2 FS EU 32-6 32 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

12.0 10.0 (7.5) (6.3)

Reverse

10.0 11.0 13.5 15.5 20.5 21.5 26.5 28.5 (6.3) (6.9) (8.4) (9.7) (12.8)(13.4) (16.6) (17.8)

Forward Speed km/h (mile/h) Automatic shift map (Normal mode) 115V2U62008

3rd → 3rd lock-up

15.5 km/h (9.6 MPH)

4th → 4th lock-up

28.5 km/h (17.7 MPH)

4th lock-up → 4th

26.5 km/h (16.5 MPH)

3rd lock-up → 3rd

13.5 km/h (8.4 MPH)

Shift Up

Shift Down

115ZV-2 FS EU 32-7 32 Function & Structure Torque Converter and Transmission Group Torque Converter Gear Pump

Torque Converter Gear Pump

Torque converter pump

Torque converter

115V2E32002

Gear pump specifications Theoretical discharge

100.4 cm3/rev (6.13 in3/rev)

Maximum operation pressure

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

Maximum operation speed

2,500 min-1 (rpm)

Actual discharge

Approx. 70 L/min (18.5 gpm) Conditions: Pump speed 900 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)

115ZV-2 FS EU 32-8 32 Function & Structure Torque Converter and Transmission Group Transmission

Transmission 14

4 2 7

10 115V2E32003

1. Input flange 2. Low range clutch 3. High range clutch 4. Reverse clutch 5. 1st speed clutch 6. 2nd speed clutch

7. 3rd speed clutch 8. Output gear 9. Output shaft 10. Output flange (3rd propeller shaft side)

11. Output flange (2nd propeller shaft side) 12. Modulator valve unit 13. Clutch solenoid valve assembly 14. Clutch valve assembly

115ZV-2 FS EU 32-9 32 Function & Structure Torque Converter and Transmission Group 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

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

Function

Automatic or manual speed change is available depending on the position of the shift lever, as shown in the 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.

115ZV-2 FS EU 32-10 32 Function & Structure Torque Converter and Transmission Group Transmission

Gear train and number of teeth

2 94

R 94

H From 1st propeller shaft

59 83

2nd propeller shaft

3rd propeller shaft

115V2E32008

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

6.0±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) 6

Reverse clutch

7.0±0.5

High range clutch

3.0±0.5

1st speed clutch

5.0±0.5

2nd speed clutch

3.0±0.5

3rd speed clutch

4.0±0.5

ø420 ø260 ø420

ø330

4±0.15 / 3.5 (Sintered)

ø171

4±0.15 / 3.8 (Paper)

ø330

7 7 4

ø482 ø276 ø482

ø350 ø187 ø350

3.2±0.1 / 3.0 3.2±0.1 / 3.0 3.2±0.1 / 3.0

9 12 12 12 12 12

115ZV-2 FS EU 32-11 32 Function & Structure Torque Converter and Transmission Group Transmission

Friction plate: mm (in) For low, reverse clutch

0.6 (0.02)

0.2 (0.008) above Detail drawing of groove 115V2E32027

1. Plate 2. Facing (sintered)

For 2nd, 3rd speed clutch

2.0 (0.08)

0.2 (0.008) above Detail drawing of groove 115V2E32004

1. Plate 2. Facing (paper)

115ZV-2 FS EU 32-12 32 Function & Structure Torque Converter and Transmission Group Transmission For high, 1st speed clutch

2.0 (0.08)

2 0.2 (0.008) above Detail drawing of groove

115V2E32005

1. Plate 2. Facing (paper)

Steel plate: mm (in) For low, reverse, 2nd, 3rd speed clutch

115V2E32006

115ZV-2 FS EU 32-13 32 Function & Structure Torque Converter and Transmission Group Transmission For high, 1st speed clutch

115V2E32007

115ZV-2 FS EU 32-14 32 Function & Structure Torque Converter and Transmission Group Clutch Pack

Clutch Pack Inlets for 2nd and 3rd speed clutch oil

13 14 25

21 22

Inlets for reverse and low range clutch oil

10 9

6 7 3

31 33 Inlet of 1st speed clutch oil

Inlet of high range clutch oil

Inlet of lubricating and cooling oil

34 2

2 30

5 29 28

1. Clutch input shaft 2. High range clutch drum 3. High range clutch piston 4. High range clutch piston return spring 5. Spider 6. Friction plate 7. Steel plate 8. Reverse clutch piston 9. Reverse planetary gear carrier 10. Reverse planetary gear 11. Reverse ring gear 12. Reverse sun gear 13. Friction plate 14. Steel plate 15. Anchor pin 16. Piston return spring 17. Low range clutch piston 18. Low range planetary gear

24 23

20 15 16

115V2E32009

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

115ZV-2 FS EU 32-15 32 Function & Structure Torque Converter and Transmission Group Power Flow Path in the Transmission

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

1st speed clutch

Inlet of low range clutch oil

Input power

33 Inlet of 1st speed clutch oil

34 32

Output power

24 23 35

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 low range clutch piston (17), low range ring gear (19) is locked to the housing by anchor pins (15). The torque converter rotates low range sun gear (20) via clutch input shaft (1). This causes low range planetary gears (18) to rotate around sun gear (20) while rotating on their own axis. This forces the carrier to rotate. Since the low range planetary carrier and 3rd speed planetary carrier (35) are one piece, 3rd speed planetary gears (22) also rotate around sun gear.

Low range ring gear (19) Sun gear (20) Low range planetary gear (18) 95ZV32006

K115V2J32007

When the 1st speed clutch is engaged, drop gear (32), 1st speed clutch gear (26), 3rd speed ring gear (23), 3rd speed sun gear (24), 2nd speed sun gear (29) and clutch output shaft (34) form one unit. As a result, the rotation of 3rd speed planetary gear (22) around sun gear is output as the rotation of drop gear (32).

3rd speed planetary gear (22) (does not rotate on its own axis)

3rd speed ring gear (23) and clutch output shaft (34) form one unit 95ZV32007

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

115ZV-2 FS EU 32-16 32 Function & Structure Torque Converter and Transmission Group Power Flow Path in the Transmission

Forward 2nd speed power flow path 2nd speed clutch oil Low range Low range clutch oil clutch 2nd speed clutch

Input power

Output power 115V2E32011

Forward 3rd speed power flow path

3rd speed clutch

3rd speed clutch oil Low range Low range clutch oil clutch Input power

Output power 115V2E32012

115ZV-2 FS EU 32-17 32 Function & Structure Torque Converter and Transmission Group Power Flow Path in the Transmission

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

High range clutch

2nd speed clutch

Input power

High range clutch oil

Output power 115V2E32013

Reverse 1st speed power flow path Reverse clutch oil

Reverse clutch

1st speed clutch Input power 1st speed clutch oil

Output power 115V2E32014

115ZV-2 FS EU 32-18 32 Function & Structure Torque Converter and Transmission Group Power Flow Path in the Transmission

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

Reverse clutch oil

2nd speed clutch

Reverse clutch

Input power

Output power 115V2E32015

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

Input power

Output power 115V2E32016

115ZV-2 FS EU 32-19 32 Function & Structure Torque Converter and Transmission Group Hydraulic System Diagram

Hydraulic System Diagram Note Numbers below correspond to page 32-20.

Shift lever

Option

MCU

34 3

2 14

3 22 25

L H

18 15

16 21

8 11

26 27 28 31

2 1

115V2E32017

115ZV-2 FS EU 32-20 32 Function & Structure Torque Converter and Transmission Group Hydraulic Circuit Diagram

Hydraulic Circuit Diagram Neutral position Limit switch

PMa PMb Dr (T/M side)

29 21

T/C

11 33

44cc 0.1 - 0.58 MPa (1 - 5.9 kgf/cm2) (14 - 84 psi)

1st

Option

175cc

35 PR

Dr (T/M side)

ACC2

ACC1

220cc

PG PH

26 15

14 0.007 MPa (0.07 kgf/cm2) (0.1 psi)

H 75cc

5 PF

28 19

0.39 ~ 2.65 MPa (4 ~ 27 kgf/cm2) (56.8 ~ 384 psi)

18 PG

Dr (T/M side)

L 150cc

30L/min

4.0 0.88 MPa (9 kgf/cm2) (128 psi)

2nd 113cc

31 25

PG Dr (T/M side)

3rd 113cc

4 Clutch valve assembly

Clutch solenoid valve assembly

Modulator valve unit

Modulator valve unit Direct charge valve

Lock-up clutch solenoid valve

100.4 cc/rev

Clutch solenoid valve assembly Clutch valve assembly

K115V2U32002

115ZV-2 FS EU 32-21 32 Function & Structure Torque Converter and Transmission Group Hydraulic Circuit Diagram

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

Note The orifice in the clutch valve 17, 19 and 23 is to reduce shock at clutch engagement.

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

115ZV-2 FS EU 32-22 32 Function & Structure Torque Converter and Transmission Group Oil Flow

Oil Flow Oil flow in the torque converter line From torque converter gear pump to torque converter The oil discharged from torque converter gear pump (3) goes through line filter (4) into priority valve (7). Priority valve (7) will transfer the specified amount (30 L/min) of the oil to the clutch circuit, and the rest amount of the oil will be supplied to torque converter (11).

Oil flow in the transmission line From torque converter gear pump to clutch solenoid valve assembly The clutch solenoid valve consists of the solenoid valves for the forward and backward driving gears and the shift gears. By the specific shift operation, the clutch solenoid valve is activated to send the pressure oil to the clutch valve as the pilot pressure.

When the input pressure at torque converter (11) inlet exceeds 0.9 MPa (9 kgf/cm2) (128 psi), torque converter inlet relief valve (8) automatically opens to release the excessive pressure to the cooler line.

From clutch solenoid valve to clutch valve assembly

From torque converter to cooling circuit

The pilot pressure sent from the clutch solenoid valve moves the spool to open the hydraulic line in the clutch valve. The pressure-adjusted oil by proportional relief valve (6) will go through the specified clutch valve, and filled in the clutch piston chamber to complete the clutch engagement.

Return oil from the torque converter flows through outlet relief valve (12) (set pressure = 0.3 MPa (3 kgf/cm2) (42.7 psi)) in the torque converter housing and to torque converter cooler (13).

From torque converter gear pump to lockup clutch (option) 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.

The oil sent from torque converter gear pump (3) is transferred through line filter (4) and priority valve (7) to lock-up solenoid valve (35). When the machine speed reaches the preset level, the MCU sends the signal activating solenoid valve (35) to open the hydraulic line. The pressure-adjusted oil by proportional relief valve (6) will be filled in lock-up clutch piston chamber (36) to engage the lock-up clutch.

115ZV-2 FS EU 32-23 32 Function & Structure Torque Converter and Transmission Group Oil Flow

From accumulator to clutch valve

From direct charge valve to clutch valve

Refer to "Hydraulic Circuit Diagram" page 32-20.

This valve is to supply the hydraulic pressure to the clutch valve subsidiarily, in case it is short depending on the selected shift gear, in order to keep the potential time lag at clutch engagement.

Two accumulators (32)(33) are installed between proportional relief valve (6) and the clutch valve assembly. One (32) is for the reverse clutch and the 1st speed clutch. The other (33) is for the high range clutch, low range clutch, 2nd speed clutch and 3rd clutch. - Initial oil charging into clutch piston chamber In order to make the initial oil charging into the clutch piston chamber quickly, the accumulated oil (0.58 MPa (5.9 kgf/cm2) (84 psi)) in the accumulator is supplied to the clutch piston chamber first. - Accumulator filling Torque converter gear pump (3) supplies the oil to the clutch piston chamber and the accumulator simultaneously. Torque converter gear pump (3) continues to fill the oil into the accumulator and it also increases the oil pressure in the clutch piston chamber gradually.

Limit switch The limit switch is built-in the accumulator, and is turned ON when the accumulator is fully filled up with the pressure oil. When the limit switch is turned ON, the MCU determines the pressurization and starts gradually increasing the pressurizing current to proportional relief valve (6).

The hydraulic pressure is supplied from the torque converter gear pump to direct charge valve (34) through P1 port, and then, directly supplied to the clutch valve by switching the solenoid valve without going through the modulator valve. Direct charge valve solenoid valve (34) is closely controlled by the signals from the MCU.

115ZV-2 FS EU 32-24 32 Function & Structure Torque Converter and Transmission Group T/C and T/M Oil Circulation

T/C and T/M Oil Circulation Radiator

Torque converter oil cooler (S/N 9051~)

Engine

Modulator valve unit Transmission oil filter

Torque converter

Clutch solenoid valve assembly Clutch valve assembly

Transmission (FM)

115ZV-2 FS EU 32-25 32 Function & Structure Torque Converter and Transmission Group Modulator Valve Unit

Modulator Valve Unit T/M S/N: PS400D01 - 0101~0126 8

5 (P4)

9 10 (P2)

Orifice ø1.0

9 10

(Acc2)

Orifice ø3.0

(Acc1)

(P3)

(P) (PM)

(P1)

8 (P5)

5 115V2E32020

Numbers below also correspond to page 32-20. 1. — 2. — 3. — 4. — 5. Clutch pressure regulator valve

6. Proportional relief valve 7. Priority valve 8. T/C inlet relief valve 9. Check valve (1) 10. Check valve (2)

115ZV-2 FS EU 32-26 32 Function & Structure Torque Converter and Transmission Group Modulator Valve Unit T/M S/N: PS400D01 - 0127~ 8

5 (P4)

9 10 (P2)

9 6

Orifice ø1.0

10 (Acc2)

Orifice ø3.0

(Acc1)

(P3)

(P) (PM)

7 (P1)

8 (P5)

5 115V2E32035

Numbers below also correspond to page 32-20. 1. — 2. — 3. — 4. — 5. Clutch pressure regulator valve 6. Proportional relief valve 7. Priority valve 8. T/C inlet relief valve 9. Check valve (1) 10. Check valve (2)

115ZV-2 FS EU 32-27 32 Function & Structure Torque Converter and Transmission Group Modulator Valve Unit

Interior schematic (simple explanation) From direct charge valve PG

To clutch valve

ACC2

To lock-up clutch solenoid valve (opt) ACC1

10 5

Relief valve

Drain

8 P1

To clutch From To Drain solenoid pump T/C valve To direct charge valve

To T/M To T/C lubrication cooling line line ACC2

6 To T/C P3

ACC1

Drain

Numbers below also correspond to page 32-20. 1. — 2. — 3. — 4. — 5. Clutch pressure regulator valve From direct 6. Proportional relief valve charge valve PG 7. Priority valve 8. T/C inlet relief valve PG 9. Check valve (1) 10. Check valve (2)

0.007 MPa (0.07 kgf/cm2) (0.1 psi)

0.39 - 2.65 MPa (4 - 27 kgf/cm2) (56.8 - 384 psi) P4

To T/C return line

8 30L/min

0.88 MPa (9 kgf/cm2) (128 psi)

Drain (T/M side)

To T/M lubrication P5 line

Drain (T/M side) T/M solenoid From T/C valve gear pump

115V2E32021

115ZV-2 FS EU 32-28 32 Function & Structure Torque Converter and Transmission Group Modulator Valve Unit

Modulation Mechanism

Modulator valve function From direct To clutch charge valve valve

When changing direction or speed, the modulation mechanism works to reduce the time required for clutch engagement (time lag). This prevents the shock at clutch engagement, improves the work efficiency and durability of the power system, and to ensures the operator's comfort.

To lock-up clutch Clutch pressure solenoid valve regulator valve

Drain

The modulation mechanism controls the clutch oil pressure rising time as follows. P

For information on the MCU refer to section "Electrical Group".

F f

To clutch From To Drain To T/M To T/C Drain Proportional solenoid pump T/C lubrication cooling relief valve valve line line Modulator valve 115V2E32022

The modulator valve is a solenoid-operated proportional relief 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 proportional relief valve acts on the left end of the clutch pressure regulator valve, and so the hydraulic force from the torque converter gear pump to the clutch is also controlled by the proportional relief valve. In other words, when the control pressure from the proportional relief valve 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 oil cooler circuit, reducing clutch oil pressure. The relief valve (2.65 MPa (27 kgf/cm2) (384 psi)) is installed inside of the clutch oil pressure regulator valve.

115ZV-2 FS EU 32-29 32 Function & Structure Torque Converter and Transmission Group Modulator Valve Unit

Modulator valve operation

Initial oil charging (t1) into the clutch piston chamber When the shift lever is shifted from the neutral to the 1st speed forward, the low range clutch solenoid valve is energized and oil in the accumulator flows into the empty clutch piston chamber first.

Modulation chart (Neutral1st forward) ON

Then oil under pressure flows into the clutch piston chamber. After a given time, the control current to the modulator valve is reduced. Accordingly the main clutch oil pressure is reduced, concluding the initial oil charging into the clutch chamber.

Low range clutch OFF solenoid valve ON

1st speed clutch solenoid valve

Modulator valve

Oil filling completed Engagement (clutch) (Acc.) completed

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

Current (mA)

Clutch piston chamber filling (t2)

Main pressure

Pressure MPa (kgf/cm2) (psi)

Low range clutch Pressure pressure MPa (kgf/cm2) (psi)

P1 P2 0

To reduce clutch engagement shock, it is necessary to engage the clutch while allowing some slippage of it. To do this, the current to the modulator valve is held low for a given time. The torque converter gear pump fills the oil both into the accumulator and into the clutch piston chamber. During this time, the clutch piston moves while compressing the piston return spring. The holding pressure in this time depends on the speed of the engine: lower pressure with lower engine speed, higher pressure with higher engine speed.

This time is also controlled by the MCU.

t2 t1

When shifted

Shift completed

Accumulator filling (t3) The pump continues to fill the oil into the accumulator. At the same time the clutch oil pressure is raised slowly.

115V2E32023

Initial charging time

Changes with combination of clutches

0~0.12 sec

pressure t2 Low holding time

Changes with engine speed

Less than 0.5 sec

rise t3 Pressure time

Changes with combination of clutches

0.3~0.7 sec

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

P1 0.5~1.5 MPa (6~15 kgf/cm2) (85~213 psi) P2 2.6~2.9 MPa (27~30 kgf/cm2) (384~427 psi) - E/G high idle

This prevents the clutch engagement shock caused by a rapid pressure rise.

115ZV-2 FS EU 32-30 32 Function & Structure Torque Converter and Transmission Group Modulator Valve Unit

Pressure rise (t4) Since the accumulator is completely accumulated at the start point of t4, the limit switch is turned ON, sending the signal to the MCU. At that point, the clutch piston comes into contact with the clutch plate and the clutch plates start to transmit power. The MCU recognizes that the accumulator is at the full accumulation by this signal, and gradually increases the driving current to the modulator valve. Then the hydraulic pressure for the clutch will consequently increases to complete the clutch engagement.

115ZV-2 FS EU 32-31 32 Function & Structure Torque Converter and Transmission Group Control Valve Assembly

Control Valve Assembly T/M S/N: PS400D01 - 0101~0152 Valve location

Torque converter Transmission

1st propeller shaft

115V2E32025

1. Clutch solenoid valve assembly 2. Clutch valve assembly 3. Accumulator assembly 4. Direct charge valve 5. Lock-up clutch solenoid valve (option)

115ZV-2 FS EU 32-32 32 Function & Structure Torque Converter and Transmission Group Control Valve Assembly T/M S/N: PS400D02 - 0101~ Valve location

Torque converter Transmission

1st propeller shaft

115V2E32036

1. Clutch solenoid valve assembly 2. Clutch valve assembly 3. Accumulator assembly 4. Direct charge valve 5. Lock-up clutch solenoid valve (option)

115ZV-2 FS EU 32-33 32 Function & Structure Torque Converter and Transmission Group Control Valve Assembly

Clutch solenoid valve assembly T/M S/N: PS400D01 - 0101~ PS400D02 - 0101~0132 5 P3

2 PL

2nd

A P1

P3~PR

T H

3rd

1st P

A-A

A P

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

Hydraulic Diagram 115V2E32037

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

115ZV-2 FS EU 32-34 32 Function & Structure Torque Converter and Transmission Group Control Valve Assembly T/M S/N: PS400D03 - 0133~ 5 P3

2 PL

2nd

P3~PR

T 3rd

1st

H P

A-A

A P

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

Hydraulic Diagram K115V2U32001

115ZV-2 FS EU 32-35 32 Function & Structure Torque Converter and Transmission Group Control Valve Assembly

For high, low, 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

Under such a condition, pressing manual control push button (6) (for emergency) opens the line between port A and B, and engages the clutch. Releasing the manual control push button returns spool (5) fully to the right, and disengages the clutch.

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. After power-on (Clutch engaged status)

Modulator valve

A Transmission C oil pan

B Clutch valve

3 115V2E32033

When the power is supplied to the coil, the magnetic power attracts the plunger (2) to the left, and the line between port A and B is opened. Pressure oil flows into the clutch valve.

115ZV-2 FS EU 32-36 32 Function & Structure Torque Converter and Transmission Group Control Valve Assembly

Clutch valve assembly A

From clutch solenoid valve (P3, PH, P1)

From clutch solenoid valve (P2, PL, PR)

Orifice

T T

A-A

B-B

3 T1

T PM PR

PC T1

T PM P1

PC T1

T PM PL

PC T1

T PM PH

PC T1

T PM P2

PC T1

T PM P3

Hydraulic Diagram K115V2J32013

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

115ZV-2 FS EU 32-37 32 Function & Structure Torque Converter and Transmission Group Control Valve Assembly

Accumulator assembly

1st, reverse clutch, ACC1

High, low, 2nd, 3rd clutch

From ACC2

9 Drain 115V2E32029

Accumulator structure

45.5

60.5

Stroke 28.3 115V2E32030

1. Tube 2. Piston 3. Rod cover 4. Spring 5. U-packing 6. O-ring 7. Wear ring 8. Socket bolt 9. Limit switch

Operating pressure

0.1~0.58 MPa (1~5.9 kgf/cm2) (14~84 psi)

115ZV-2 FS EU 32-38 32 Function & Structure Torque Converter and Transmission Group Control Valve Assembly

Direct charge valve

To clutch valve

P 4.0 mm

From torque converter gear pump

PA Hydraulic Diagram

PA From T/C gear pump

P Solenoid power OFF

P To clutch valve Solenoid power ON 115V2E32031

1. Direct charge solenoid valve 2. Plug (Orifice: ø 4.0 mm)

115ZV-2 FS EU 32-39 32 Function & Structure Torque Converter and Transmission Group Control Valve Assembly

Lock-up clutch solenoid valve

Lock-up solenoid valve

From modulator valve To lock-up clutch

T Drain (T/M side)

Hydraulic Diagram

Transmission oil pan

Lock-up clutch

Transmission oil pan

Modulator valve unit

Solenoid power OFF

Solenoid power ON

115V2E32032

115ZV-2 FS EU 32-40 32 Function & Structure Torque Converter and Transmission Group

MEMO

115ZV-2 FS EU 33-1 33 Check & Adjustment Torque Converter and Transmission Group

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

115ZV-2 FS EU 33-2 33 Check & Adjustment Torque Converter and Transmission Group Clutch Oil Pressure and Time Lag

Clutch Oil Pressure and Time Lag Measuring clutch oil pressure

Gauge port 1. Location:

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

T/M S/N: PS400D01 - 0101~0152 Main clutch

1 R

Transmission Torque converter

Reverse clutch 1st clutch Low range clutch High range clutch 2nd clutch 3rd clutch Lock-up clutch

Measurement instrument - Pressure gauge - Tachometer (MODM) - Stop watch Transmission oil pressure test port location

115V2E33001

115ZV-2 FS EU 33-3 33 Check & Adjustment Torque Converter and Transmission Group Clutch Oil Pressure and Time Lag

Clutch oil pressure measurement procedure

T/M type: PS400D02 - S/N 0101~ Main clutch

Standard measurement value Main pressure (engine speed)

1 R

Transmission

Reverse clutch 1st clutch Low range clutch High range clutch 2nd clutch 3rd clutch

Idling (LI)

2.6±0.2 MPa (27±2 kgf/cm2) (384±28 psi)

Maximum (HI)

2.6±0.2 MPa (27±2 kgf/cm2) (384±28 psi)

Idling (LI)

2.1~2.5 MPa (21.5~25.5 kgf/cm2) (305~363 psi)

Maximum (HI)

2.1~2.5 MPa (21.5~25.5 kgf/cm2) (305~363 psi)

Clutch pressure (engine speed)

1. Press the brake pedal, and set and confirm the transmission shift lever is at the neutral position.

Lock-up clutch

2. Set and confirm the parking brake is at the "ON" position. 3. Press the brake pedal, and lower the bucket onto the ground. Torque converter

4. Stop the engine. Transmission oil pressure test port location

K115V2E33001

2. Measuring port: PF 1/4

5. Attach the pressure gauge to the pressure measurement port. Place the gauge inside the operator's area, and start the engine.

3. Oil pressure gauge: 5 MPa (50 kgf/cm2) (1,000 psi) with 2~3 m (6~10 ft.) hose

6. As the clutch oil pressure rises just after the engine is started, keep the engine at low-idling before the pressure measurement.

Note Warm-up the engine before measuring the clutch oil pressure and time lag

7. Measure and record the pressure in each speed range. 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. 9. As the clutch oil pressure rises just after the engine is started, adjust the engine at high-idling before the pressure measurement.

115ZV-2 FS EU 33-4 33 Check & Adjustment Torque Converter and Transmission Group Clutch Oil Pressure and Time Lag 10. Measure and record the pressure in each speed range. 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.

Time lag measurement procedure

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.

Possible causes for low clutch pressure Possible cause Malfunctioning modulator valve operation

Solution

Standard measurement value

Inspection & repair

Defective MCU

Replacement

Oil leakage from clutch

Disassembly & repair

Clutch time lag (sec)

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

0.3±0.1

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 accumulator limit switch

Replacement

Malfunctioning modulator valve operation

Inspection & repair

Defective MCU

Replacement

Defective clutch

Disassembly & repair

115ZV-2 FS EU 42-1 42 Function & Structure Hydraulic Group

42 Function & Structure Hydraulic Group Flushing Hydraulic Circuit........................................ 42-2 Cautions on Hydraulic Parts Replacement.............. 42-3 Hydraulic Circuit Symbols ....................................... 42-4 Hydraulic System Operation.................................... 42-8 Layout of Hydraulic Units ........................................ 42-10 Hydraulic Tank......................................................... 42-11 Hydraulic Pump ....................................................... 42-17 Hydraulic Cylinder ................................................... 42-21 Loading System ...................................................... 42-24 Reducing Valve (for Pilot Pressure) ........................ 42-25 Pilot valve (S/N 9001~9100) ................................... 42-26 Pilot valve (S/N 9101~9105) ................................... 42-31 Pilot valve (S/N 9106~) ........................................... 42-36 Multiple Control Valve (KML35A/2T103) ................. 42-41 Adapter (Orifice) ...................................................... 42-52 Ride Control (OPT).................................................. 42-53 Steering System ...................................................... 42-63 Orbitrol® ................................................................... 42-64 Steering Valve (KVS32-A4.0/21) ............................. 42-71 Stop Valve ............................................................... 42-83 Reducing Valve (for Orbitrol®) ................................. 42-85 Steering Line Filter .................................................. 42-86 Efficient Loading System......................................... 42-87 Fan Motor System ................................................... 42-91 Fan Motor Line ........................................................ 42-92 Reversing Fan Motor Line (OPT) ............................ 42-103 Secondary Steering ................................................. 42-108

115ZV-2 FS EU 42-2 42 Function & Structure Hydraulic Group Flushing Hydraulic Circuit

Flushing Hydraulic Circuit Purpose of flushing

Debris To tank

95ZV42001

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

115ZV-2 FS EU 42-3 42 Function & Structure Hydraulic Group Cautions on Hydraulic Parts Replacement

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

115ZV-2 FS EU 42-4 42 Function & Structure Hydraulic Group Hydraulic Circuit Symbols

Hydraulic Circuit Symbols Hydraulic lines

Pumps & motors (1)

Working hydraulic line

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

Pilot line Drain line

(2)

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

Lines joining

Flexible line

(2)

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

Lines passing

Line to tank (Above fluid level)

(2)

(1)

Line to tank (Below fluid level)

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

Hydraulic tank (Pressurized type)

Fixed restriction

(2)

Cylinders (1)

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

(2)

(1)

(2)

(1)

(2)

(1)

(2)

(1)

(2)

Single acting cylinder (without spring)

Single acting cylinder (with spring)

Double acting cylinder (single rod)

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

115ZV-2 FS EU 42-5 42 Function & Structure Hydraulic Group Hydraulic Circuit Symbols

Operation methods

Pressure control valve

Spring

Single flow path valve, Normally closed

Adjustable spring

Single flow path valve, Normally open

Control methods Pressure relief valve

Lever

Push button Unloading valve Pedal or treadle

Mechanical control Sequence valve Plunger

Pressure reducing valve

Spring

Solenoid control Single acting solenoid

Flow control valve

Double acting solenoid

Flow control valve, Adjustable noncompensated

Electric motor control Unidirectional

Pressure compensated flow control valve

M fixed

Bidirectional

M variable

Detent

Flow dividing valve

115ZV-2 FS EU 42-6 42 Function & Structure Hydraulic Group Hydraulic Circuit Symbols

Directional control valve

Check valve

Two position Two ports

Check valve

Three position Four ports

Check valve Pilot operated

Four ports with restrictor

Shuttle valve

Two position Two ports Mechanical control Spring offset Pressure control Two position Three ports Pressure control

Spring offset Solenoid control Restrictor Two ports

Three ports

Four ports

Servo valve

115ZV-2 FS EU 42-7 42 Function & Structure Hydraulic Group Hydraulic Circuit Symbols

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

(2)

Manual shut off valve

Pressure switch

Accumulator

Electric motor

Internal combustion

Power source

Filter or strainer

Heater

Cooler

Pressure gauge

Temperature gauge

Flow meter

115ZV-2 FS EU 42-8 42 Function & Structure Hydraulic Group Hydraulic System Operation

Hydraulic System Operation Hydraulic system operation outline

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

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

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

- Efficient loading system - Fan motor system

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

Loading system The loading system consists of the following components. All numbers base on page 92-5. - 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 (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 pilot control lever is operated, the pilot valve line is opened, and the oil pressure is generated depending on the position of the pilot control lever. The pilot pressure entering the oil pack to multiple control valve (3) moves the spool against its return spring. The spool press-in distance (displacement) depends on the pilot valve pressure. Oil from the loader pump is then directed through multiple control valve (3) to boom cylinders (5) and bucket cylinders (6).

- Hydraulic pump (1) - Steering valve (4) - Line filter (81) - Reducing valve (18) - Orbitrol® (14) - Stop valve (15) - Steering cylinder (8) Oil from pump (1) flows to Orbitrol® (14) through steering valve (4), line filter (81) and reducing valve (18). Oil to Orbitrol® (14) is reduced to 3.5 MPa (36 kgf/cm2) (512 psi) by reducing valve (18). A small amount of pilot oil supplied from Orbitrol® (14) controls steering valve (4) to realize steering operations. When the steering wheel is turned, oil at a flow rate proportional to the turning speed is sent from Orbitrol® (14) and supplied to the oil pack of steering valve (4). At this time, the pilot pressure is generated. The pilot pressure strokes the spool of steering valve (4), and supplies hydraulic oil at large flow rate proportional to the flow rate of the supplied pilot oil to the cylinder line. The excessive pilot oil flows through steering valve (4) to the other side of the pilot port. Stop valves (15) are used in the circuit to stop the flow of oil from Orbitrol® (14) to steering valve (4) when the machine reaches full turn.

115ZV-2 FS EU 42-9 42 Function & Structure Hydraulic Group Hydraulic System Operation When the steering wheel is not turned, the flow control spool built in steering valve (4) supplies almost all amount of the hydraulic oil fed from steering pump (1) to the loading circuit.

Fan motor system

Oil returns from steering cylinders (8) flows through steering valve (4) and oil cooler or cooler bypass valve (11).

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

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

Efficient loading system 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.

The fan motor system consists of the following components.

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). Three kinds of signals sent from the engine water temperature sensor (S/N 9001~9050), ECM (S/N 9051~), torque converter oil temperature sensor, and hydraulic oil temperature sensor, are input into the machine control unit (MCU) as information to regulate the maximum fan revolution. The fan revolution is regulated by proportional relief valve (72). The setting pressure of the proportional relief valve is changed in proportion as the engine revolution and electric current value from MCU.

Ride control system (OPT) Refer to "Ride Control (OPT)" page 42-53 for the information.

115ZV-2 FS EU 42-10 42 Function & Structure Hydraulic Group Layout of Hydraulic Units

Layout of Hydraulic Units

12 3 16 4

115V2E42001

1. Multiple control valve 2. Pilot valve 3. Pilot valve (for stick steering) 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 18. Torque converter pump

115ZV-2 FS EU 42-11 42 Function & Structure Hydraulic Group Hydraulic Tank

Hydraulic Tank Hydraulic Tank (S/N 9001~9150) 13

Viewed from top

8 7

A-A

13 A

A Outside of machine

As seen from chassis out

To chassis

15,16

6 5

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 ~9100)) 14. Temperature sensor 15. Oil level sensor 16. Flange bolt : #16: 11.8 N-m (1.2 kgf-m) (8.7 lb-ft) Don’t use the air tool when fasten #16.

115V2E42002

115ZV-2 FS EU 42-12 42 Function & Structure Hydraulic Group Hydraulic Tank

Hydraulic tank breather valve (tank cap) (S/N 9001~9150) 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). Suction valve (b) is then opened to let the air flow into the tank. When the air pressure inside the hydraulic tank rises to a certain point 29 kPa (0.3 kgf/cm2) (4.3 psi), Exhaust valve (a) is lifted (opened) so that the air can flow out of the tank through filter element (2). 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). 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.

115ZV-2 FS EU 42-13 42 Function & Structure Hydraulic Group Hydraulic Tank

Hydraulic Tank (S/N 9151~) 13

Viewed from top

8 7 13

A-A

A Outside of machine

As seen from chassis out

To chassis

15,16 14

5 11

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

K115V2U42005

9. Spring 10. Cover 11. Drain plug (Magnet plug S/N 9201~ square socket head) 12. Inspection port 13. Plug 14. Temperature sensor 15. Oil level sensor 16. Flange bolt : #16: 11.8 N-m (1.2 kgf-m) (8.7 lb-ft) Don’t use the air tool when fasten #16.

115ZV-2 FS EU 42-14 42 Function & Structure Hydraulic Group Hydraulic Tank

Hydraulic tank breather valve (tank cap) (S/N 9151~) 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.

115ZV-2 FS EU 42-15 42 Function & Structure Hydraulic Group Hydraulic Tank

Hydraulic tank specifications Type

Semi-closed type

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

225 (59 US gal)

Filtration area (cm2)

16,900 x 2

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 9001~9150)

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 9151~)

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)

115ZV-2 FS EU 42-16 42 Function & Structure Hydraulic Group Hydraulic Tank

Hydraulic oil level check

Bucket on ground

Hydraulic tank

(59 US gal)

225 L

Oil level sight gauge

115ZV42005

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 225 L (59 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.

115ZV-2 FS EU 42-17 42 Function & Structure Hydraulic Group Hydraulic Pump

Hydraulic Pump Loading and pilot and brake pump 5

2 6

K115V2U42006

5. Oil seal 6. Bushing 7. Wear plate (floating type) 8. Sleeve (S/N 9051~)

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

Pump specifications Applicable circuit Theoretical discharge Maximum operation pressure Maximum speed

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

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

Front

Rear

Loading circuit

Pilot & Brake circuit

100.4

71.3

20.6±0.5 (210±5) (2,986±71)

11.8 (120) (1,711) 2,500

115ZV-2 FS EU 42-18 42 Function & Structure Hydraulic Group Hydraulic Pump

Steering pump 5

2 6

K115V2U42007

5. Oil seal 6. Bushing 7. Wear plate (floating type) 8. Sleeve (S/N 9051~)

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

Steering pump specifications Front Applicable circuit Theoretical discharge Maximum operation pressure Maximum speed

Rear Steering circuit

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

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

90.7 20.6±0.5 (210±5) (2,986±71) 2,500

115ZV-2 FS EU 42-19 42 Function & Structure Hydraulic Group Hydraulic Pump

Hydraulic pump principle

Inlet

Outlet

Inlet

Outlet

Inlet

Outlet

95ZV42040

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

115ZV-2 FS EU 42-20 42 Function & Structure Hydraulic Group Hydraulic Pump

Hydraulic pump wear plate

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

General structure of pressure plate Suction

Discharge

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

Discharge High pressure area Backup ring

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

Hydraulic pump bushing lubrication

O-ring

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

Suction

Oil groove for lubricating bearing

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

Suction

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

Discharge

115ZV42006

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

115ZV-2 FS EU 42-21 42 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

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

14 12,13 15 1

9 10,11

6,7 5,17

18 115V2E42011

: Piston nut (16): 9,807 N-m (1,000 kgf-m) (7,235 lb-ft) : Bolt (18): 843 N-m (86 kgf-m) (622 lb-ft)

Bucket cylinder 20,23

22 16 21 14 13 12 10 15 1

6 11 9 17 5

20,23

(Gauge port PF1/4)

27,28 25,26

A A

27,28 (Gauge port PF1/4)

: Piston nut (16): 5,884 N-m (600 kgf-m) (4,340 lb-ft) : Bolt (25): 883 N-m (90 kgf-m) (651 lb-ft)

4 115V2E42012

115ZV-2 FS EU 42-22 42 Function & Structure Hydraulic Group Hydraulic Cylinder

Steering cylinder

20,23

16,22 21 14 13 12 1

8 6,7 10,11 9 11 17 5

20,23

4 115V2E42013

: Rod cover (4): 2,550 N-m (260 kgf-m) (1,880 lb-ft) : Piston nut (16): 1,373 N-m (140 kgf-m) (1,013 lb-ft)

115ZV-2 FS EU 42-23 42 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

ø120 x 272 (4.72 x 10.70)

Cylinder

ø120 x 208.5 (4.72 x 8.21)

Inner diameter x rod diameter x stroke Bucket cylinder

Pin hole (inner diameter x width)

ø190 x ø100 x 767 (7.48 x 3.93 x 30.19)

Piston rod

ø100 x 120 (3.93 x 4.72)

Cylinder

ø100 x 120 (3.93 x 4.72)

Inner diameter x rod diameter x stroke Steering cylinder

ø225 x ø120 x 1,132 (8.85 x 4.72 x 44.56)

ø110 x ø60 x 720 (4.33 x 2.36 x 28.34)

Piston rod

ø70 x 80 (2.75 x 3.14)

Cylinder

ø70 x 80 (2.75 x 3.14)

115ZV-2 FS EU 42-24 42 Function & Structure Hydraulic Group Loading System

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

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

Pilot valve

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

Valve (for safety lock) Reducing valve

From brake line

Oil packs

Multiple control valve

From steering valve

Oil packs

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.

115ZV-2 FS EU 42-25 42 Function & Structure Hydraulic Group Reducing Valve (for Pilot Pressure)

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

Ball

CXCD-XAN

Passage Y (T)

(P) (TA) (ACCR)

(PARKING)

(ACCF)

(PA) (Z1)

(Z)

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)

115ZV-2 FS EU 42-26 42 Function & Structure Hydraulic Group Pilot valve (S/N 9001~9100)

Pilot valve (S/N 9001~9100) 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

115ZV-2 FS EU 42-27 42 Function & Structure Hydraulic Group Pilot valve (S/N 9001~9100)

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

115ZV-2 FS EU 42-28 42 Function & Structure Hydraulic Group Pilot valve (S/N 9001~9100)

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.

115ZV-2 FS EU 42-29 42 Function & Structure Hydraulic Group Pilot valve (S/N 9001~9100)

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.

115ZV-2 FS EU 42-30 42 Function & Structure Hydraulic Group Pilot valve (S/N 9001~9100)

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.

115ZV-2 FS EU 42-31 42 Function & Structure Hydraulic Group Pilot valve (S/N 9101~9105)

Pilot valve (S/N 9101~9105) 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

115ZV-2 FS EU 42-32 42 Function & Structure Hydraulic Group Pilot valve (S/N 9101~9105)

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

115ZV-2 FS EU 42-33 42 Function & Structure Hydraulic Group Pilot valve (S/N 9101~9105)

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.

115ZV-2 FS EU 42-34 42 Function & Structure Hydraulic Group Pilot valve (S/N 9101~9105)

21 20

Predetent section

Lever is shifted from the neutral K92V2E42004

115ZV-2 FS EU 42-35 42 Function & Structure Hydraulic Group Pilot valve (S/N 9101~9105)

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

115ZV-2 FS EU 42-36 42 Function & Structure Hydraulic Group Pilot valve (S/N 9106~)

Pilot valve (S/N 9106~) 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

115ZV-2 FS EU 42-37 42 Function & Structure Hydraulic Group Pilot valve (S/N 9106~)

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

115ZV-2 FS EU 42-38 42 Function & Structure Hydraulic Group Pilot valve (S/N 9106~)

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

115ZV-2 FS EU 42-39 42 Function & Structure Hydraulic Group Pilot valve (S/N 9106~)

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

115ZV-2 FS EU 42-40 42 Function & Structure Hydraulic Group Pilot valve (S/N 9106~)

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

115ZV-2 FS EU 42-41 42 Function & Structure Hydraulic Group Multiple Control Valve (KML35A/2T103)

Multiple Control Valve (KML35A/2T103)

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

115ZV-2 FS EU 42-42 42 Function & Structure Hydraulic Group Multiple Control Valve (KML35A/2T103)

Boom

B2 A2

Multiple control valve specifications

Bucket

B1 A1

Model

KML35A/2T103

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.

115ZV-2 FS EU 42-43 42 Function & Structure Hydraulic Group Multiple Control Valve (KML35A/2T103)

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.

115ZV-2 FS EU 42-44 42 Function & Structure Hydraulic Group Multiple Control Valve (KML35A/2T103) 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.

115ZV-2 FS EU 42-45 42 Function & Structure Hydraulic Group Multiple Control Valve (KML35A/2T103)

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.

115ZV-2 FS EU 42-46 42 Function & Structure Hydraulic Group Multiple Control Valve (KML35A/2T103)

Make-up valve operation

Adjusting set pressure Plunger Plunger seat Adjusting screw Spring A

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.

115ZV-2 FS EU 42-47 42 Function & Structure Hydraulic Group Multiple Control Valve (KML35A/2T103)

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.

115ZV-2 FS EU 42-48 42 Function & Structure Hydraulic Group Multiple Control Valve (KML35A/2T103) 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.

115ZV-2 FS EU 42-49 42 Function & Structure Hydraulic Group Multiple Control Valve (KML35A/2T103)

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

115ZV-2 FS EU 42-50 42 Function & Structure Hydraulic Group Multiple Control Valve (KML35A/2T103) 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

115ZV-2 FS EU 42-51 42 Function & Structure Hydraulic Group Multiple Control Valve (KML35A/2T103) 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

115ZV-2 FS EU 42-52 42 Function & Structure Hydraulic Group Adapter (Orifice)

Adapter (Orifice)

ø1.3 mm

O-ring

Orifice

Adapter

Installation position

Port b2

Multiple control valve

80ZV42018

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

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

115ZV-2 FS EU 42-53 42 Function & Structure Hydraulic Group Ride Control (OPT)

Ride Control (OPT) Ride control hydraulic circuit 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)

(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.

115ZV-2 FS EU 42-54 42 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)

(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)

(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

115ZV-2 FS EU 42-55 42 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.

115ZV-2 FS EU 42-56 42 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

115ZV-2 FS EU 42-57 42 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.

115ZV-2 FS EU 42-58 42 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

115ZV-2 FS EU 42-59 42 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. Selector valve 3. Solenoid 4. Valve 5. Shuttle valve 6. Plug

95V2E42016

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

(Ac2) (Ac) Hydraulic circuit

95V2E42017

115ZV-2 FS EU 42-60 42 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

Tank

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.

Shuttle valve

Passage A A Selector

valve

Sleeve 95V2E42019

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

DC 24 V

Current

0.92 A

Resistance

26.2 Ω

115ZV-2 FS EU 42-61 42 Function & Structure Hydraulic Group Ride Control (OPT)

Selector valve Passage B

Reducing valve (solenoid 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.

115ZV-2 FS EU 42-62 42 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) (284 psi).

Accumulator specification Maximum operation pressure MPa (kgf/cm2)(psi) 20.6 (210)(2,986) Nitrogen gas pressure MPa (kgf/cm2) (psi)

1.96 (20) (284)

Capacity (l)

9.5

115ZV-2 FS EU 42-63 42 Function & Structure Hydraulic Group Steering System

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

From reducing valve

Orbitrol®

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

Steering cylinder

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

Stop valve

Stop valve RH

While the steering wheel is not turned, almost all 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

115ZV-2 FS EU 42-64 42 Function & Structure Hydraulic Group Orbitrol®

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

Orbitrol® structure 1. Spool 2. Sleeve 3. Stator 4. Rotor

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

Valve part

6 7

T L Valve

1 2

3 4

Rotor

85V2E42018

115ZV-2 FS EU 42-65 42 Function & Structure Hydraulic Group Orbitrol® - Spool (1) and sleeve (2) as a set form a rotary-type directional change-over valve. Spool (1) in this valve is linked to the steering wheel by means of a spline.

Orbitrol® 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 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

115ZV-2 FS EU 42-66 42 Function & Structure Hydraulic Group Orbitrol®

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

L Oil hole

6 7

Oil groove

1 2

70ZV42025

3 4

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.

115ZV-2 FS EU 42-67 42 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.

115ZV-2 FS EU 42-68 42 Function & Structure Hydraulic Group Orbitrol®

Orbitrol® feed-back mechanism operation

Spool

Sleeve

Cross pin

Drive shaft Steering cylinder

Steering cylinder

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.

115ZV-2 FS EU 42-69 42 Function & Structure Hydraulic Group Orbitrol®

Steering speed and flow rate control Low steering speed

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

High steering speed

1 3 Small displacement angle

Large displacement angle

Hydraulic pump oil amount and steering force

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) 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.

115ZV-2 FS EU 42-70 42 Function & Structure Hydraulic Group Orbitrol®

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

Drive shaft (1/14 rotation)

Drive shaft (1/7 rotation)

Rotor (rotation) Stator (fixed)

Locus of rotor center

1 7

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.

115ZV-2 FS EU 42-71 42 Function & Structure Hydraulic Group Steering Valve (KVS32-A4.0/21)

Steering Valve (KVS32-A4.0/21) To loading line

From pump To reducing valve PC P 2

(G)

MR 3

Pilot operation port

T Tank port

To loading line

(F)

P. B.

A-A

Orifice

Cylinder port

(LC)

4 AR

Drain port

B-B

1. Steering spool 2. Flow control spool 3. Main relief valve 4. Overload relief valve (with make-up valve) 5. Gauge port 115V2U42001

115ZV-2 FS EU 42-72 42 Function & Structure Hydraulic Group Steering Valve (KVS32-A4.0/21) 1. Steering spool

AB AR

The movement of the steering spool is controlled by the pilot pressure from the pilot valve. 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.

BR Pa

(G)

Pb 0.5 RF

T MR

3.0 Orifice

P. B. Pc

P Hydraulic circuit

115V2E42031

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-A4.0/21

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)

115ZV-2 FS EU 42-73 42 Function & Structure Hydraulic Group Steering Valve (KVS32-A4.0/21)

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

Loading circuit

115V2E42015

- 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.

115ZV-2 FS EU 42-74 42 Function & Structure Hydraulic Group Steering Valve (KVS32-A4.0/21)

Left turn position

Loading circuit Pump

Pilot pressure

Check valve

1 Tank Variable throttle

115V2E42016

- 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.

115ZV-2 FS EU 42-75 42 Function & Structure Hydraulic Group Steering Valve (KVS32-A4.0/21) - 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 115V2E42017

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).

115ZV-2 FS EU 42-76 42 Function & Structure Hydraulic Group Steering Valve (KVS32-A4.0/21)

Steering valve flow control spool Loading circuit Pump

Spring

PA PB

Variable throttle

Steering circuit

Loading circuit Pump

PA PB

Variable throttle

Steering circuit

115V2E42018

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.

115ZV-2 FS EU 42-77 42 Function & Structure Hydraulic Group Steering Valve (KVS32-A4.0/21)

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

115V2E42019

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.

115ZV-2 FS EU 42-78 42 Function & Structure Hydraulic Group Steering Valve (KVS32-A4.0/21)

When the pressure exceeds the preset value

Loading circuit

Pump

Flow control spool

Steering spool

Tank

115V2E42020

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.

115ZV-2 FS EU 42-79 42 Function & Structure Hydraulic Group Steering Valve (KVS32-A4.0/21)

Steering valve overload relief valve External force

Makeup function

Overload relief function

Tank

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

115V2E42021

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.

115ZV-2 FS EU 42-80 42 Function & Structure Hydraulic Group Steering Valve (KVS32-A4.0/21)

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.

115ZV-2 FS EU 42-81 42 Function & Structure Hydraulic Group Steering Valve (KVS32-A4.0/21)

Steering pilot circuit and its operation

From pump Orbitrol®

Reducing valve

To tank

Steering valve Filter To tank

To cylinder

From cylinder Stop valve

Stop valve

End cover

Flow amp. notch Pilot circuit To tank Pilot orifice

K115V2J42009

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.

115ZV-2 FS EU 42-82 42 Function & Structure Hydraulic Group Steering Valve (KVS32-A4.0/21)

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.

115ZV-2 FS EU 42-83 42 Function & Structure Hydraulic Group Stop Valve

Stop Valve

(S/N ~9107) 17 mm (S/N 9108~) 14.5 mm (Full stroke)

From Orbitrol®

A B

To steering valve

3 (S/N 9101~) K115V2E42004

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

115ZV-2 FS EU 42-84 42 Function & Structure Hydraulic Group Stop Valve

Stop valve function

Stopper (bolt) Spool

Port B To steering valve

Stop valve operation Port A From Orbitrol®

P Installed on front chassis

Check valve Installed on rear chassis 90V2U42003

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

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.

115ZV-2 FS EU 42-85 42 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)

115ZV-2 FS EU 42-86 42 Function & Structure Hydraulic Group Steering Line Filter

Steering Line Filter

From pump (steering valve)

To reducing valve

FILTER

5 70ZV42040

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

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

ELS valve

Stop valve (RH) Stop valve (LH)

Center pin Center line

Reducing valve Line filter Steering valve

115V2E42006

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.

115ZV-2 FS EU 42-87 42 Function & Structure Hydraulic Group Efficient Loading System

Efficient Loading System Efficient loading system outline

Efficient loading system (it is assumed ELS as follows) improves the performance of excavating and scooping when operating, and 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.

115ZV-2 FS EU 42-88 42 Function & Structure Hydraulic Group Efficient Loading System

Mounting of the ELS valve 3

PG1 From main pump

(P)

(A) Multiple control valve

(T1) (T2)

PG2 1

2 Center pin Center line

To hydraulic tank

From Orbitrol®

Hydraulic line ELS valve

Rear chassis

2 PG2

4 PG1 A T2 T1

Detail of ELS valve section 115V2E42007

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

115ZV-2 FS EU 42-89 42 Function & Structure Hydraulic Group Efficient Loading System

Mounting of the variable kickout sensor 5

8 2 3

Apply grease at area

1 Detail of grease applying

A Boom

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

115ZV-2 FS EU 42-90 42 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

115V2E42008

115V2E42009

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.

115ZV-2 FS EU 42-91 42 Function & Structure Hydraulic Group Fan Motor System

Fan Motor System Mounting of fan motor

-./ 0 !

-./ 0!

A-Detail

' ( ) * % + ) ) % ! " # !

$ % & ! " # !

Gauge port (PF 3/8)

B-Detail

1. Fan motor 2. Fan (S/N ~9114) 3. Flange (S/N ~9107) 4. Fan (S/N 9115~) 5. Flange (S/N 9108~9200) 6. Flange (S/N 9201~) 7. Proportional relief valve

: Bolt tightening torque 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)

115ZV-2 FS EU 42-92 42 Function & Structure Hydraulic Group Fan Motor Line

Fan Motor Line Fan revolution (min-1)

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

1,300 Stepless control range

1,120

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

(900)

Low temperature [below 60ºC (160ºF)]

0 725 (Hibernate mode) 925

1,200

(1,260) Engine revolution (min-1)

(1,787) Values inside ( ) are offered as reference.

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

Fan motor (1) Cooling fan

K115V2E42001

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, one each is from the engine water temperature sensor (S/N 9001~9050), ECM (S/N 9051~), torque converter oil temperature sensor, and hydraulic oil temperature sensor, are input into the MCU as information to regulate the maximum fan revolution.

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

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. 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.

115ZV-2 FS EU 42-93 42 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

1,120

270 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 K115V2E42002

When the input electric current value to proportional relief valve (2) is maximum (approximately 270 mA), the fan revolution is minimum value (1,120 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. 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. For example, 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).

115ZV-2 FS EU 42-94 42 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.

115ZV-2 FS EU 42-95 42 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.

115ZV-2 FS EU 42-96 42 Function & Structure Hydraulic Group Fan Motor Line

Proportional relief valve (S/N 9001~9050) 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, and the plunger is pressed against the body by the spring 1 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.

115ZV-2 FS EU 42-97 42 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: 19.6±0.5 MPa (200±5 kgf/cm2) (2,844±71 psi) at 0 mA

115ZV-2 FS EU 42-98 42 Function & Structure Hydraulic Group Fan Motor Line

Proportional relief valve (S/N 9051~)

(G1) T1

(P1)

(T1)

(G1) P1

(P2)

P2 (G1)

(G3/8) PG2

(PG2) (T2)

3 (PG1)

T2 (G1)

PG1 (G1/4)

Hydraulic line diagram

5 1

K115V2U42001

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

115ZV-2 FS EU 42-99 42 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 (7), if necessary. : Tightening torque Relief valve (2): 60~70 N-m (6.1~7.1 kgf-m) (44~51 lb-ft) Relief valve (7): 35~40 N-m (3.5~4.0 kgf-m) (25~29 lb-ft)

K115V2U42002

115ZV-2 FS EU 42-100 42 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

115ZV-2 FS EU 42-101 42 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

115ZV-2 FS EU 42-102 42 Function & Structure Hydraulic Group Fan Motor Line Fan motor function and the operation principle Y

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.

ri F3

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

85V2E42043

This force pushes thrust plate (3) fixed at a certain angle  for 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 the plate (6) separated by Y-Y line linking a top dead center to a bottom dead center.

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

85V2E42044

4 5

Supply side

3 Discharge side

85V2E42045

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

115ZV-2 FS EU 42-103 42 Function & Structure Hydraulic Group Reversing Fan Motor Line (OPT)

Reversing Fan Motor Line (OPT) Reversing fan motor function

Functional limitation conditions: When either one of the following temperature exceeds the preset upper limit(s), the cooling fan reverse rotation function does not work. 1. Signal of engine water temperature > 94ºC (201.2ºF)

Switch

2. Signal of torque converter oil temperature > 115ºC (239ºF) 3. Signal of the hydraulic oil temperature > 95ºC (203ºF) 115V2U62017a

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.

115ZV-2 FS EU 42-104 42 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

115ZV-2 FS EU 42-105 42 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

115ZV-2 FS EU 42-106 42 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. 340

F VR2

85V2E42047

115ZV-2 FS EU 42-107 42 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.

115V2U42025

115ZV-2 FS EU 42-108 42 Function & Structure Hydraulic Group Secondary Steering

Secondary Steering Secondary steering circuit

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)

16 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)

16 cm3/rev

90.7 90.7 cm3/rev cm3/rev

Magnetic switch (on motor and pump) Steering pump Hydraulic line Electrical circuit

Secondary Steering Circuit 115V2E42025

115ZV-2 FS EU 42-109 42 Function & Structure Hydraulic Group Secondary Steering

Secondary steering relay

Hydraulic pump

Battery relay

(V4) (E7)

Secondary steering motor and pump

Check valve

(H8)

To MCU

To steering valve Pressure sensor

(P4)

Hydraulic tank

Secondary steering motor and pump

Magnetic switch

Check valve

Hydraulic circuit Electrical circuit K115V2U42008

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

Machine speed signal

The signal from MCU to magnetic switch

Secondary steering operation

Machine speed

OFF

(km/h)

85V2E42051

115ZV-2 FS EU 42-110 42 Function & Structure Hydraulic Group Secondary Steering

Secondary steering motor and pump CW rotation

Magnetic switch

Relief valve

+24 V

Motor

+24 V

Pump

Relief valve 11.7 MPa (119.3 kgf/cm2)

Customer's power connection

Customer's MCU connection

Customer's ground connection Electric/Hydraulic schematic

85V2E42053

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

115ZV-2 FS EU 43-1 43 Check & Adjustment Hydraulic Group

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

115ZV-2 FS EU 43-2 43 Check & Adjustment Hydraulic Group Loading/Steering Circuit Relief Valve/Ride Control Circuit Reducing Valve (OPT)

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

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

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

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

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

20.6±0.5 (210±5) (2,986±71)

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

23.5±0.5 (240±5) (3,413±71)

Pilot line

MPa (kgf/cm2) (psi)

3.5 (36) (512)

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

115ZV-2 FS EU 43-3 43 Check & Adjustment Hydraulic Group Loading/Steering Circuit Relief Valve/Ride Control Circuit Reducing Valve (OPT)

Gauge port

Valve assembly Gauge port location

Port size

(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

(1)

(2) K115V2J43001

Multiple control valve

Make-up valve

Overload relief valve

(T)

Main relief valve

(3) 95ZV43002

115ZV-2 FS EU 43-4 43 Check & Adjustment Hydraulic Group Loading/Steering Circuit Relief Valve/Ride Control Circuit Reducing Valve (OPT)

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

Adjusting main relief pressure

Cap Lock nut

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

Adjusting screw Main relief valve 95ZV43004

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

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

115ZV-2 FS EU 43-5 43 Check & Adjustment Hydraulic Group Loading/Steering Circuit Relief Valve/Ride Control Circuit Reducing Valve (OPT)

Measuring loading circuit overload relief pressure 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)) 1. Lower the boom to the lowest limit.

Adjusting screw Overload relief valve 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. Keep the engine speed at low idle. 4. Hold the bucket control lever at the roll back position and record the pressure. Bucket cylinder rod side (gauge port (1) or (3)) 1. Lower the boom to the lowest limit. 2. Move the bucket control lever to the roll back position. 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 775 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.

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.

115ZV-2 FS EU 43-6 43 Check & Adjustment Hydraulic Group Loading/Steering Circuit Relief Valve/Ride Control Circuit Reducing Valve (OPT)

Measuring pilot circuit reducing valve pressure

Adjusting pilot line pressure

WARNING

Lock nut

Trapped pressure in brake circuit could cause serious injury when the plug is removed. Fully release all residual accumulator pressure before servicing. 1. Attach the pressure gauge to port (4).

Adjusting screw

2. Place the shift lever to the forward position. Reducing valve

Note Avoid “Hibernate mode” during the measurement. In the “Hibernate mode”, the engine speed is decreased to 775 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.

115ZV-2 FS EU 43-7 43 Check & Adjustment Hydraulic Group Loading/Steering Circuit Relief Valve/Ride Control Circuit Reducing Valve (OPT)

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

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

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

8.34±0.3 (85±3) (1,209±43.5)

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

Reference

Valve assembly (Reducing valve circuit)

Valve assembly (Accumulator circuit)

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.

115V2E43001

115ZV-2 FS EU 43-8 43 Check & Adjustment Hydraulic Group Loading/Steering Circuit Relief Valve/Ride Control Circuit Reducing Valve (OPT)

Measuring ride control circuit reducing pressure

Gauge port Gauge port location Reducing pressure

AC2

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

Pump

Tank (T)

Reducing valve Lock nut

(P)

Adjusting screw T

(R) (Ac1)

Tank

Air bleeder nipple

Boom cylinder bottom side

AC1

Reducing valve

Plug

AC2

Valve assembly (Reducing valve circuit)

95V2E43004

Accumulator

Valve assembly (Accumulator circuit)

95V2E43003

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) (12.3~15.2 lb-ft) 3. Keep the engine speed at low idle and then measure and record the 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.

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

115ZV-2 FS EU 43-9 43 Check & Adjustment Hydraulic Group Loading/Steering Circuit Relief Valve/Ride Control Circuit Reducing Valve (OPT)

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

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)

Steering valve Main relief valve

Overload relief valve 95ZV43006

115ZV-2 FS EU 43-10 43 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 cylinder

(2)

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

K115V2J43002

Reducing valve

(A)

(3)

(B)

115ZV43006

115ZV-2 FS EU 43-11 43 Check & Adjustment Hydraulic Group Loading/Steering Circuit Relief Valve/Ride Control Circuit Reducing Valve (OPT)

Measuring steering circuit main relief pressure

WARNING

2. Press the brake pedal, and set and confirm the transmission shift lever is at the neutral position.

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

3. Set and confirm the parking brake is at the "ON" position.

8. Increase the engine speed to high idle, and measure and record the pressure.

1. Unload the bucket.

4. Press the brake pedal.

Adjusting steering line main pressure Steering cylinder Lock nut Adjusting screw

(2)

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

K115V2J43002

Main relief valve 5. Attach the pressure gauge to the gauge port ((1) or (2)). 6. Set the declutch ON/OFF switch to ON. Press down the brake pedal all the way to the floor to avoid the “fuel saving mode at idle time”. Note In the “fuel saving mode at idle time”, the engine is not activated promptly and may not reach the maximum revolution. 7. In case the pressure gauge is installed to (1), steer the machine to the left until the front and rear chassis contact each other. Continue to hold the steering wheel fully turned. Note Because the stop valve is installed into the steering line, oil pressure does not reach the set point when the steering is fully turned. When measuring oil pressure, be sure to apply the articulation stopper or screw the stopper (bolt) in until the front and rear chassis contact each other.

95ZV43007

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

115ZV-2 FS EU 43-12 43 Check & Adjustment Hydraulic Group Loading/Steering Circuit Relief Valve/Ride Control Circuit Reducing Valve (OPT)

Measuring steering circuit overload relief pressure

Adjusting overload relief pressure Lock nut

Stopper (bolt)

Installed on front chassis

Port B to steering valve

Adjusting screw

Port A from pilot valve

Spool

Installed on rear chassis

95ZV43008 115V2U43001

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.

WARNING 3. Steer the machine until the front and rear chassis contact each other. Continue to hold the steering wheel fully turned. Note Because the stop valve is installed into the steering line, oil pressure does not reach the set point when the steering is fully turned. When measuring oil pressure, be sure to apply the articulation stopper or screw the stopper (bolt) in until the front and rear chassis contact each other. 4. Place the shift lever to the forward position. Note Avoid “Hibernate mode” during the measurement. In the “Hibernate mode”, the engine speed is decreased to 775 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.

115ZV-2 FS EU 43-13 43 Check & Adjustment Hydraulic Group Loading/Steering Circuit Relief Valve/Ride Control Circuit Reducing Valve (OPT)

Measuring pilot circuit relief pressure (reducing pressure)

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.

Adjusting screw

Adjusting pilot line pressure

Lock nut

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

IMPORTANT

(T)

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

(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. 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.

115ZV-2 FS EU 43-14 43 Check & Adjustment Hydraulic Group Hydraulic Cylinder

Hydraulic Cylinder Cylinder natural drift

Measurement procedure 1. Unload the bucket.

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

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

Measurement instrument

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

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

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

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

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

3 (1/8) or less

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

4 (5/32) or less

115ZV-2 FS EU 43-15 43 Check & Adjustment Hydraulic Group Hydraulic Cylinder Reference

Mark (Vinyl tape) Scale 95ZV43009

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

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

115ZV-2 FS EU 43-16 43 Check & Adjustment Hydraulic Group Stop Valve

Stop Valve Stop valve adjustment procedure

Reference dimension Front chassis

Stop valve (rear chassis)

Stopper (bolt)

(L.H, R.H)

Front chassis

Rear chassis

Reference dimension 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", while not rolling machine. - 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)

115ZV-2 FS EU 52-1 52 Function & Structure Brake Group

52 Function & Structure Brake Group Brake System Outline.............................................. 52-2 Brake Units Layout .................................................. 52-3 Unloader Valve ........................................................ 52-4 Valve Unit ................................................................ 52-7 Accumulator ............................................................ 52-9 Brake Valve ............................................................. 52-10 Service Brake .......................................................... 52-14 Parking Brake.......................................................... 52-22 Parking Brake Manual Release............................... 52-30 Brake Circuit Check Valve....................................... 52-32 Auto Brake .............................................................. 52-33 Pressure Sensor (for stop lamp and declutch) ........ 52-36

115ZV-2 FS EU 52-2 52 Function & Structure Brake Group Brake System Outline

Brake System Outline The brake system is the all-hydraulic type, and has two independent systems consisting of the front system and the rear system for enhancing safety. The service brake and the parking brake are the wet disc type. (Refer to "Hydraulic & Brake Circuit" page 92-5 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.

115ZV-2 FS EU 52-3 52 Function & Structure Brake Group Brake Units Layout

Brake Units Layout The brake system is the all-hydraulic type, and has two independent systems consisting of the front system and the rear system for enhancing safety.

The service brake is the wet disc type. The parking brake is the spring applied oil pressure released type.

115V2E52001

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

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

115ZV-2 FS EU 52-4 52 Function & Structure Brake Group Unloader Valve

Unloader Valve (S/N 9001~9050)

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

115ZV-2 FS EU 52-5 52 Function & Structure Brake Group Unloader Valve (S/N 9051~)

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

115ZV-2 FS EU 52-6 52 Function & Structure Brake Group Unloader Valve The unloader valve controls the flow rate and the pressure of the hydraulic oil sent from the pump to the accumulator. Body (1) is equipped with ports (pump, fan motor, accumulator, pilot and tank). Spool (3) which opens and closes the pump port to the fan motor port, orifice (6) which regulates the flow rate to the accumulator port with high priority, and the pressure governor mechanism which controls the pressure on the accumulator port side are built in the unloader valve.

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

OFF

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

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

115ZV-2 FS EU 52-7 52 Function & Structure Brake Group Valve Unit

Valve Unit 4

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

Loading line pilot valve

(PPI)

(Z)

(Z1)

(Z2) (PA)

ACF

(ACCF)

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 85V2E52002

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

115V2U52002

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

115ZV-2 FS EU 52-8 52 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

115ZV-2 FS EU 52-9 52 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)

115ZV-2 FS EU 52-10 52 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

Tank port Universal joint assembly

10 2 5

Front brake port

11 13

Pilot port

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

115V2E52009

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

115ZV-2 FS EU 52-11 52 Function & Structure Brake Group Brake Valve

Brake valve performance chart

Pedal pressing force (F)

N (kgf) (lbf)

338 (34.5) (75)

300 (30.6) (67)

200 (20.4) (45)

162(16.5) (36.4)

100 (10.2) (22)

93.3(9.5)(21)

76.1 (7.76) (17)

67.1(6.84) (15) 0

3.9

( ) 10

18.5 19

Pedal stroke

Output oil pressure (Brake port)

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

4.90 (50.0) (711)

2 (20) (290) 1.57 (16.0) (229)

0.36 (3.7) (52)

( ) 0

3.9 5

Pedal stroke

Output oil pressure (Brake port)

MPa (kgf/cm2) (psi) 4 (41) (580)

4.94 (50.4) (716)

2 (20) (290)

0 0 0.41 (4.2) (59)

2 (20) (290)

4 (41) (580)

5.35 (54) (768)

MPa (kgf/cm2) (psi)

Pilot oil pressure (pilot port input) K115V2U52006

115ZV-2 FS EU 52-12 52 Function & Structure Brake Group Brake Valve

Brake valve outline

While the valve is not operating

The brake valve is integrated into the pedal and 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

115ZV-2 FS EU 52-13 52 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 springs (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) lets each spool (2) drop down by way of springs (22)(23). When spools (2) are pushed down, at first the passage from out-port B1, B2, and pressure sensor port to the tank port are shut down. When spools (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 the each spool (2) through the orifices and works as the hydraulic reactive force to return spools (2) upward. When the sum of hydraulic reactive force and spring load (6)(13) becomes balanced with spring load (22)(23), it returns spools (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 springs (22)(23) are 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.

115ZV-2 FS EU 52-14 52 Function & Structure Brake Group Service Brake

Service Brake Piston stroke adjuster

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.

9 Wheel hub

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.

Brake oil inlet port

12 Axle housing

1 5

Service brake operation

10 11

115ZV52003

1. Internal gear hub 2. Brake piston 3. Piston return spring 4. Steel plate 5. Friction disc 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.

(S/N ~9100) 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.

115ZV-2 FS EU 52-15 52 Function & Structure Brake Group Service Brake

Service brake friction disc 6.8 0.1 mm (0.268 0.004 in)

430 mm (16.9 in)

5 0.15 mm (0.197 0.006 in)

1.2 mm (0.047 in)

0.55 mm (0.022 in) Detailed drawing of groove 115V2E52011

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. Note When installing friction discs, soak these in oil and antichatter mixture for at least 30 minutes prior to installation.

115ZV-2 FS EU 52-16 52 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.

Spring pins

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.

Friction disc

There is no inside or outside on this plate either. It may be installed either way. (A) Cooling holes

(A)

Steel plate

Spring pins

Internal gear

Friction disc wear measurement point

115ZV52005

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.

115ZV-2 FS EU 52-17 52 Function & Structure Brake Group Service Brake

Service brake piston Upper side

A 3

4 4

3 2

6 3

4 A

4 6

1. Hole for piston return spring (16 positions on circumference) 2. Hole for brake pedal stroke adjusting mechanism (6 positions on circumference, M10 x 1.5) 3. Hole for pushing in piston — use a M10 x 1.5 - 45~50 L (1.8~1.97 in) (Fully threaded) for this. (4 equivalent divisions of circumference) 4. Hole for removing piston (6 positions on circumference) 5. Hole to drain oil from piston rear side 6. Cooling oil hole

A-A 115ZV52006

115ZV-2 FS EU 52-18 52 Function & Structure Brake Group Service Brake

Service brake pedal stroke adjusting mechanism

Fig. 2

1.8 mm (0.07 in) Brake stroke adjusting mechanism

115ZV52030

115ZV52007

This shows the automatic adjuster function which always offers a constant pedal stroke as the brake disc wears.

When the brake disc wears and the brake piston is shifted by approximately 1.8 mm (0.07 in) or more, the sleeve is gradually pulled out to the left by the socket bolt by the amount corresponding to the wear. At that time, there is clearance of approximately 1.8 mm (0.07 in) between the sleeve and the socket bolt.

Fig. 1 Fig. 3

Piston Sleeve

Tolerance ring

Approx. 1.8 mm (0.07 in)

1.8 mm (0.07 in)

Socket bolt

Bushing 115ZV52028 115ZV52031

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 1.8 mm (0.07 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 1.8 mm (0.07 in), and stopped by the sleeve. In other words, the brake piston return amount is set to approximately 1.8 mm (0.07 in) so that a constant pedal stroke is always offered. Motions of the sleeve are regulated by the tolerance ring (spring). The sleeve is not moved by the return spring force of the piston.

115ZV-2 FS EU 52-19 52 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).

115ZV-2 FS EU 52-20 52 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

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.

Service brake valve

IMPORTANT Before bleeding the service brakes, it is important to remove all air from the brake valve manifold block, and all related valves. These include the reducing valve and park brake valve. Failure to do this correctly will result in unsatisfactory brake modulation. Perform the following to do this: 1. Verify that the wheels are securely blocked, and the articulation lock is in the "locked" position. Air bleeder nipple

2. Charge the accumulator to full pressure, and then, shut off the engine.

Auto brake solenoid valve

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. 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.

Reducing valve

Button (diameter: approximately 4 mm)

Solenoid valve for auto-brake

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.

Solenoid valve pressure nut

6. Close the bleeder nipple and remove the vinyl tube from the brake valve.

115V2E52002

115ZV-2 FS EU 52-21 52 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 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.

115ZV-2 FS EU 52-22 52 Function & Structure Brake Group Parking Brake

Parking Brake (S/N 9001~9050) 2nd Propeller shaft

13 1 7 17 8

19 21

12 11

18 16 20

Front differential assy

115V2E52003

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. Flange 17. Oil seal (single lip) 18. Oil seal 19. Pin 20. Spring pin

21. Spring

115ZV-2 FS EU 52-23 52 Function & Structure Brake Group Parking Brake (S/N 9051~9100) 2nd Propeller shaft

7 14 19

2 12

8 3 11 16

13 18 17 15

Front differential assy

K115V2J52003

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 16. Pin 17. Spring pin 18. Spring 19. Oil seal (double lip)

115ZV-2 FS EU 52-24 52 Function & Structure Brake Group Parking Brake (S/N 9101~) 2nd Propeller shaft

4 5

1 7

14 19

12 8 3 11 16

13 18 17 15

Front differential assy

K115V2J52004

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 16. Pin 17. Spring pin 18. Spring 19. Oil seal (double lip)

115ZV-2 FS EU 52-25 52 Function & Structure Brake Group Parking Brake

Parking brake operation 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 pistons (2) to the upward over coming spring force (4)(5), and release the brake.

Operation of parking brake Parking switch

OFF

Solenoid valve

Power OFF

Power ON

Brake piston chamber

Oil discharge

Oil charge

Braking

Released

Parking brake

Turning the starter key off works the same as turning the parking switch "ON".

5 A

(0.197~0.236 in)

5~6 mm

(S/N 9001~9050)

1 7

Brake oil

115V2U52005

115ZV-2 FS EU 52-26 52 Function & Structure Brake Group Parking Brake (S/N 9051~9100)

A 1 5 4

Brake oil

K115V2J52004

(S/N 9101~)

5 1

7 Brake oil

K115V2U52005

115ZV-2 FS EU 52-27 52 Function & Structure Brake Group Parking Brake Note - 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 26.4±1.3 mm (1.039±0.051 in) (S/N 9001~9100) 42.4±1.3 mm (1.669±0.051 in) (S/N 9101~) With completely worn out discs, and plates this measures 22.4±1.3 mm (0.881±0.051 in) (S/N 9001~9100) 38.4±1.3 mm (1.512±0.051 in) (S/N 9101~) - When the parking brake is operated as emergency around maximum speed out of necessity, check the wear on parking brake. - Bolt (7) must be tight in the piston to take this measurement.

115ZV-2 FS EU 52-28 52 Function & Structure Brake Group Parking Brake

Parking brake friction disc Seven friction plates and seven 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)

ø220 (8.7 in) ø330 (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

ø394 (15.5 in)

ø220 (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

115ZV-2 FS EU 52-29 52 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 

85V2E52007

115ZV-2 FS EU 52-30 52 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.

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.

(S/N 9001~9050)

14 13

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.

115V2E52005

1. Remove each of two places of lock nuts (14) from manual release bolt (7) and tighten flange nuts (13) 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 they feel 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.

115ZV-2 FS EU 52-31 52 Function & Structure Brake Group Parking Brake Manual Release (S/N 9051~)

Top Hose band

Rubber cap

7 1

Lock bolt

Flange nut

Detail of A K115V2J52005

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.

115ZV-2 FS EU 52-32 52 Function & Structure Brake Group Brake Circuit Check Valve

Brake Circuit Check Valve

Poppet (T)

(P)

Pump supply through reducing valve

(TA)

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

115ZV-2 FS EU 52-33 52 Function & Structure Brake Group Auto Brake

Auto Brake When the traveling direction is switched over between forward and reverse at a machine speed of 12 km/h (7.5 mph) or more, the auto brake is applied to protect the transmission clutches. When the machine speed is too high, the auto brake is applied also to prevent problems caused by excess speed in the engine and the transmission (over speeding).

Auto brake circuit

To front service brake

From unloader valve (Pump)

1. When the traveling direction is switched over between forward and reverse at a machine speed of 12 km/h (7.5 mph) or more while the shift lever is set to position A. 2. When the machine speed is too high in each speed range. Actual speed will vary with tire size. Speed range

Shown in the "released" position To rear service brake

Auto brake operation set value

MCU signal

1.6 MPa 2 16.3 kgf/cm (232 psi)

From unloader valve

K115V2U52007

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 unloader valve (22) enters the pilot port of left brake valve (23) through reducing valve (37) (setting pressure: 1.6 MPa (16 kgf/cm2) (230 psi)), 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

1st

Approximately 13 (8.125)

Approximately 12 (7.5)

2nd

Approximately 22 (13.75)

Approximately 24 (15.0)

3rd

Approximately 36 (22.5)

4th/A

Approximately 39 (24.375)

—

115ZV-2 FS EU 52-34 52 Function & Structure Brake Group Auto Brake

Reducing valve (for Autobrake circuit)

Orifice 1

Plunger

Orifice 2

B Seat face A

Pilot oil circuit Z From unloader valve

Brake valve

B Seat face B

Tank

T Spool

Reducing valve (for autobrake) Passage Y

Hydraulic circuit diagram

Solenoid valve (for autobrake)

115V2U52004

This reducing valve provides pilot oil pressure to operate the auto brake. The oil fed from the unloader valve 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 down and closes passage Z so that the pressure on the pilot oil circuit side does not exceed the set pressure. When the oil pressure on the pilot oil circuit side becomes less than the set pressure, the ball moves up and the pressure at chamber C becomes equivalent to the pressure on the pilot oil circuit side (B). As a result, the plunger moves up by a spring, opens the passage Z, then introduces the unloader pressure to the pilot oil circuit side so that the pressure is maintained at the specified value.

115ZV-2 FS EU 52-35 52 Function & Structure Brake Group Auto Brake When the solenoid valve for auto brake is energized and magnetized, this pressurized oil is supplied to the brake valve through the solenoid valve for auto brake and brake is applied. Set pressure 1.3 MPa (13 kgf/cm2) (185 psi)

Solenoid valve (for Autobrake circuit) 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. 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 upward, 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.

Solenoid specifications Voltage

DC 24 V

Current

0.92 A

Resistance

26.2 

Amp

a 0

Volt

Varistor 95ZV42079

Note The varistor (variable resistor) is used for the solenoid coil to protect the circuit.

115ZV-2 FS EU 52-36 52 Function & Structure Brake Group Pressure Sensor (for stop lamp and declutch)

Pressure Sensor (for stop lamp and declutch) Pressure sensor (for declutch) Refer to "Electrical Group: Adjustable declutch preset switch".

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 setting of the MCU (0.26 MPa (2.5 kgf/ cm2) (35 psi)), the stop lamp turns on.

Pressure sensor for stop lamp and declutch Left brake valve

115V2E52007

115ZV-2 FS EU 52-37 52 Function & Structure Brake Group Pressure Sensor (for stop lamp and declutch)

Pressure sensor (stop lamp) (S/N 9001~9150)

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

115ZV-2 FS EU 52-38 52 Function & Structure Brake Group Pressure Sensor (for stop lamp and declutch)

Pressure sensor (stop lamp) (S/N 9151~)

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

115ZV-2 FS EU 53-1 53 Check & Adjustment Brake Group

53 Check & Adjustment Brake Group Brake Circuit Oil Pressure ....................................... 53-2 Service Brake .......................................................... 53-6 Parking Brake.......................................................... 53-9

115ZV-2 FS EU 53-2 53 Check & Adjustment Brake Group Brake Circuit Oil Pressure

Brake Circuit Oil Pressure Unloader valve setting pressure WARNING Unexpected movement of the machine may cause an accident resulting in injury or death. Therefore, to provide repair service with the engine running, be sure to observe the following items: - Park the machine on level ground. - Apply the parking brake. - Block the tires with chocks to prevent the tires from moving. - Determine the signals between the service men.

(PPI)

(Z2)

(Z)

(Z1)

(PA)

ACF

(ACCF)

(ACCR)

(PARKING) (TA)

(T)

(P)

ACF port

Valve assembly

85V2E53001

WARNING

Injection Hazard Depress brake pedal 80~100 times to completely discharge the brake accumulators prior to removing these test plugs. 135ZV52035

Brake line main pressure is regulated by the unloader valve.

115ZV-2 FS EU 53-3 53 Check & Adjustment Brake Group Brake Circuit Oil Pressure

Unloader valve setting pressure measurement

Unloader valve setting pressure adjustment (S/N 9001~9050)

Measurement instrument

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 Cut-out Cut-in

Pump port

11.8±0.5 MPa (120±5 kgf/cm2) (1,706±71 psi) 2

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

Unloader valve 70ZV53001

Measurement procedure 1. Lower the boom to the lowest limit, and tilt the bucket down to the ground. Then set the parking brake switch to the "ON" position.

(S/N 9051~)

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)

Pump port Unloader valve

4. Start the engine, and keep the speed at low idle. Measure and record the pressure when the pointer of the pressure gauge stops rising (cut-out pressure). 5. Keep the engine at low idle, and repeatedly depress and release the brake pedal to reduce the accumulator pressure. Measure and record the pressure when the pointer of the pressure gauge stops and then starts rising again (cut-in pressure). 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 62-90 and 9253 for information.

K115ZV53002

1. Remove cap nut (24) and loosen lock nut (22). 2. Adjust the pressure by adjusting screw (21). Turn the screw clockwise to raise the pressure. Note In a case that the "ON" or "OFF" pressure does not match the standard setting pressure, set the "ON" (cutin) pressure to the standard setting pressure. : 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)

115ZV-2 FS EU 53-4 53 Check & Adjustment Brake Group Brake Circuit Oil Pressure

Brake valve oil pressure

Measurement procedure 1. Check to be sure the brake valve is fully released.

Force

la ng

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.

0 m m

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 62-90 and 92-53 for information. 85V2E53002

Brake valve oil pressure measurement Measurement instrument Hydraulic pressure gauge 10 MPa (105 kgf/cm2) (1,500 psi)

Gauge port Remove air bleeder nipple fitting on the axle housing, and then install the pressure gauge to the bleeder position. Size of air bleeder port: Rc (PT) 3/8 (In case of the bleeder valve: M10 X 1.0)

Air bleeder nipple fitting [59 N-m (6.0 kgf-m) (43 lb-ft)]

85ZVE53001

115ZV-2 FS EU 53-5 53 Check & Adjustment Brake Group Brake Circuit Oil Pressure

Brake valve performance

Output oil pressure (brake port)

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

4.90 (50.0) (711)

2 (20) (290) 1.57 (16.0) (229)

0.36 (3.7) (52)

( ) 0

3.9 5

Pedal stroke

18.5 19 K115V2U53001

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

Blown brake seals

Repair

Lost plugs in axle or hub

Repair

IMPORTANT After measuring oil pressure, be sure to tighten the air bleeder valve. Also be sure to bleed air.

115ZV-2 FS EU 53-6 53 Check & Adjustment Brake Group Service Brake

Service Brake Service brake performance check

Method 2

Method 1

If no test course available as described "Method 1", carry out the following method.

IMPORTANT

WARNING Separate the test course by using rope etc. and keep persons away from the test course. In addition, post persons in several positions near the course to warn others and avoid an accident while checking the service brake performance. Condition

The following method is easy and simple, however it is not an accurate way, because the braking force and rim-pull may vary on each machine. Confirm engine & transmission performance via using a stall test. See page 03-3. Reconfirm the brake performance by the method 1 as soon as possible.

1. Test course Level, straight, dry and the paved ground. 2. Run the machine and depress the brake pedal at 35 km/h (22 mph). Measure and record the braking distance.

Standard measurement value Braking distance 20 m (22 1/4 yard) or shorter

Possible causes of extremely long braking distance Possible cause Low brake line pressure

Solution

WARNING Unexpected movement of the machine may cause an accident resulting in injury or death. Before starting brake performance check, be sure to observe the following items: - Place the machine on level ground. - Check that there is enough clearance for brake performance check around the machine. - During performance check, prohibit any person to walking near the machine. 1. Lower the boom to the lowest limit, and roll back the bucket fully until the bucket contacts to the stopper. 2. Set the parking brake switch to the "OFF" position.

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 Low brake line pressure

Solution Check and repair

Friction plate wear

Check and repair

Brake valve malfunction

Check and repair

115ZV-2 FS EU 53-7 53 Check & Adjustment Brake Group Service Brake

Service brake friction plate wear measurement A

Air bleeder nipple

200 mm slide caliper

Slide caliper

Steel plate

Brake backing plate Friction plate 115ZV53002

IMPORTANT Oil inlet port Spring pin

Inner steel plate

Internal gear

Top about 2.5º

Spring pin

Outer steel plate

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.

Measurement procedure

115ZV53003

WARNING 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.

Turn the planetary gear so that the oil supply plug is positioned at ±2.5º from the top. Check that the teeth of steel plate are as shown (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 35.2 mm (1.386 in). Note that dimension A is 40.4 mm (1.590 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.

115ZV-2 FS EU 53-8 53 Check & Adjustment Brake Group Service Brake

Cautions on installing brake discs

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.

Upper side

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 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: 186.85~188.25 mm (7.356~7.411 in) 115V2E53001

Note: Piston stroke B: 1.45~4.35 mm (0.057~0.171 in) 4. After confirming that the piston is fully retracted (Dimension A is correct) remove all four bolts.

A B Wheel hub

Brake piston

115V2E53002

5. After finishing the installation work, bleed air completely from the brake line.

115ZV-2 FS EU 53-9 53 Check & Adjustment Brake Group Parking Brake

Parking Brake Parking brake performance check

Method 2

Method 1

If no test course available as described "Method 1", carry out the following method.

IMPORTANT

The following method is easy and simple, however it is not an accurate way, because the braking force and rim-pull may vary on each machine. Confirm engine & transmission performance via stall test. See page 03-3. Reconfirm the brake performance by the method 1 as soon as possible.

Condition 1. Test course 1/5 slope (Approx. 11º 19') 2. Bucket empty 3. Parking switch ON

1. Set the parking brake switch to the "ON" position. Standard measurement value 2. Disconnect the cable connector of parking brake solenoid valve.

No movement on 1/5 slope

3. Set the parking brake switch to the “OFF” position. Possible cause of machine moving during brake performance check Possible cause Wear or breakage of brake disc

Solution Check and repair

Parking brake switch malfunction

Check and repair

Parking brake solenoid valve malfunction

Check and repair

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

115ZV-2 FS EU 53-10 53 Check & Adjustment Brake Group

MEMO

115ZV-2 FS EU 62-1 62 Function & Structure Electrical Group

62 Function & Structure Electrical Group How to Use Electrical Wiring Diagram .................... 62-2 Electrical Cable Color Codes .................................. 62-8 Electrical Circuit Symbols........................................ 62-9 Sensor Mount .......................................................... 62-10 Fuse ........................................................................ 62-11 Engine Start Circuit.................................................. 62-13 Power Generating/Charging Circuit......................... 62-21 ECM (Engine Controller) ......................................... 62-22 Transmission Control Circuit and Monitor Circuit .... 62-36 Instrument Panel and Switch................................... 62-63 MODM ..................................................................... 62-70 Electrical Detent Circuit ........................................... 62-109 Diode ....................................................................... 62-115

115ZV-2 FS EU 62-2 62 Function & Structure Electrical Group How to Use Electrical Wiring Diagram

How to Use Electrical Wiring Diagram Example 10

10 9

20 19 18 17 16

15 14 13 12 11 21

40 39

32 31

WIDTH LAMP RELAY

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.

115ZV-2 FS EU 62-3 62 Function & Structure Electrical Group Utilisation des schémas des câblages électriques (FRANÇAIS)

Utilisation des schémas des câblages électriques (FRANÇAIS) Exemple 10

10 9

20 19 18 17 16

15 14 13 12 11 21

40 39

32 31

Relais de la lampe d’ écartement

Relais du contrôle de marche

Relais neutre

Relais de la lampe arrière

Relais du klaxon

RB B611

LgSb YV H133 E214

RL SbP H610 E220

RL LB H128 E219

GW GL H127 B501

R R D114 D114

Br Lg D112 D103

G L D102 D002

R Lg D111 D103

G G D107 D107

A520 C201 H129

LgW E218

LgW L A405 D001 1

Relais de défaillance du contrôleur

(Noir)

(Blue)

(1) (2)

6 D507 A306 F306 OR RO RW

A905 RLg

A503 YB

1 D112 E802 E803 Br GL GO

C206 A302 F303 E312 PB RBr RY WO

E523 G302 SbY BrB

C205 F504 F704 F804 RB RL GW PL

E109 G402 A105 E522 W BrW WP BrL

E501 C801 A005 B304 WL RG RGy LgG 40

E520 E108 F004 LgL W LgSb 36

E804 WY

E601 BrR 31

(3)

Les schémas des câblages électriques sont basés sur la méthode de l’adressage. Suivant cette méthode, un symbole correspond à chaque connecteur et à chaque borne du connecteur de manière à localiser facilement la borne de connection de l’autre extrémité du câble. Exemple 1 Symbole au-dessous (ou au-dessus) du connecteur, comme F6: Il indique l’adresse du connecteur. Exemple 2 Symbole sur le connecteur multibornes, comme 1 et 10: Il indique le numéro de la borne et le sens de la numérotation.

95ZV62001

Exemple 3 Contrôle de la borne du connecteur à laquelle F704 RL (point (3)) est connectée: 1. F704 Indique que la borne est connectée à la 4ème borne du connecteur F7. Contrôlez la description de la 4ème borne du connecteur F7 (F704), elle indique que la borne F704 est connectée à H128. Ceci signifie que la 4ème borne du connecteur F7 est connectée à la 28ème borne du connecteur H1. 2. RL Indique la couleur du fil. “RL” signifie que la couleur de l’isolation est rouge, et “L” que la raie bleu est sur l’isolation rouge.

115ZV-2 FS EU 62-4 62 Function & Structure Electrical Group Verwendung des elektrischen Schaltplans (DEUTSCH)

Verwendung des elektrischen Schaltplans (DEUTSCH) Beispiel 10

10 9

20 19 18 17 16

15 14 13 12 11 21

40 39

32 31

Breitenleuchtenrelais

Fahrtsteuerrelais

Neutrales Relais

Rückleuchtenrelais

Hupenrelais

RB B611

LgSb YV H133 E214

RL SbP H610 E220

RL LB H128 E219

GW GL H127 B501

R R D114 D114

Br Lg D112 D103

G L D102 D002

R Lg D111 D103

G G D107 D107

A520 C201 H129

Reglerfehlerrelais

LgW L A405 D001 1

LgW E218

(Schwarz)

(Blau)

(1) (2)

6 D507 A306 F306 OR RO RW

A905 RLg

A503 YB

1 D112 E802 E803 Br GL GO

C206 A302 F303 E312 PB RBr RY WO

E523 G302 SbY BrB

C205 F504 F704 F804 RB RL GW PL

E109 G402 A105 E522 W BrW WP BrL

E501 C801 A005 B304 WL RG RGy LgG 40

E520 E108 F004 LgL W LgSb 36

E804 WY

E601 BrR 31

(3)

Für den elektrischen Schaltplan wird die Adressenmethode verwendet. Damit wird jeder Steckvorrichtung und jeder Anschlußklemme ein Symbol zugeordnet, damit die Klemme, an die das andere Ende des Kabels angeschlossen werden muß, leicht gefunden werden kann. Beispiel 1 Symbol unterhalb (oder oberhalb) der Steckvorrichtung, wie z. B. F6: Zeigt die Adresse der Steckvorrichtung an. Beispiel 2 Symbol an der Mehrklemmen- Anschlußstelle, wie z. B. 1 und 10: Zeigt die Klemmennummer und die Zählrichtung an.

95ZV62001

Beispiel 3 Überprüfung der anderen Steckvorrichtungsklemme, wo F704 RL (Artikel (3)) angeschlossen ist: 1. F704 Zeigt, daß die Klemme an die vierte Klemme der F7-Steckvorrichtung angeschlossen ist. Überprüfen Sie die Beschreibung in der vierten Klemme des F7-Steckvorrichtung (F704). Zie gibt an, daß die Steckvorrichtung F704 an H128 angeschlossen ist. Dies bedeutet, daß die vierte Klemme der F7-Steckvorrichtung an die 28. Klemme der H1-Steckvorrichtung angeschlossen ist. 2. RL Zeigt die Farbe des Kabels an. „ RL ” bedeutet, daß der lsolierdraht rot ist, und „ L ” bedeutet, daß sich auf dem roten lsoliermaterial ein blauer Streifen befindet.

115ZV-2 FS EU 62-5 62 Function & Structure Electrical Group Modalità di utilizzo dello schema dei collegamenti elettrici (ITALIANO)

Modalità di utilizzo dello schema dei collegamenti elettrici (ITALIANO) Esempio 10

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.

115ZV-2 FS EU 62-6 62 Function & Structure Electrical Group Cómo utilizar un Diagrama de Alambrado Eléctrico (ESPAÑOL)

Cómo utilizar un Diagrama de Alambrado Eléctrico (ESPAÑOL) Ejemplo 10

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.

115ZV-2 FS EU 62-7 62 Function & Structure Electrical Group Como Utilizar o Diagrama de Ligações Eléctricas (PORTUGUÊS)

Como Utilizar o Diagrama de Ligações Eléctricas (PORTUGUÊS) Exemplo 10

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.

115ZV-2 FS EU 62-8 62 Function & Structure Electrical Group Electrical Cable Color Codes

Electrical Cable Color Codes Color of stripe Color of insulation

Y G (yellow) (green)

(sky blue)

Br (brown)

L (blue)

W (white)

R (red)

YSb

YBr

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

115ZV-2 FS EU 62-9 62 Function & Structure Electrical Group Electrical Circuit Symbols

Electrical Circuit Symbols Name

Symbol

Name

Direct current

Motor

Alternating current

Equipment

Conductor (General)

Fuses

Branching connection

Lamp

Conductors (Connected)

Rectifiers

Conductors (Not connected)

Mechanical coupling

Terminal

Relay contact ("a" contact)

Ground

Relay contact ("b" contact)

Resistance or Resistor

Switch

Variable resistance or Variable resistor

Pressure switch or Temperature switch

Inductance or Electromagnetic coil

Negative -positive-negative (NPN) transistor

Battery or Direct voltage source

Positive -negative-positive (PNP) transistor

Symbol

115ZV-2 FS EU 62-10 62 Function & Structure Electrical Group Sensor Mount

Sensor Mount 1

6 3

1 For air conditioner

1. Machine speed sensor 2. T/C oil temperature sensor 3. Air cleaner sensor 4. E/G coolant temperature sensor (S/N 9001~9050) 5. Hydraulic oil level sensor 6. Hydraulic oil temperature sensor 7. Coolant level alarm sensor 8. Cold starter temperature switch

8 A-Detail

115V2E62001

115ZV-2 FS EU 62-11 62 Function & Structure Electrical Group Fuse

Fuse The following fuses are provided to protect electrical circuits. Fusible link 70 A x 2, 30 A x 1

Fuse box For chassis

Fuse No.

Fuse capacity (A)

20A

LIGHTING HEAD LIGHT

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

IMPORTANT

15A

SPARE

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.

15A

4WAY FLASHER HORN ROOM LAMP RADIO

10A

SPARE

15A

COLD STARTER

BUZZER MONITOR (MCU)

NEUTRAL RELAY

BATTERY RELAY ECM (ENGINE)

Fuse box 15 fuses x 2 (for chassis and cab) (For installation positions, refer to "Electrical Equipment Layout".)

CAUTION Possible burn hazard. Before replacing a fuse, be sure to turn off the starter switch.

Protective circuit

15A SPARE 5A

For cab

Fuse No.

Fuse box for cab

Fuse box for chassis

90V2E62002

Fuse capacity (A)

Protective circuit

SPARE

R. WIPER / WASHER

10A

F. WIPER / WASHER

10A

MODM

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

115ZV-2 FS EU 62-12 62 Function & Structure Electrical Group Fuse

Fusible link

Problems caused by blown fusible link Fuse damaged

Fusible link Cover

Box for fusible link

(081) (085) W W

Fusible link

(900) [W5]

30A

12V

BATTERY

R1 BR B AC R2 C

(063) WR1.25

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

- 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.

TO MCU

(013) (Lg)

(1)

BATTERY RELAY

STARTER

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 [R5] x 6 (910~ 915) [R5] (701)

MAGNETIC (702) S/W 5 [BW ]

VOLTAGE

WG(704) RELAY

RL1.25 (703) NR (013) (Lg)

F13

(705) (WG)

(707) WL

CHARGE LAMP 20

70A

(706) WL1.25 R I

B E

(2) ALTERNATOR

(005-a) ES (L)

M1 M2

100

SECONDARY STEERING PUMP SECONDARY STEERING PUMP

M M2

THERMO (062) (012) BW F12 BW 15A B

30A

WV (700)

70A

(014) G1.25

(708) WP

F13

F14

(064) G1.25

ECM(H) (015) (065) WR1.25 F15 WR

During engine stop - All the electrical circuit will not function. - Engine can not be started.

70ZV62010

100

(060) (901) W [W5]

During engine operation - Engine will stop automatically. - All the power for all electrical circuit will be OFF.

Fuse element

12V

Problem (symptom)

ACC’

(722) SWITCH (721) ETHER KIT (BrR) BrB

COLD STARTER SWITCH

TO PILOT LAMP

Fusible link location

K115V2U62001

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.

115ZV-2 FS EU 62-13 62 Function & Structure Electrical Group Engine Start Circuit

Engine Start Circuit Engine start circuit diagram Starter switch

B BR ACC R1 R2 C Off On Start

MCU

F N R

30A

B12

Fusible link

12V

Battery

ECM

B11

Diode unit

F15 5A

23A D12 D05 D03 (1)

D10

70A

D04

12V

B18

D11

E04 E12 E03 E11

F14

E24

Shift lever

Shift lever F/R position

E05 E06 E17

Battery relay

Starter motor 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

115V2E62033

115ZV-2 FS EU 62-14 62 Function & Structure Electrical Group Engine Start Circuit

Neutral starter To prevent the machine from unexpected movement at engine start up, the machine is so designed that the engine can start only while the shift lever is in the neutral (N) position.

Shift lever neutral (N) position When the starter switch is turned to the ON position while the shift lever is located in the N position, the coil actuation circuit of the neutral relay is connected to the ground of the MCU unit and the contact of the neutral relay is switched over to ON. 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.

115ZV-2 FS EU 62-15 62 Function & Structure Electrical Group Engine Start Circuit

Starter switch

Off Enables insertion and removal of the starter key. All the electrical circuits (except the horn and hazard flasher [OPT.]) will be turned off. On Supplies power to the charge, lamp, and monitor circuits. Start Starts the engine.

Starter switch Control box

Starter switch location 85V2E62002

OFF

30º

ON 35º Start

BR R2

BW WR WR BG WB WB

WR x 2

WB x 2

Start

W5 W3

Off

R1 BR

1.25

To neutral relay

BBG G

BR AC

To battery relay

From battery

Connection table

W3 W5

115V2E62004

115ZV-2 FS EU 62-16 62 Function & Structure Electrical Group Engine Start Circuit

ECM safety features The ECM is equipped with safety functions that are designed to limit engine revolution (min-1) in certain situations. The “zero point” of the pedal is recalibrated every time the key switch is turned to the “ON” position, so that the pedal operation positions are consistent. (Pedal angle relative to engine revolution (min-1) point.) This permits the ECM to see the signal and set the engine revolution (min-1) appropriately. This function is set to turn “on” 1 second after the key is set to the “ON” position, then adjustment is completed in 3 seconds and this function is turned “off”. Note There is no indication on the instrument panel or MODM that this function turns either “on” or “off” because there is no engine abnormality to call out or indicate. Effect on the machine (a) If the throttle pedal is applied while turning the key switch to the start position, the engine maximum speed will only increase to 80% of high idle. (b) If the throttle pedal is applied while the engine is starting, this function will turn “ON” 1 second after releasing the pedal and engine speed will only increase 80% of high idle.

Battery relay

Terminals for coil energizing current (4 mm)

Moving contact Main contacts

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.

115ZV-2 FS EU 62-17 62 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

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

115V2E62005

Engine motion-active circuit: (1) 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.

115ZV-2 FS EU 62-18 62 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 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 

115ZV-2 FS EU 62-19 62 Function & Structure Electrical Group Engine Start Circuit

Magnetic switch

Rating 24V x 200A

M’

C’

M C

C’ M’

70ZV62019

Note The illustrations show the de-energized condition. When the neutral relay is magnetized, electric current flows from the battery to the 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.

115ZV-2 FS EU 62-20 62 Function & Structure Electrical Group Engine Start Circuit

Voltage relay

Note The illustrations show the de-energized condition.

(S/N 9001~9006)

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 9007~) Blue

K70V2J62005

Voltage relay Contact point closed

Contact point open

115ZV-2 FS EU 62-21 62 Function & Structure Electrical Group Power Generating/Charging Circuit

Power Generating/Charging Circuit Alternator Engine

Mechanical energy supply

Alternator

Rotor coil excitation current

Electrical energy conversion

In the electricity generated in the alternator, the voltage fluctuates depending on the number of revolutions of the engine and the load size if no measures are taken.

Generated power

<Load>

For rotor coil initial excitation

Battery

Load circuit operation

Starter switch

Voltage adjustment

Battery charge

For battery relay operation

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.

115ZV-2 FS EU 62-22 62 Function & Structure Electrical Group ECM (Engine Controller)

ECM (Engine Controller) Function of ECM - Stops the engine. - Operates the engine. - Monitors the engine, and diagnoses it for faults.

Connection diagram

16 PIN

(081) W

(085) W

10A

B (015) WR

F15

E 10A

J K L

H 23 PIN

GR (742) GY (743) BG (744)

(A25)

(GW) (212)

THROTTLE PEDAL THROTTLE OPENING SENSOR

YV (734)

(741) BL

(751) GyR

E/G OIL PRESS.

E W

(745) BO

X O

21 22

18 GyY (736) GyW(737)

IDLE

31 PIN BrW (733) BLg (735)

IDLE S/W OFF IDLE

(730) (BrR)

STOP

(731) (BrB)

WARNING

(013) (Lg)

F13

(732) MAINTENANCE (BrW)

9 10 11

(161) W

(E15)

DIAGNOSTIC S/W BrG (738)

S2H S2L

INC/DEC S/W INC

PG (739)

(m)

PW (740)

DEC AI

SbY (209)

Sb (205)

SbW(207) RLg (206)

CAN

S2S 23

RESISTOR

24 14

B 9 PIN C

12 13

D E F

S2H

(060) W

B C

S2L

S2S

(YL) (747)

(Y0) (748)

G A E

DATA LINK CONNECTOR

E/G ECM connection diagram

115V2E62006

115ZV-2 FS EU 62-23 62 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

(S/N 9001~9200)

(S/N 9201~)

F E

0 x100min

-1

STOP

Engine maintenance lamp Engine warning lamp Engine stop lamp 115V2E62035

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.

115ZV-2 FS EU 62-24 62 Function & Structure Electrical Group ECM (Engine Controller)

Failure diagnosis

The diagnosis for the engine failure should be done by the following steps.

Engine diagnostic switch (option) 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 ON

START

95ZV62028

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

115ZV-2 FS EU 62-25 62 Function & Structure Electrical Group ECM (Engine Controller)

Failure diagnostic chart ON Key switch OFF ON Diagnostic switch OFF

[When there is no fault code] ON Engine 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

115ZV-2 FS EU 62-26 62 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 "-".

115ZV-2 FS EU 62-27 62 Function & Structure Electrical Group ECM (Engine Controller)

Quantum fault code information

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)

QSC8.3 (80ZV-2)

DESCRIPTION

QSB6.7 (70ZV-2) (70TMV-2)

FAULT CODE/ LAMP

Please note that not all are used in the 115ZV-2 machine application. Refer to Cummins Engine troubleshooting fault codes list for more information. QSB4.5 (60ZV-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).

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)

115ZV-2 FS EU 62-28 62 Function & Structure Electrical Group ECM (Engine Controller)

EG286 Yellow

SAE J1939 Data Link Multiplexing Configuration Error.

EG287 Red

SAE J1939 Multiplexing Accelerator Pedal Sensor System Error.

EG295 Yellow

Ambient Air Pressure Sensor Circuit - data incorrect.

EG299 Yellow

Engine stopped not using Starter Switch.

EG311 Yellow

Injector Solenoid Valve Cylinder #1 Circuit - grounded circuit.

EG312 Yellow

Injector Solenoid Valve Cylinder #5 Circuit - grounded circuit.

EG313 Yellow

Injector Solenoid Valve Cylinder #3 Circuit - grounded circuit.

EG314 Yellow

Injector Solenoid Valve Cylinder #6 Circuit - grounded circuit.

EG315 Yellow

Injector Solenoid Valve Cylinder #2 Circuit - grounded circuit.

EG319 Yellow

Real Time Clock - power Interrupt.

EG321 Yellow

Injector Solenoid Valve Cylinder #4 Circuit - grounded circuit.

EG322 Yellow

Injector Solenoid Valve Cylinder #1 Circuit - open circuit.

EG323 Yellow

Injector Solenoid Valve Cylinder #5 Circuit - open circuit.

EG324 Yellow

Injector Solenoid Valve Cylinder #3 Circuit - open circuit.

EG325 Yellow

Injector Solenoid Valve Cylinder #6 Circuit - open circuit.

EG331 Yellow

Injector Solenoid Valve Cylinder #2 Circuit - open circuit.

EG332 Yellow

Injector Solenoid Valve Cylinder #4 Circuit - open circuit.

EG334 Yellow

Coolant Temperature Sensor Circuit - data erratic, intermittent, or incorrect.

EG341 Yellow

Engine Control Module - data lost.

EG342 Red

Engine Control Module - out of calibration.

EG343 Yellow

Engine Control Module - warning internal hardware failure.

EG346 Yellow

Engine Control Module - warning software error.

EG351 Yellow

Injector Power Supply.

EG352 Yellow

Sensor Supply Voltage #1 Circuit - shorted low.

EG378 Yellow

Fueling Actuator #1 Circuit - open circuit.

EG379 Yellow

Fueling Actuator #1 Circuit - grounded circuit.

EG386 Yellow

Sensor Supply Voltage #1 Circuit - shorted high.

QST30 (135ZV-2)

QSK19 (115ZV-2)

QSX15 (95ZV-2)

QSM11 (92ZV-2)

QSM11 (90ZV-2)

QSC8.3 (85ZV-2)

QSC8.3 (80ZV-2)

DESCRIPTION

QSB6.7 (70ZV-2) (70TMV-2)

FAULT CODE/ LAMP

QSB4.5 (60ZV-2)

115ZV-2 FS EU 62-29 62 Function & Structure Electrical Group ECM (Engine Controller)

EG387 Yellow

Accelerator Pedal Position Sensor Supply Voltage Circuit - shorted high.

EG394 Yellow

Timing Actuator #1 Circuit - open circuit.

EG395 Yellow

Timing Actuator #1 Circuit - grounded circuit.

EG396 Yellow

Fueling Actuator #2 Circuit - open circuit.

EG397 Yellow

Fueling Actuator #2 Circuit - grounded circuit.

EG398 Yellow

Timing Actuator #2 Circuit - open circuit.

EG399 Yellow

Timing Actuator #2 Circuit - grounded circuit.

EG415 Red

Engine Oil Pressure Low - critical.

EG418 Yellow

Water in Fuel Indicator High - maintenance.

EG419 Yellow

Intake Manifold Boost Pressure Imbalance.

EG423 Yellow

Fuel Timing Pressure or Timing Actuator Stuck.

EG428 Yellow

Water in Fuel Sensor Circuit - shorted high.

EG429 Yellow

Water in Fuel Sensor Circuit - shorted low.

EG431 Yellow

Accelerator Pedal Idle Validation Circuit - data incorrect.

EG432 Red

Accelerator Pedal Idle Validation Circuit - out of calibration.

EG433 Yellow

Intake Manifold Pressure Sensor Circuit - data incorrect.

EG434 Yellow

Voltage to ECM less than 6 V

EG435 Yellow

Engine Oil Pressure Switch Circuit - data incorrect.

EG441 Yellow

Battery #1 Voltage Low - warning.

EG442 Yellow

Battery #1 Voltage High - warning.

EG443 Yellow

Accelerator Pedal Position Sensor Supply Voltage Circuit - shorted low.

EG449 Yellow

Fuel Pump Delivery Pressure High - warning.

EG451 Yellow

Injector Metering Rail #1 Pressure Sensor Circuit - shorted high.

EG452 Yellow

Injector Metering Rail #1 Pressure Sensor Circuit - shorted low.

EG465 Yellow

Turbocharger #1 Wastegate Control Circuit - shorted high.

EG466 Yellow

Turbocharger #1 Wastegate Control Circuit - shorted low.

EG482 Yellow

Fuel Pressure Low - warning.

QST30 (135ZV-2)

QSK19 (115ZV-2)

QSX15 (95ZV-2)

QSM11 (92ZV-2)

QSM11 (90ZV-2)

QSC8.3 (85ZV-2)

QSC8.3 (80ZV-2)

DESCRIPTION

QSB6.7 (70ZV-2) (70TMV-2)

FAULT CODE/ LAMP

QSB4.5 (60ZV-2)

115ZV-2 FS EU 62-30 62 Function & Structure Electrical Group ECM (Engine Controller)

EG483 Yellow

Injector Metering Rail #2 Pressure Sensor Circuit - shorted high.

EG484 Yellow

Injector Metering Rail #2 Pressure Sensor Circuit - shorted low.

EG485 Yellow

Injector Metering Rail #2 Pressure High - warning.

EG486 Yellow

Injector Metering Rail #2 Pressure Low - warning.

EG488 Yellow

Intake Manifold Temperature High - warning.

EG491 Yellow

Turbocharger #2 Wastegate Control Circuit - shorted high.

EG492 Yellow

Turbocharger #2 Wastegate Control Circuit - shorted low.

EG496 Yellow

Engine Speed / Position Sensor #2 (Camshaft) Supply Voltage.

EG524 Yellow

OEM Alternate Droop Switch Validation - data incorrect.

EG527 Yellow

Auxiliary Input / Output #2 Circuit - shorted high.

EG528 Yellow

OEM Alternate torque validation switch - data incorrect.

EG529 Yellow

Auxiliary Input / Output #3 Circuit - shorted high.

EG546 Yellow

Fuel Delivery Pressure Sensor Circuit - shorted high.

EG547 Yellow

Fuel Delivery Pressure Sensor Circuit - shorted low.

EG551 Yellow

Accelerate Pedal Idle Validation Circuit - shorted low.

EG553 Yellow

Injector Metering Rail #1 Pressure High - warning level.

EG554 Yellow

Fuel Pressure Sensor Error.

EG559 Yellow

Injector Metering Rail #1 Pressure Low - data valid but below normal operational range - moderately severe level.

EG596 Yellow

Electrical Charging System Voltage High - warning level.

EG598 Red

Electrical Charging System Voltage Low - critical level.

EG689 Yellow

Crankshaft Engine Speed Signal Error.

EG731 Yellow

Mechanical Timing Misalignment.

EG753 Yellow

Crankshaft Position Sensor and Camshaft Position Sensor - data erratic, intermittent, or in correct.

EG757 Yellow

Electronic Control Module Data Lost.

EG758 Yellow

Injector Metering Rail #2 Pressure Malfunction.

EG778 Yellow

Engine Speed Sensor (Camshaft) - data erratic, intermittent, or incorrect.

EG951 None

Cylinder Power Imbalance Detected.

QST30 (135ZV-2)

QSK19 (115ZV-2)

QSX15 (95ZV-2)

QSM11 (92ZV-2)

QSM11 (90ZV-2)

QSC8.3 (85ZV-2)

QSC8.3 (80ZV-2)

DESCRIPTION

QSB6.7 (70ZV-2) (70TMV-2)

FAULT CODE/ LAMP

QSB4.5 (60ZV-2)

115ZV-2 FS EU 62-31 62 Function & Structure Electrical Group ECM (Engine Controller)

EG1117 None

Power Lost with Ignition ON - data erratic, intermittent, or incorrect.

EG1358 Yellow

Accelerator Pedal Position Sensor 1 Circuit - voltage above normal or shorted high.

EG1359 Yellow

Accelerator Pedal Position Sensor 1 Circuit - voltage below normal or shorted low.

EG1361 Yellow

Remote Accelerator Pedal Position Sensor 1 Circuit - voltage below normal or shorted low.

EG1376 Orange

Engine Camshaft Speed / Position Sensor - data erratic, intermittent, or incorrect.

EG1595 Yellow

Remote Accelerator Pedal Position Sensor 1 Circuit - voltage above normal or shorted high.

EG1597 Orange

Engine Control Module Critical Internal Failure - bad intelligent device or component.

EG1845 Orange

Water in Fuel Indicator Sensor Circuit - voltage above normal or shorted to high source.

EG1846 Orange

Water in Fuel Indicator Sensor Circuit - voltage below normal or shorted to low source.

EG1852 Yellow

Water in Fuel Indicator - data valid but above normal operational range moderately severe level.

EG1911 Yellow

Injector Metering Rail 1 Pressure - above normal operating range.

EG2185 Yellow

Sensor Supply Voltage #4 Circuit - shorted high.

EG2186 Yellow

Sensor Supply Voltage #4 Circuit - shorted low.

EG2215 Yellow

Fuel Pump Delivery Pressure - data valid but below normal operational range moderately severe level.

EG2249 Yellow

Fuel Pump Delivery Pressure Sensor Circuit - shorted low.

EG2261 Orange

Fuel Pump Delivery Pressure - data valid but above normal operational range least severe level.

EG2262 Orange

Fuel Pump Delivery Pressure - data valid but below normal operational range least severe level.

EG2265 Yellow

Fuel Priming Pump Control Signal Circuit - shorted high.

EG2266 Yellow

Fuel Priming Pump Control Signal Circuit - shorted low.

EG2311 Yellow

Fueling Actuator #1 Circuit Error - condition exists.

EG2321 None

Engine Speed Sensor #1 - data erratic, intermittent, or incorrect.

EG2322 None

Engine Speed Sensor #2 - data erratic, intermittent, or incorrect.

EG2697 Orange

Accelerator Pedal Position Sensor Circuit and Idling Position Detection Switch Circuit - data erratic, intermittent, or incorrect.

EG2963 None

Engine Coolant Temperature High - warning.

EG2964 None

Intake Manifold Temperature High - warning.

EG2973 Yellow

Intake Manifold Pressure Sensor Circuit - data erratic, intermittent, or incorrect.

(09D20E)

QST30 (135ZV-2)

QSK19 (115ZV-2)

QSX15 (95ZV-2)

QSM11 (92ZV-2)

QSM11 (90ZV-2)

QSC8.3 (85ZV-2)

QSC8.3 (80ZV-2)

DESCRIPTION

QSB6.7 (70ZV-2) (70TMV-2)

FAULT CODE/ LAMP

QSB4.5 (60ZV-2)

115ZV-2 FS EU 62-32 62 Function & Structure Electrical Group ECM (Engine Controller)

115ZV-2 FS EU 62-33 62 Function & Structure Electrical Group ECM (Engine Controller)

Accelerator pedal

Pedal A-Black-APS signal B-White-APS ground C-Red-APS supply (5 V) D-Green-Throttle active E-Blue-Idle active F-Orange-IVS supply (5 V)

Throttle pedal Throttle opening sensor

BrW (733) R

YV (734)

BLg (735)

20 21 22

W IDLE S/W OFF IDLE

GyY (736) G GyW (737)

IDLE

L BL (741)

E C M 9 10

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

115V2E62010

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

 at pedal up position

 at pedal down position

R-B

1,540~2,310

260~390

W-B

260~390

1,540~2,310

R-W

2,000~3,000

G-O

Open

L-O

Open

115ZV-2 FS EU 62-34 62 Function & Structure Electrical Group ECM (Engine Controller) When the accelerator pedal is pressed, the voltage corresponding to the pressing angle is input as a signal from the potentiometer to the ECM (engine controller) to control the engine revolution.

Pedal stop

Stroke

Pedal angle K65V2U62004

17 Installation angle 45

Note Part “A” is added on S/N 9151 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

115ZV-2 FS EU 62-35 62 Function & Structure Electrical Group ECM (Engine Controller)

Accelerator pedal installation Throttle pedal sends electrical signal to the engine ECM*. When the throttle pedal or the ECM* is replaced or when the battery cable is disconnected the throttle pedal must be calibrated, or "initialized", with the ECM*. Failure to initialize the throttle pedal will result in a fault code warning light, and a possible power deration. When a new throttle pedal or ECM* is installed or when the battery cable is re-connected or a fault code (listed below) is indicated follow these steps within a time frame of about 5 or 6 seconds to initialize the throttle pedal with the ECM*. 1. Shut off the engine 2. Turn the key to "ON" 3. Fully depress and release the throttle pedal three times. 4. Turn the key to "OFF". The throttle pedal and ECM* have now been initialized or calibrated. The engine may be restarted and retested for proper performance. If the problem continues disconnect the wiring harness connector at the throttle pedal and inspect both sides. The pins and sockets should be clean, dry and straight. If there is a problem correct it, reconnect the connector, follow the steps above and retest. Using the Quantum fault code information section the following fault codes may indicate a non-initialized throttle pedal: - Fault Code 132 - Fault Code 134 - Fault Code 287 - Fault Code 431 - Fault Code 432 - Fault Code 443 If the problem is not corrected contact your Cummins Engine distributor for assistance. *Engine Control Module; Computer that controls engine functions, and monitors engine faults.

115ZV-2 FS EU 62-36 62 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit

Transmission Control Circuit and Monitor Circuit Machine control unit (MCU)

To S5

To S6

To S7

To S8

To S9

85V2E62041

115ZV-2 FS EU 62-37 62 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit

Connector

MCU

To S5

To S6

To S7

To S8

To S9

C 1.2S_SE C 2.DSUB2 C 3.DSUB4 C 4.BSLC 5.TT C 6.AC C 7.ET C 8.BL C 9.BD C10.DSUB1 C11.DSUB3 C12.DR C13.BSL+ C14.TF C15.WL

C16.EP C17.F C18.ASUB1 C19.ASUB2 C20.1/2 C21.1/8 C22.2S C23.EG_H C24.IP_SW C25.FR C26.KO_P C27.ES_SE C28.3/4 C29.1/4 C30.DC

MCU A 1.2S_SO A 2.2_SO A 3.ES_R A 4.DD_SO A 5.3_SO A 6.HM A 7.LU_SO A 8.4_SO A 9.OTH_OUT A10.R_L A11.F_L A12.ST_L A13.WL_L A14.CW_L A15.ET_L

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.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

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 115V2E62028

115ZV-2 FS EU 62-38 62 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit

MCU connection diagram (S/N 9001~9200)

ACC’

(L) (005-b) F5

(005) L2

TO PARKING S/W

(L) (005-a)

30A G (010)

F10 E ACC’

LX4 (005-A~005-D) E05 E06 E17 WL (707)

E12

E04 E03

E11 B18

E24

B12 LR (126)

23A

LW (120)

LG (122) LY (121)

YO (232) YW (233)

S/S SHIFT S/W R

S/S SHIFT SELECTION S/W (OPT)

YV (231) LB (230)

LG (122)

SHIFT UP S/W (OPT)

LY (121)

SHIFT DOWN S/W (OPT)

(YL) (124)

DOWNSHIFT BUTTON

YSb (125)

SHIFT HOLD S/W (OPT)

LP (168)

DECLUTCH SET-UP TRACTION CONTROL S/W LIFT KICKOUT SET-UP

(GW) (210)

LOWER KICKOUT SET-UP

BW (271)

BrG (255)

(GB) (277)

PRESSURE INTENSIFYING S/W (OPT) REVERSAL FAN S/W (OPT)

Lg (222)

AUTO FAN REVERSAL S/W (OPT)

LgY (223)

RECALL S/W RESET S/W

(Y)

(105)

(R)

(106)

LLg (165) GO (164)

F13

GyW (200)

(013) (Lg)

GL (265)

YO(176)

(GyW ) (260)

(LgY) (167)

HYD. OIL LEVEL S/W

(163) (SbW)

OFF ON

PARKING SOL (162) LgG

E/G OIL PRESS S/W

DECLUTCH

AIR CLEANER CLOGGING S/W (005-b) (L)

OFF

B10

D12 D05 D03 D10

D19 D26

D18 D24

D06 D07

D14 D17

A03 B13 B01 B04 A18

A02

(273)

NEUTRAL RELAY

MCU FAILURE RELAY

LIFT KICKOUT RELAY LOWER KICKOUT RELAY

A05

A08

A17 B14 A07

D23

A04

D22

A01 B03

Gy (750) BrY (181) LgL (182)

B06

H SOLENOID VALVE

(148) LBr

R SOLENOID VALVE

(141) LY

1ST SPEED SOLENOID VALVE

(142) LG

2ND SPEED SOLENOID VALVE

4S (132)(LG)

(143) LO

3RD SPEED SOLENOID VALVE

(144) LW

E01 B07

BRAKE SOLENOID VALVE

LLg (140)

LU SOLENOID VALVE (OPT)

LgL (261)

RIDE CONTROL SOLENOID VALVE

GB (267)

EFFICIENT LOADING SYSTEM SELECTION SOLENOID VALVE

GB (278)

PRESSURE INTENSIFYING SOLENOID VALVE (OPT)

LgL (225)

REVERSAL FAN SOLENOID VALVE (OPT)

(150) LgR

SPPC SOLENOID VALVE

(236) BR (237) BL

S/S SOLENOID VALVE R (OPT)

S/S SOLENOID VALVE L (OPT)

C12 E02

(226) LgB

(221) LgB 1A

D21

(013) (Lg)

D01

FAN SPEED CONTROL SOLENOID VALVE

F13

C23

A21

C22

A29

C33

A14

C16

A28 A19

C06

D SOLENOID VALVE

WR (170)

C25

C11

4TH INDICATOR RELAY

(LW) LP (149)

B05

C30

L SOLENOID VALVE

(147) LB

(154) LgR

C24

C34

SECONDARY STEERING MOTOR RELAY COIL

(LO)

D15

C13

YGy (242) (146) LR

(LG)

A15 A16 A27 A12

BrB (258)

(LY)

C31

LOWER KICKOUT S/W

DECLUTCH S/W

D04

ARMREST S/W (OPT)

B11

LgW (101)

OPT

LO (123)

S/S SHIFT S/W F

D11

MACHINE CONTROL UNIT (MCU)

F N R

SHIFT LEVER

LBr (128)

E/G DROOP SELECTION 1 (SbP) (145)

(LgR) (130) (GR) (135) (GyB) (103) (LgY) (173) (Gy)

(749)

(GyG) (753) (GyL) (190) (LgW) (192) (O)

(241)

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)

WARNING BUZZER

(112)

Note Refer to Section 92 for the detailed electrical connection diagram for the MCU including modification information. K115V2E62001

115ZV-2 FS EU 62-39 62 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit

#-! ) () # - " )"# "# - (% ( (% (% - (% (% -

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)$ %#

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Note Refer to Section 92 for the detailed electrical connection diagram for the MCU including modification information.

115ZV-2 FS EU 62-40 62 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit

MCU connection diagram (S/N 9201~) 0

&+ 2 -1!

% & ' &

)

-32 5 -1! -32 ! -1!

! -32 "5 -32 3 -1!

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1 2 -- -1!

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- -

2 2 5 - &5 ! 2 5 - &5

, ,

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- -1! 5 - -1! ! 5 3 - 2 ! 6 77869: 7 ! 4 ;87:7, - 2

3 - 2

, ,

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)

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5 4 5 2 5 2 2 5 ! 2 5 - - 2 4 2

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--5 2 -2 2 -1!

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2 -1!

4 5 2 5

,! ,-+

! 2 "5//

2 - 54

Note Refer to Section 92 for the detailed electrical connection diagram for the MCU including modification information.

115ZV-2 FS EU 62-41 62 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit

'! 2'! 2

$2$ , ) #

% -

) * $ $ #

! + $ $ #

#* , # $$ $ $ # #* , # $$ $ $ #

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#$ *

Note Refer to Section 92 for the detailed electrical connection diagram for the MCU including modification information.

115ZV-2 FS EU 62-42 62 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

Modulation mechanism

Surge suppression diode (incorporated in solenoid valve)

R 1

A 23

Clutch valve

Clutch piston

1 Speed indicator lamp (instrument panel)

Downshift button

+24 V

MCU

Machine speed sensor

Solenoid valve for clutch

Torque converter pump

During energized: Clutch is engaged. During de-engaged: Clutch is disengaged.

2 Direct charge valve

Lockup clutch piston

Machine with lockup clutch: To solenoid valve for each clutch

ECM

Solenoid valve Modulation mechanism

Engine speed sensor

Solenoid valve for clutch

+24 V Clutch valve

AUTO indicator lamp

Clutch piston

ON when shift lever in A position Direct charge valve

Torque converter pump

During energized: Clutch is engaged. During de-engaged: Clutch is disengaged.

115V2E62013

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 by the shift-up/shift-down signal, the MCU judges the set speed 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.

115ZV-2 FS EU 62-43 62 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.

115ZV-2 FS EU 62-44 62 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit

Automatic shift

Operation of solenoid valve Clutch solenoid valve

Shift up

Shift down

10.8 N-m (1.1 kgf-m) (8 lb-ft) Speed F4

+ side

SKM6 G24D

K W E 6 K- 21/ N 12.0 10.0

– side

Reverse

View from A

10.0 11.0

17.0 19.0

Speed km/h

Forward

Automatic shift map (Normal mode)

115V2E62014

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 

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.

11.5 9.5

Reverse

9.5 10.5

Speed km/h

16.5 18.5

Forward

Automatic shift map (Fuel efficient mode)

115V2E62015

When the shift lever is set to A position, the AUTO indicator lamp in the cab will light and one of the solenoid valves will be automatically energized according to the machine speed. In addition, the speed indicator lamp will light. The input signal for automatic shift is controlled by the pulse generated by the speed sensor.

115ZV-2 FS EU 62-45 62 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

12.0 10.0

Reverse

10.0 11.0

13.5 15.5

20.5 21.5

26.5 28.5

Forward Speed km/h Automatic shift map (Normal mode) 115V2E62016

Shift up Shift down

Speed

F4L F4 F3L 3 2

11.5 9.5

Reverse

9.5 10.5

12.0 14.0

20.0 22.0

24.0 26.0

Forward Speed km/h Automatic shift map (Fuel efficient mode) 115V2E62017

115ZV-2 FS EU 62-46 62 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit

Machine speed sensor Machine speed sensor

115V2E62026

39 N-m (4.0 kgf-m) (29 lb-ft)

Clearance adjustment 0.45~1.6 mm (0.018~0.063 in) 115V2E62018

Internal resistance *

2.3±0.2 k (25ºC) (77ºF)

* Internal resistance changes greatly with temperature. At lower temperature the resistance is lower. At operating temperature the resistance increases. If resistance is 0  or   the speed sensor is defective.

The detector is adjacent to the transmission output gear. The pulse voltage is transmitted to the MCU. Note To prevent electronic "noise" from other sources that may corrupt signal, "twist" the wire from sensor all the way to the MCU.

IMPORTANT Make sure to apply the correct torque value when replacing the sensor. Shims help to set clearance between sensor & gear but over-torque can change clearance.

115ZV-2 FS EU 62-47 62 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit

Downshift button operation Downshift button

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.

115ZV-2 FS EU 62-48 62 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit

Modulation at clutch switching MCU

Shift lever

Output current control

R Clutch selection input signal

2 3

+ 24 V

Modulator valve

B05

T/M accumulator limit switch Machine speed sensor E/G speed sensor

ECM

115V2E62024

To T/C ACC2

ACC1

P2 PG

0.007 MPa (0.07 kgf/cm2) (0.1 psi)

0.39 ~ 2.65 MPa (4 ~ 27 kgf/cm2) (56.8 ~ 384 psi)

Drain (T/M side)

To T/C return line

30L/min 4.0

0.88 MPa (9 kgf/cm2) (128 psi)

To T/M lubrication line

To T/M solenoid valves

PG Drain (T/M side)

From pump 115V2E62025

The rise time of clutch oil pressure is controlled by modulator valve (proportional relief valve) (6) to shorten the time lag and reduce shock that occurs when shifting between forward and reverse, and between gears.

115ZV-2 FS EU 62-49 62 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit

Modulator valve operation

Modulation chart (Neutral1st forward) ON

Then, oil under pressure flows into the clutch piston chamber. After a given time, the control current to the modulator valve is reduced. Accordingly the main clutch oil pressure is reduced, concluding the initial oil charging into the clutch chamber.

Low range clutch OFF solenoid valve ON

1st speed clutch solenoid valve

Modulator valve

Oil filling completed Engagement (clutch) (Acc.) completed

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

Current (mA)

Clutch piston chamber filling (t2)

Main pressure

Pressure MPa (kgf/cm2) (psi)

Low range clutch Pressure pressure MPa (kgf/cm2) (psi)

P1 P2 0

0 t2 t1

When shifted

Accumulator filling (t3)

Shift completed

The pump continues to fill the oil into the accumulator. At the same time the clutch oil pressure is raised slowly. This prevents the clutch engagement shock caused by a rapid pressure rise.

115V2E32023

Pressure rise (t4)

charging t1 Initial time

Changes with combination of clutches

0~0.12 sec

pressure t2 Low holding time

Changes with engine speed

Less than 0.5 sec

rise t3 Pressure time

Changes with combination of clutches

0.3~0.7 sec

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

P1 0.5~1.5 MPa (6~15 kgf/cm2) (85~213 psi) P2 2.6~2.9 MPa (27~30 kgf/cm2) (384~427 psi) - E/G high idle

Since the accumulator is completely accumulated at the start point of t4, the limit switch is turned ON, sending the signal to the MCU. At that point, the clutch piston comes into contact with the clutch plate and the clutch plates start to transmit power. The MCU recognizes that the accumulator is at the full accumulation by this signal, and gradually increases the driving current to the modulator valve. Then, the hydraulic pressure for the clutch will consequently increases to complete the clutch engagement.

115ZV-2 FS EU 62-50 62 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

115V2U62019

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.

115ZV-2 FS EU 62-51 62 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.

115ZV-2 FS EU 62-52 62 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.

115ZV-2 FS EU 62-53 62 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit Solenoid valve for parking brake Spring chamber (brake actuator) B

Reducing valve

Solenoid

Knob

T Seat face A

Manual release (counterclockwise rotation)

Spool

Seat face B Tank

115V2E62020

Solenoid specifications Rated voltage

Hydraulic circuit diagram

95ZV52045

Valve assembly (Brake manifold block assembly) Front

Solenoid valve for auto brake

Solenoid valve for parking 115V2E62021

DC 24 V

Rated current

0.92 A

Resistance

26.2 

115ZV-2 FS EU 62-54 62 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit

Auto brake

Input side

1 23A

Solenoid valve for auto brake

+24V

Machine speed

Shift lever

Shift lever position selector signal

Output side

MCU

Machine speed sensor

B14

Auto brake monitor lamp, buzzer

+24V

A20 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 12 km/h (7.5 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.

From unloader valve (Pump)

When the auto brake signal enters from the MCU to solenoid valve (29) for auto brake and solenoid valve (29) is energized and magnetized, the pilot oil from unloader valve (22) enters the pilot port of left brake valve (23) through reducing valve (37) (setting pressure: 1.3 MPa (13 kgf/cm2) (185 psi)), and actuates the pilot piston and the spool of the brake valve.

MCU signal

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.

1.6 MPa 2 16.3 kgf/cm (232 psi)

From unloader valve

K115V2U52007

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.

115ZV-2 FS EU 62-55 62 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 12 km/h (7.5 mph) or more

When machine speed is excessive

Operation chart (Example: Shifting from forward to reverse)

Machine speed

Machine Machine speed speed 2 km/h 5 km/h Shifting between forward and reverse (3.12 mph) (1.25 mph)

Operation chart (Example: Machine speed excessive in forward direction)

F solenoid valve

Speed clutch solenoid valve

ON Brake solenoid valve OFF OFF Monitor lamp Buzzer Neutral indicator lamp Service brake operating

ON OFF T/M in neutral

R solenoid valve

115ZV62067

OFF

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 Brake solenoid valve OFF Monitor lamp Buzzer

ON OFF

Machine speed

F solenoid valve

T/M in neutral

OFF ON 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 12 km/h (7.5 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 5 km/h (3.12 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 km/h (mph) F

1st

Approximately 13 (8.125)

Approximately 12 (7.5)

2nd

Approximately 22 (13.75)

Approximately 24 (15.0)

3rd

Approximately 36 (22.5)

4th/A

Approximately 39 (24.375)

—

115ZV-2 FS EU 62-56 62 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit Auto brake solenoid valve

Seat face A

Pilot oil circuit

From unloader valve

Brake valve

B Seat face B

Tank

T Spool

Reducing valve (for autobrake)

Hydraulic circuit diagram

Solenoid valve (for autobrake)

115V2E52006

Valve assembly (Brake manifold block assembly)

Solenoid valve for auto brake

Solenoid valve for parking 115V2E62021

Solenoid specifications Rated voltage

DC 24 V

Rated current

0.92 A

Resistance

26.2 

115ZV-2 FS EU 62-57 62 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit

Machine control unit (MCU) failure warning Should the MCU stop working due to the following cause, a dash mounted monitor lamp lights up to give warning. MCU failure monitor lamp

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

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

If a warning is given as a result of self-diagnosis of the MCU

Chassis side coupler

When installing a new MCU on the machine, all specifications must be registered into the MCU through the MODM.

85V2E62030

Rating

DC 24 V

Operation voltage

16 V or less

Reset voltage

2.4 V or more

Coil resistance

320 

MCU fault relay (Normally closed)

115ZV-2 FS EU 62-58 62 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit

Secondary steering function (OPT)

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)

16 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)

16 cm3/rev

90.7 90.7 cm3/rev cm3/rev

Magnetic switch (on motor and pump) Steering pump Hydraulic line Electrical circuit

115V2E42025

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

115ZV-2 FS EU 62-59 62 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

115ZV-2 FS EU 62-60 62 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit

Monitoring system If a problem of a unit is detected while the engine is running, a monitor lamp lights to inform the operator. For some problems, the buzzer sounds also, and the central alarm lamp flashes also. When the starter switch is set to ON, all of the monitor lamps are lit for 3 seconds and buzzer sounds to check whether the monitor lamps are normal (not burn out).

Items to be monitored and operation condition Monitor lamp No.

Item to be monitored

Lighting color

Machine control unit (MCU)

Operation condition

Buzzer

Lamp test

Remarks

Symbol

Defective machine control unit (MCU)

—

(red) 2

Brake oil pressure (red)

Engine oil pressure (red)

Engine coolant temperature (red)

Torque converter oil (transmission) temperature

(red)

Clogged air cleaner (red)

Clogged transmission oil filter

(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 0.3 MPa (45±4 psi) or more

—

Defective charge system

—

For items 1~7, 10

—

(red) 9

Central alarm (red)

Steering oil pressure (red)

Engine cooling water level

When operates steering pressure is less than 0.4 MPa (4 kgf/cm2) (57 psi), machine speed is more than 2 km/h. When engine cooling water level drops (before start up only)

—

Flashing type

115ZV-2 FS EU 62-61 62 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit

Monitor lamp No.

Item to be monitored

Auto brake operation

Lighting color

Operation condition

Buzzer

Lamp test

(red) (S/N ~9200)

F/R: No buzzer sounds

When auto-brake works

(red) (S/N 9201~)

(red) 13

Hydraulic oil level

Hydraulic oil level is low when the engine is stopped

(red) 14

Engine protection lamp

— (orange)

Engine warning lamp (yellow)

Engine stop lamp

Any fault in engine detected by ECM (Engine controller)

—

— (red)

Remarks

Symbol

(2 sec.)

115ZV-2 FS EU 62-62 62 Function & Structure Electrical Group Transmission Control Circuit and Monitor Circuit

Operation monitor lamps Monitor lamp No.

Monitor item

Lighting color

Lighting condition

Remarks

Symbol

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

K-Lever indicator

Green

When K-Lever system is ON.

Turn signal indicator (left)

Green

When turn signal lever (left) is actuated

Turn signal indicator (right)

Green

When turn signal lever (right) is actuated

High beam

Blue

When head lamp is set to high beam

Auto shift

Green

When transmission shift lever is set to automatic position

Neutral

Green

When transmission shift lever is set to neutral position

Transmission status

Yellow

When transmission shift lever is set to corresponding gear (1~4)

Reversal fan

Green

When the reversal fan switch is ON.

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

115ZV-2 FS EU 62-63 62 Function & Structure Electrical Group Instrument Panel and Switch

Instrument Panel and Switch Instrument panel (S/N 9001~9200)

6 17

19 5 18

11(37) 12

27 13

34 14 35

15 36 16 STOP

38 39

25 (37)

22 8

115V2E62022

1. Tachometer 2. Engine coolant temperature gauge 3. Transmission oil temperature gauge 4. Fuel gauge 5. Parking brake indicator lamp 6. Auto brake indicator lamp 7. Declutch selector lamp 8. Working light indicator lamp (rear) 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. F/R switch indicator lamp (option) 30. Four-way flasher switch (option) 31. Engine protection lamp 32. Engine warning lamp 33. Engine stop lamp 34. Efficient loading system switch 35. Cold start (ether injection) switch 36. Selection switch for shift lever or F/R switch (option) 37. Hydraulic oil level warning lamp 38. Transmission oil filter warning lamp 39. Coolant level warning lamp

115ZV-2 FS EU 62-64 62 Function & Structure Electrical Group Instrument Panel and Switch (S/N 9201~)

% '

' # $

& &

!" !#

# !%

! ! " # $

!' !& !! ! ! #8 -$ !$

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. F/R switch indicator lamp (option) 30. Four-way flasher switch (option) 31. Engine protection lamp 32. Engine warning lamp 33. Engine stop lamp 34. Efficient loading system switch 35. Cold start (ether injection) switch (S/N ~9202) 36. Selection switch for shift lever or F/R switch (option) 37. Hydraulic oil level warning lamp 38. Transmission oil filter warning lamp 39. Coolant level warning lamp

115ZV-2 FS EU 62-65 62 Function & Structure Electrical Group Instrument Panel and Switch

Instrument panel rear surface (S/N 9001~9200) 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) A8

A9 46 47 48

53 54 55 56

57 115V2E62027

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

—

+24 V power supply

—

Central alarm lamp

L14

Secondary steering

L22

—

GND (–)

—

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

—

115ZV-2 FS EU 62-66 62 Function & Structure Electrical Group Instrument Panel and Switch (S/N 9201~)

CN2

E S

CN1(24P)

CN2(36P)

12 11 10 9 8 7 6 5 4 3 2 1 24 23 22 21 20 19 18 17 16 15 14 13

18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19

CN1-Signal Secondary steering (option)

—

Lamp No.

Pin No.

CN2-Signal

Reversal fan (option)

—

Pin No.

E S

CN1 12

—

— F/R switch (option)

Lamp No.

Pin No.

CN2-Signal

Fuel level lamp (3/4)

—

80Z562010

— T/C (T/M) oil temperature gauge

—

Lamp No. 4 — 3 —

—

Coolant level warning lamp

4th speed indication

Declutch lamp

Charge lamp

3rd speed indication

Auto brake lamp

Air cleaner clogging alarm

2nd speed indication

Central alarm lamp

T/C (T/M) oil temperature alarm

1st speed indication

Neutral indication

Engine water temperature alarm

GND (–)

—

Turn signal (left) lamp

Engine oil pressure alarm

Backup battery

—

AUTO lamp

+24 V power supply

—

Tachometer

Instrument panel illumination

—

Parking brake lamp

—

High-beam lamp

—

Work lamp

Turn signal (right) lamp

—

19 20

—

Hour meter

Fuel level lamp (E)

Fuel level lamp (1/2)

Fuel level lamp (1/4)

Engine water temperature gauge

— Controller failure alarm

— Brake alarm

— 11

— —

E/G stop lamp

E/G warning lamp

—

E/G protection lamp

—

115ZV-2 FS EU 62-67 62 Function & Structure Electrical Group Instrument Panel and Switch

Gauge circuit

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. Controller

Grounding

Power supply 24V

S E

Note If a gauge is removed from the panel, the resistance between the terminals will differ from the standard value shown in the table.

15V (S/N ~9200) 13V (S/N 9201~)

Viewed from rear surface of instrument panel K90ZV62016

(S/N ~9200) Gauge

Engine water temperature 97ºC(206ºF)

T/C, T/M oil temperature 110ºC(230ºF)

100ºC(212ºF)

35ºC(95ºF)

103ºC(217ºF)

100ºC(212ºF)

120ºC(248ºF)

50ºC(122ºF)

125ºC(257ºF)

Indication

White

Red

White

Resistance between S and E ()

120~125

75~80

Resistance between S and V ()

120~125

85~90

Resistance between E and V ()

170~190

130~150

Engine water temperature

T/C, T/M oil temperature

(S/N 9201~) Gauge

67C° (152.6°F) 50C° (122°F)

125C° (257°F)

56C° 102C° (132.8°F) (215.6°F)

Indication

White Red

White

Red

Resistance between S and E ()

80~95

Resistance between S and V ()

26~30

Resistance between E and V ()

106~126

115ZV-2 FS EU 62-68 62 Function & Structure Electrical Group Instrument Panel and Switch Temperature sensor (For engine water temperature (S/N 9001~9050), torque converter oil temperature and hydraulic oil temperature)

115V2E62023

Temperature of detection part (ºC)

80 [176ºF]

90 [194ºF]

100 [212ºF]

120 [248ºF]

Resistance (k)

6.2~6.9

4.7~5.2

3.6~3.9

2.1~2.4

115ZV-2 FS EU 62-69 62 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 lamps +24V

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)

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

◎ –

1L 3L 4L

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

–

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. 2L

Float switch

Indicator lamp ◎ : Flashing ● : Lit – : Extinguished

Float switch ○ : ON × : OFF

C29

Actual fuel level

YR (405)

FUEL LEVEL F

115ZV-2 FS EU 62-70 62 Function & Structure Electrical Group MODM

MODM Monitor Changeover

(Machine Operation Diagnostic Module)

[ ]button

Display window

[

]button

[ (step back)] [ (step forward)] button button

Replacement monitor

Fault log monitor

Information monitor

Input/Output monitor

Specification setting monitor

Parameter setting monitor

90ZV-262001

MODM function The MODM has the following functions:

Change over the monitor using the following procedure: When the starter switch is ON, the MODM software version displays for 3 seconds.

- Information monitor Displays outside air temperature, machine speed and engine speed, engine coolant temperature, transmission oil temperature, hydraulic oil temperature and miles driven etc.

80V2U62001

After this, machine information screen displays information relative to the machine function.

- Replacement monitor Allows check of the replacement time for the parts and oil periodically replaced, allows setting of the replacement interval, and displays the replacement pop-ups. - Fault log monitor Allows check of previous errors, and displays active errors. - Input/Output monitor - Parameter setting monitor Allows check and change of the parameter setting. - Specification setting monitor Allows check and change of the specification setting.

80V2U62002

115ZV-2 FS EU 62-71 62 Function & Structure Electrical Group MODM

Changing display from one function to next Press both the [ (step back)] button and [ (step forward)] button at the same time to change over the monitor mode in sequence "Information monitor  Replacement monitor  Fault log monitor  Input/Output monitor  Parameter setting monitor  Specification setting monitor Information monitor".

From Information monitor to Replacement monitor: Press both the [ (step back)] and [ ward)] buttons at the same time. Display should now appear as shown below.

However the monitor mode can not be changed in reverse such as "Information monitor  Specification setting monitor  Parameter setting monitor ....." The display will not be changed to the next monitor when you hold the buttons. For the display sequence, refer to "Outline of MODM (Machine Operation Diagnostic Module) Operation" page 92-48.

(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.

115ZV-2 FS EU 62-72 62 Function & Structure Electrical Group MODM

From Fault log monitor to Input/Output monitor:

From Specification setting monitor to Information monitor:

Press both the [ (step back)] and [ ward)] buttons at the same time.

(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.

115ZV-2 FS EU 62-73 62 Function & Structure Electrical Group MODM

Information Monitor

1. Outside air temperature

(Refer to page 92-50)

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 92-48 and 92-50.

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".

115ZV-2 FS EU 62-74 62 Function & Structure Electrical Group MODM

3. Current engine coolant temperature and maximum engine coolant temperature recorded (which can be reset)

4. Current transmission oil temperature and maximum transmission oil temperature recorded (which can be reset)

Press the [

(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".

115ZV-2 FS EU 62-75 62 Function & Structure Electrical Group MODM

5. Current hydraulic oil temperature and maximum hydraulic oil temperature recorded (which can be reset)

6. Odometer (total miles driven) and trip meter (which can be reset) Press the [

Press the [

(step forward)] button and release.

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.

115ZV-2 FS EU 62-76 62 Function & Structure Electrical Group MODM

8. Hydraulic system oil pressure

Unit conversion and language selection

Press the [

Select the unit and language using the [ ] button.

(step forward)] button and release.

Unit conversion (for traveling distance, temperature and pressure) 80V2U62008

Press the [ ] button once to change the display unit. Press the [ ] button again to return to the previous display unit.

You will now be at the screen shown above. The monitor displays the unloader pressure of the efficient loading system (ELS). Press the [ ] button to change over the display unit from "MPa" to "psi". Press the [ ] button again to return the display unit from "psi" to "MPa".

Language selection Press and hold the [ ] button for 3 seconds or longer to get language selection screen.

9. Voltage Press the [

80V2U62009

(step forward)] button and release. You will now be at the screen shown above. English is selected as the initial setting. 90ZV-262032

You will now be at the screen shown above.

Japanese, French, German, Italian, Spanish, Turkish, Dutch and English can also be selected.

Shows complete electrical system voltage as is seen at the battery level.

Press the [ (step forward)] button or [ back)] button to view the language selections.

Note If voltage drops below 27 V DC, the hibernate mode (lowers RPM’s to conserve fuel) will not work.

For returning to the information monitor after selecting the desired language, press and hold the [ ] button for 2 seconds or longer.

10. Hour meter (total operating hours) and trip meter (which can be reset) Press the [

(step forward)] button and release.

90ZV-262033

You will now be at the screen shown above. The monitor displays total operating hours in upper line, and trip meter hours in lower line. Press the [ ] button to reset the trip meter displayed in the lower line.

(step

For returning to the information monitor without selecting another language, press the [ ] button. Refer to "Main Menu" page 92-49.

115ZV-2 FS EU 62-77 62 Function & Structure Electrical Group MODM

Replacement Monitor

2. Fuel filter

(Refer to page 92-51)

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.

115ZV-2 FS EU 62-78 62 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.

115ZV-2 FS EU 62-79 62 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.

115ZV-2 FS EU 62-80 62 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.

115ZV-2 FS EU 62-81 62 Function & Structure Electrical Group MODM

9. Hydraulic oil

Replacement interval set (timer reset)

Press the [

When the machine is shipped, the standard replacement interval is set as the initial setting.

(step forward)] button and release.

80V2U62017

You will now be at the screen shown above. The display window displays remaining time until next replacement of hydraulic oil. Note If an exclamation mark shows before the numbers that indicate hours, this shows how many hours overdue the oil change is. Ex. "!12 h" indicates that it is 12 hours overdue.

70V2U62025

Note Make sure to set the replacement interval (timer reset) whenever hydraulic oil is replaced. It may be necessary to change this oil more frequently, depending on work site conditions, oil sampling results and oil cleanness.

Press and hold the [ ] button for 2 seconds or more on the replacement monitor screen to display the timer reset screen. The timer reset screen displays the standard replacement interval. For setting the standard replacement interval, press the [ ] button. Then, the standard replacement interval is set, and it returns to the replacement monitor screen again.

115ZV-2 FS EU 62-82 62 Function & Structure Electrical Group MODM

Replacement interval pop-up

Example: Engine oil

90ZV-262037

When the remaining time until the next replacement interval reaches " 0 " (or 0 hours), the replacement popup appears and flashes in the display window.

For setting the replacement interval other than the standard replacement interval, follow the procedure below: 90ZV-262038

 50  100 (2 seconds or more)  50  100 (2 seconds or more) Press the [ (step forward)] button once to add "50" hours. Press the [ (step forward)] button twice to add "100" hours. Press the [ (step forward)] button three times to add "150" hours. "50" hours is added every time the [ (step forward)] button is pressed. Every time the [ (step back)] button is pressed, "50" hours is subtracted. When the [ (step forward)] button is pressed and held for 2 seconds or more, "100" hours is added continuously. It means that "100", "200", "300" hours ..... is added in 100 hour increments. 90ZV-262039

When the [ (step back)] button is pressed and held for 2 seconds or more, "100" hours is subtracted continuously in the same manner. After setting the replacement interval, press and hold the [ ] button for 2 seconds or more. The replacement interval is reset, and the display returns to the replacement monitor screen again.

When two or more replacement pop-ups occur at the same time, the corresponding items flash in turn. After the remaining time for the next replacement reaches " 0 ", the corresponding pop-up appears up to three times when the starter switch is ON. (The MODM software version is displayed for 3 seconds, and then the replacement pop-up flashes.) When the [ (step forward)] button, [ (step back)] button, [ ] button or [ ] button is pressed, it returns to the previous screen again. After replacing the corresponding filter or oil, return to the timer reset screen and set the replacement interval. Refer to the replacement interval set (timer reset) procedure above.

115ZV-2 FS EU 62-83 62 Function & Structure Electrical Group MODM

Display language The same language selected in the information monitor is used as the display language for the replacement monitor. For selecting the display language, it is necessary to return to the information monitor. The display language can be selected only on the information monitor screen.

Fault Log Monitor (Refer to page 92-52) 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 92-48.

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.

115ZV-2 FS EU 62-84 62 Function & Structure Electrical Group MODM

2. Inactive faults (Checking history )

Selection of machine fault log and engine fault log

Again, up to 100 machine faults and 100 engine faults can be recorded in the fault log (200 faults total). Failure codes that begin with CN are machine faults.

You can toggle between viewing the engine faults or machine faults.

Failure codes that begin with EN are engine faults.

Machine fault

What is shown The following list of items are shown. Order of occurrences, fault code number, date, hour-minute-second, and frequency of occurrence. Examples shown below.

When the machine fault log screen is displayed, press and hold the [ (step forward)] button for 2 seconds or more to display the engine fault log screen which shows the latest engine fault code.

This shows fault CN321. This is caused by an engine coolant temperature fault (open circuit). Note descriptions.

Order of occurrences 100 total 01~00 Fault code number

A=Active fault 002 is q’ty 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

115ZV-2 FS EU 62-85 62 Function & Structure Electrical Group MODM

Machine fault log navigation When two or more fault codes are recorded, press the [ (step forward)] button to display the next latest fault code. Press the [ (step back)] button to display the fault code in chronological order.

Engine fault log navigation When two or more fault codes are recorded, press the [ (step forward)] button to display the next latest fault code. Press the [ (step back)] button to display the fault code in chronological order.

Clear fault log Clear inactive fault log Fault codes can be cleared by pressing the [ ] button and holding it for more than 2 seconds while in the engine fault mode, or in the machine fault mode screens. Note When pressing the [ ] button to clear a fault code, password entry is required on the 115ZV-2 S/N 9103 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.

115ZV-2 FS EU 62-86 62 Function & Structure Electrical Group MODM

Clear active fault log (error pop up) (S/N 9001~9006) 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.

115ZV-2 FS EU 62-87 62 Function & Structure Electrical Group MODM

Failure code (Input side) Code

Failure

Detection condition (In case of)

CN121

Shift lever F & R switch malfunction

Shift lever F & R contact ON at the same time Failure continues for more than 3 seconds

CN122

Shift lever 1•2•3•A switch malfunction (1)

Shift lever any of more than two 1•2•3•A contact ON at the same time Failure continues for more than 3 seconds (30 seconds from program ver. 100915)

CN123

Shift lever 1•2•3•A switch malfunction (2)

All 1•2•3•A signal OFF continues for more than 3 seconds (30 seconds from program ver. 100915)

CN141

Shift-up switch malfunction

Switch is ON for more than 10 seconds

CN142

Shift-down switch malfunction

Switch is ON for more than 10 seconds

CN143

Shift-up switch & shift-down switch malfunction

Shift-up switch & shift-down switch contact ON at the same time Failure continues for more than 3 seconds

CN145

Kick-down switch malfunction

Switch is ON for more than 10 seconds

CN146

Shift hold switch malfunction

Switch is ON for more than 10 seconds

CN151

T/M oil pressure switch malfunction (This applies to the model 115ZV-2/135ZV-2 only)

Signal OFF continues for more than 10 seconds during engine running

CN152

T/M oil pressure sensor malfunction (This applies to the model 95ZV-2 only)

T/M pressure below 294 kPa (3.0 kgf/cm2) (43 psi) continues for more than 10 seconds during engine running

CN161

Machine speed sensor malfunction (1)

Input circuit is disconnected for more than 3 seconds

CN162

Machine speed sensor malfunction (2)

Input value is over 70 km/h (44 mile/h) for more than 3 seconds

CN163

E/G speed sensor 1 (ECM output) malfunction (1)

No E/G speed sensor input for more than 3 seconds when E/G speed sensor selection is OFF (Input circuit is disconnected)

CN164

E/G speed sensor 1 (ECM output) malfunction (2)

Input value is more than 3,000 min-1 for more than 3 seconds when E/G speed sensor selection is OFF

CN165

E/G speed sensor 2 (Sensor output) malfunction (1)

No E/G speed sensor input for more than 3 seconds when E/G speed sensor selection is ON (Input circuit is disconnected)

CN167

E/G speed sensor 2 (Sensor output) malfunction (2)

Input value is more than 3,000 min-1 for more than 3 seconds when E/G speed sensor selection is ON

CN213

Inching sensor malfunction (1)

Voltage is lower than 0.2 V for more than 3 seconds

CN214

Inching sensor malfunction (2)

Voltage is larger than 4.6 V for more than 3 seconds

CN232

S/S potentiometer malfunction (1)

Voltage is lower than 0.1 V for more than 3 seconds

CN234

S/S potentiometer malfunction (2)

Voltage is larger than 4.9 V for more than 3 seconds

CN236

S/S shift switch (F & R contact) malfunction

Failure continues for more than 3 seconds

CN251

Secondary steering oil pressure sensor malfunction (1)

Voltage is lower than 0.2 V for more than 3 seconds

CN252

Secondary steering oil pressure sensor malfunction (2)

Voltage is larger than 4.6 V for more than 3 seconds

CN254

Low secondary steering oil pressure

Oil pressure sensor detects secondary steering oil pressure below 306 kPa (3.1 kgf/cm2) (44 psi) for more than 3 seconds during engine running

CN262

Kickout potentiometer malfunction (1)

Voltage is lower than 0.2 V for more than 3 seconds

CN263

Kickout potentiometer malfunction (2)

Voltage is larger than 4.6 V for more than 3 seconds

CN271

Efficient loading system hydraulic oil pressure senVoltage is lower than 0.2 V for more than 3 seconds sor malfunction (1)

CN272

Efficient loading system hydraulic oil pressure senVoltage is larger than 4.6 V for more than 3 seconds sor malfunction (2)

CN312

Brake oil pressure sensor 1 malfunction (1)

Voltage is lower than 0.2 V for more than 3 seconds

CN313

Brake oil pressure sensor 1 malfunction (2)

Voltage is larger than 4.6 V for more than 3 seconds

CN315

Brake oil pressure sensor 2 malfunction (1)

Voltage is lower than 0.2 V for more than 3 seconds

CN316

Brake oil pressure sensor 2 malfunction (2)

Voltage is larger than 4.6 V for more than 3 seconds

CN321

E/G coolant temperature sensor malfunction (1)

Input voltage is larger than 3.56 V for more than 3 seconds

CN323

E/G coolant temperature sensor malfunction (2)

Input voltage is lower than 0.263 V for more than 3 seconds

CN341

T/M oil temperature sensor malfunction (1)

Input voltage is larger than 3.56 V for more than 3 seconds

CN342

T/M oil temperature sensor malfunction (2)

Input voltage is lower than 0.263 V for more than 3 seconds

115ZV-2 FS EU 62-88 62 Function & Structure Electrical Group MODM

Code

Failure

Detection condition (In case of)

CN351

Hydraulic oil temperature sensor malfunction (1)

Input voltage is larger than 3.56 V for more than 3 seconds

CN352

Hydraulic oil temperature sensor malfunction (2)

Input voltage is lower than 0.263 V for more than 3 seconds

CN381

Fuel level sensor malfunction

Input signal corresponds to "any other pattern" in fuel level indication table

CN391

Air temperature probe malfunction (1)

Input voltage is larger than 4.35 V for more than 3 seconds

CN392

Air temperature probe malfunction (2)

Input voltage is lower than 0.13 V for more than 3 seconds

CN412

Abnormal brake oil pressure (1)

Brake oil pressure sensor 1 detects pressure below 4,081 kPa (41.6 kgf/ cm2) (592 psi) for more than 1 second during engine running

CN413

Abnormal brake oil pressure (2)

Brake oil pressure sensor 2 detects pressure below 4,081 kPa for (41.6 kgf/cm2) (592 psi) more than 1 second during engine running

CN414

Abnormal brake oil pressure difference

Brake oil pressure difference switch is in abnormal condition for more than 1 second

CN415

Abnormal brake oil amount

Brake oil amount switch is in abnormal condition for more than 1 second

CN421

Abnormal engine oil pressure

Engine oil pressure switch is OFF for more than 2 seconds during engine running

CN431

Abnormal engine coolant temperature (1)

Engine coolant temperature switch is ON for more than 2 seconds

CN432

Abnormal engine coolant temperature (2)

Engine coolant temperature sensor is in 101 deg. C (214 deg. F) condition for more than 2 seconds

CN451

Abnormal T/M oil temperature (1)

T/M oil temperature switch is ON for more than 2 seconds

CN452

Abnormal T/M oil temperature (2)

T/M oil temperature sensor is in 122 deg. C (252 deg. F) condition for more than 2 seconds

CN461

Abnormal hydraulic oil temperature

Hydraulic oil temperature sensor is in 100 deg. C (212 deg. F) condition for more than 2 seconds

CN471

Clogged T/M oil filter

30 minutes after starter switch is ON, T/M oil filter switch is ON for more than 2 seconds when T/M oil temperature sensor detects oil temperature more than 60 deg. C (140 deg. F)

CN481

Clogged air cleaner element

Air cleaner switch is ON for more than 2 seconds

CN491

Abnormal cooling water level in radiator

Radiator cooling water level switch is OFF for more than 2 seconds when the engine is off.

CN496

Abnormal hydraulic oil level

Hydraulic oil level switch is in abnormal condition for more than 30 seconds

CN497

Abnormal brake disc oil temperature (This applies to the model 135ZV-2 only)

Brake disc oil temperature switch is ON for more than 1 second

CN498

Abnormal disc wear (This applies to the model 135ZV-2 only)

Brake disc wear switch is ON for more than 1 second

CN801

CAN disconnect

CAN line is disconnected

CN802

Abnormal engine coolant temperature (CAN)

No engine coolant temperature data received for more than 3 seconds

CN912

Abnormal MCU voltage (1)

Voltage is larger than 32±1 V

CN913

Abnormal MCU voltage (2)

Voltage is lower than 22±0.5 V for more than 10 seconds during engine running

(CN_In 14F05)

Fuel level display table Input

Output

1/8

1/4

1/2

3/4

1/4

1/2

3/4

—

x Other than above : No input signal given x : Input signal given

—

: Lamp on — : Lamp off

—

: Lamp flashing

—

Note This table applies to the 95/115/135ZV-2 units.

115ZV-2 FS EU 62-89 62 Function & Structure Electrical Group MODM

Failure code (Output side) Code

Failure

Detection condition

CN512

F solenoid valve malfunction

F solenoid valve is short-circuited or disconnected

CN514

R solenoid valve malfunction

R solenoid valve is short-circuited or disconnected

CN516

1st solenoid valve malfunction

1st solenoid valve is short-circuited or disconnected

CN518

2nd solenoid valve malfunction

2nd solenoid valve is short-circuited or disconnected

CN521

3rd solenoid valve malfunction

3rd solenoid valve is short-circuited or disconnected

CN524

4th solenoid valve malfunction

4th solenoid valve is short-circuited or disconnected

CN526

D solenoid valve malfunction

D solenoid valve is short-circuited or disconnected

CN528

H solenoid valve malfunction

H solenoid valve is short-circuited or disconnected

CN531

LU solenoid valve malfunction

LU solenoid valve is short-circuited or disconnected

CN534

Auto brake solenoid valve malfunction

Auto brake solenoid valve is short-circuited or disconnected

CN536

Speed change control solenoid valve malfunction (1)

Speed change control solenoid valve is short-circuited

CN537

Speed change control solenoid valve malfunction (2)

Speed change control solenoid valve is disconnected

CN621

S/S solenoid valve R malfunction (1)

S/S solenoid valve R is short-circuited

CN622

S/S solenoid valve R malfunction (2)

S/S solenoid valve R is disconnected

CN623

S/S solenoid valve L malfunction (1)

S/S solenoid valve L is short-circuited

CN624

S/S solenoid valve L malfunction (2)

S/S solenoid valve L is disconnected

CN631

Pressure increase solenoid valve malfunction

Pressure increase solenoid valve is short-circuited or disconnected

CN641

Ride control solenoid valve malfunction

Ride control solenoid valve is short-circuited or disconnected

CN681

Efficient loading system selection solenoid valve malfunction

Efficient loading system selection solenoid valve is short-circuited or disconnected

CN712

Cooling fan solenoid valve malfunction (1)

Cooling fan solenoid valve is short-circuited

CN713

Cooling fan solenoid valve malfunction (2)

Cooling fan solenoid valve is disconnected

CN721

Hour meter drive malfunction

Hour meter drive is short-circuited

(CN_Out 10F24)

Failure code (Engine) Refer to "Quantum fault code information" page 62-27.

115ZV-2 FS EU 62-90 62 Function & Structure Electrical Group MODM

Input/Output Monitor

By pressing the [ (step forward)] button, you will arrive at a window as shown below.

(Refer to page 92-53)

Input/Output monitor display 80V2U62026

1. Input signal monitor From a position of turning on the key switch, press both the [ (step back)] and [ (step forward)] buttons simultaneously 3 times, you will arrive at the screen shown below.

80V2U62025

This is because in window 2, it shows the parking brake as being released and the corresponding slot would have a 1 in that place. In other words, the parking brake coil has been energized and the slot has a 1 in it indicating that it is energized and the parking brake is released. Now press the [ (step forward)] button once. You will arrive at the screen shown below.

This is the beginning of the section for input and output signal display. 80V2U62027

Input signal monitor (D1~D7) This monitor displays the ON/OFF status of the shift lever, setting switches, pressure switches, etc. There are seven input groups from INPUT 1 to INPUT 7.

Nothing in this case is activated, so all of the slots are occupied with the number 0. Now press the [ (step forward)] button once. You will arrive at the screen shown below.

Each group has eight items from item 0 to 7. When input signal is ON, "1" is displayed under corresponding item number.

80V2U62028

When input signal is OFF, "0" is displayed under corresponding item number.

The screen indicates that ride control and ELS are activated, or the switch for each one is energized.

Refer to "MODM: Input/Output Monitor - Input/Output Signal Correspondence Table" page 92-57.

Now press the [ (step forward)] button once. You will arrive at the screen shown below.

As shown in table of section "MODM: Input/Output Monitor - Input/Output Signal Correspondence Table" that follows, the selection below reflects that forward and automatic have been selected by the shift lever.

80V2U62029

This indicates that the engine is running as the place for alternate neutral voltage under slot 3 is occupied by a 1. 80V2U62025

115ZV-2 FS EU 62-91 62 Function & Structure Electrical Group MODM Now press the [ (step forward)] button once. You will arrive at the screen shown below.

2. Current output monitor Every time the [ (step forward)] button is pressed and held for 2 seconds, the displayed contents are changed. First item seen is as shown below.

80V2U62030

This indicates that there are no inputs happening in this situation.

Note The [ (step back)] or [ (step forward)] button must be held for 2 seconds or more with each change. If not, it will not move to next item.

Now press the [ (step forward)] button once. You will arrive at the screen shown below.

If the feature is set to "Invalid" in specification setting, the following items will be skipped. - STEERING PRESS - SP7 (Secondary steering)

80V2U62031

- BOOM ANGLE - SP15 (Lift kickout)

This indicates that there are inputs for a full fuel tank, the machine is equipped with an optional reversing fan, and the switch for the fan is in the "ON" or energized position. Now press the [ (step forward)] button once. You will arrive back the screen shown below.

90ZV-262019

This area is called the "Current Output Monitor". As seen, it first shows actual front brake circuit pressure. Next, by pressing the [ (step forward)] button, the following screen is seen if equipped with secondary steering.

80V2U62025

You have completely reviewed all of the input signals. 80V2U62032

Again, in review, note the following: - This monitor displays the ON/OFF status of the shift lever, setting switches, pressure switches, etc.

Next, by pressing the [ following screen is seen.

(step forward)] button, the

- There are seven input groups from INPUT 1 to INPUT 7. 80V2U62033

- Each group has eight items from item 0 to the item 7. - When input signal is ON, "1" is displayed under corresponding item number.

Next, by pressing the [ following screen is seen.

(step forward)] button, the

- When input signal is OFF, "0" is displayed under corresponding item number. 80V2U62034

For more clarification, refer to "MODM: Input/Output Monitor - Input/Output Signal Correspondence Table".

115ZV-2 FS EU 62-92 62 Function & Structure Electrical Group MODM Next, by pressing the [ following screen is seen.

(step forward)] button, the

80V2U62035

Note Brake main pressure 1 is accumulator oil pressure for rear accumulator which serves only the rear brake circuit. Brake main pressure 2 is accumulator oil pressure for front accumulator which serves the front brake circuit and all pilot derived pressures; these are pilot oil pressure for the pilot control valves, auto brake, park brake release, etc. The actual real-time pressures are shown in these fields. Next, by pressing the [ following screen is seen.

(step forward)] button, the

3. Output signal monitor (D1~D6) This monitor displays the ON/OFF status of the transmission forward/backward solenoid valves, speed range solenoid valves, indicator lamps and warning lamps on the instrument panel, etc. There are six output groups from OUTPUT 1 to OUTPUT 6. Each group has eight items from item 0 to 7. When output signal is ON, "1" is displayed under corresponding item number. When output signal is OFF, "0" is displayed under corresponding item number. Refer to "MODM: Input/Output Monitor - Input/Output Signal Correspondence Table" page 92-57. 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.

115ZV-2 FS EU 62-93 62 Function & Structure Electrical Group MODM Next press the [ following screen.

(step forward)] button to show the

4. Electric current output monitor This indicates the milliamps (mA) of electric current that are being sent to the fan solenoid valve from the MCU.

80V2U62038

Press the [ (step forward)] button for 2 seconds or longer to show the following screen.

All values are at 0 as there are no outputs needed in this scenario. Next press the [ following screen.

(step forward)] button to show the

80V2U62039

Note that the place under slot 5 is occupied by a 1, as MCU failure relay should be energized by MCU if MCU passes software logic test at MCU boot-up that occurs with the key in the "ON" position. Next press the [ following screen.

(step forward)] button to show the

80V2U62040

Note that the place under slot 1 is occupied by a 1, as the unit is in automatic shift mode and the dash lamp should be illuminated to indicate this. Also the place under slot 7 is occupied by a 1, as the unit is full of fuel. Next press the [ following screen.

(step forward)] button to show the

80V2U62041

Note that this shows no input signal at this time.

80V2U62042

This current output will vary as demands for fan revolutions change, according to amount of heat that is being generated. This heat must be discharged to cool the system that is heating back down. When the machine systems are cold and the machine is in warm up mode, the mA level will be higher than when the machine has worked for a time and has become heat saturated. Note Disconnecting the fan solenoid wire will increase the fan’s revolutions to full speed, and will set a CN713 fault code. This will reside in the system fault code memory until it is cleared. If you disconnect the solenoid coil, you must remember to clear this fault code when finished with work. Refer to fault code table for the chassis side for more detail.

115ZV-2 FS EU 62-94 62 Function & Structure Electrical Group MODM

Parameter Setting Monitor

1. Shift inhibitor

(Refer to page 92-54)

From turning on key switch which would default to screen shown below.

Parameter setting monitor display This monitor allows check of parameters that are currently set.

80V2U62002

Value levels to set parameter for items like ride control, tire ratios, date/time clock (used to log faults), declutch pressures, secondary steering, detent values sensor, etc. Note If the feature is set to "Invalid" in specification setting view, the following items will be skipped in the parameter setting monitor view. - RIDE CONTROL - SP5 (Ride control) - SECONDARY STEERING - SP7 (Secondary steering) - K-LEVER - SP8 (K-Lever) - TRACTION CONTROL - SP11 (Traction control) - 2 STAGE - SP13 (Efficient loading system)

Pressing both the [ (step forward)] and [ (step back)] buttons simultaneously, 4 times once after another, arrive at the screen shown below.

80V2U62005

The transmission changes the speed range automatically according to the machine speed. If the machine speed sensor is disconnected when the machine is running high, the machine speed is suddenly reduced because of that the transmission is automatically shifted to the low range. As a result, the operator becomes very unstable condition by rapid deceleration. This device prevents the above. By pressing the [ (step forward)] button, you will arrive at a window as shown below.

- BOOM SOFT LAND - SP14 (Lower kickout) - KICK OUT - SP15 (Lift kickout) 80V2U62043

115ZV-2 FS EU 62-95 62 Function & Structure Electrical Group MODM

2. Ride control

Press the [ (step forward)] button to add "1" to a numerical value.

Now press the [ (step forward)] button once. You will arrive at the screen shown below.

80V2U62044

Note Value for "ON" must be 1 km/hr or more greater than "OFF". The numerical value will increase as you press the [ (step forward)] button as follows;

The screen should appear similar to what is shown. This shows the speed at which ride control turns on and permits the base end oil to work against the accumulator piston.

0  1  2 ..... 9  0  1  2 .....

Now press the [ (step forward)] button once. You will arrive at the screen shown below.

The number then decreases as follows;

80V2U62045

The screen should appear similar to what is shown. This shows the speed at which ride control turns off and does not permit the base end oil to work against the accumulator piston. Changing ride control on/off speed values: These values can be changed for machines that are equipped with this option by doing the following. Press and hold the [ ] button for 2 seconds or more on the parameter setting screen to display the parameter change screen. The cursor flashes in a 1-second cycle (flashes on for 0.5 second and flashes off for 0.5 second). Press the [ ] button to move the cursor. The cursor moves to the right. When the cursor reaches the right end in the upper line, pressing [ ] button will move it to the left end in the lower line. When the cursor reaches the right end in the line, pressing [ ] button moves it to the left end in the line. The cursor skips digits which can not be changed. Cursor movement: Moving to the right  Right end in the upper line  Left end in the lower line  Right end in the lower line  Left end in the upper line.

Press the [ (step back)] button to subtract "1" from a numerical value.

9  8  7 ..... 0  9  8  7 ..... After changing parameter values, press and hold the [ ] button for 2 second or more to finalize the input values and return to the parameter setting screen. Press the [ ] button to return to the parameter setting screen without changing parameter values.

115ZV-2 FS EU 62-96 62 Function & Structure Electrical Group MODM

3. Meter division ratio Next, by pressing the [ following screen is seen.

4. Tachograph (step forward)] button, the

Next, by pressing the [ following screen is seen.

80V2U62046

The screen should appear similar to what is shown. This is the speed division ratio for the smaller tire. This permits the speed reading to be accurate when equipped with smaller tires. Next, by pressing the [ following screen is seen.

(step forward)] button, the

80V2U62048

Next, by pressing the [ following screen is seen.

(step forward)] button, the

(step forward)] button, the 80V2U62049

5. Secondary steering 80V2U62047

Next, by pressing the [ following screen is seen.

The screen should appear similar to what is shown. This is the speed division ratio for the larger tire. This permits the speed reading to be accurate when equipped with larger tires. Note Model

(step forward)] button, the

80V2U62050

The screen should appear similar to what is shown and indicates the engagement speed.

Tire size Small size (B)

Large size (A)

65ZV-2

17.5

20.5

70ZV-2

20.5

23.5

80ZV-2

20.5

23.5

85ZV-2

23.5

26.5

90ZV-2

23.5

26.5

92ZV-2

26.5

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

115ZV-2 FS EU 62-97 62 Function & Structure Electrical Group MODM

6. K-Lever (stick steering) Next, by pressing the [ following screen is seen.

(step forward)] button, the

Review the following screens that are able to be seen by pressing the [ (step forward)] button. (A setting shown.)

80V2U62055 80V2U62052

The screen should appear similar to what is shown and indicates the K-Lever voltage.

80V2U62056

Note The default setting for K-Lever is to the "A" type. The voltage settings are displayed in the MODM monitor display.

80V2U62057

i=Signal intensity (or mA) Review the following screens that are able to be seen by pressing the [ (step forward)] button. (A setting shown.)

A Type

Solenoid valve LH side

Solenoid valve RH side

Current (mA)

imax i2

80V2U62053

80V2U62054

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

115ZV-2 FS EU 62-98 62 Function & Structure Electrical Group MODM

7. Traction control

B Type

Solenoid valve LH side

Next, by pressing the [ following screen is seen.

Solenoid valve RH side

Current (mA)

imax

(step forward)] button, the

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 62-104)

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).)

115ZV-2 FS EU 62-99 62 Function & Structure Electrical Group MODM Next, by pressing the [ following screen is seen.

(step forward)] button, the

Next, by pressing the [ following screen is seen.

80V2U62061

This is time inching. This is time frame in lsc above. Next, by pressing the [ following screen is seen.

(step forward)] button, the

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.

115ZV-2 FS EU 62-100 62 Function & Structure Electrical Group MODM

9. Efficient loading system (ELS)

10. Engine power control

Next, by pressing the [ following screen is seen.

Temperature

(step forward)] button, the

Next, by pressing the [ following screen is seen.

(step forward)] button, the

80V2U62067

This is the voltage at the rotary sensor wire that returns signal to MCU. This signal from the rotary sensor determines the boom height position. If the boom is high, the unloader valve solenoid coil at the ELS control valve will not be energized, and the ELS will not operate to unload the loading pump.

80V2U62070

The screen should appear similar to what is shown. This is the temperature at which hibernate mode will engage.

DS=Dual Stage (or ELS)

TWni=Temperature Water normal idle.

on="on". (Thus the term "DSon".)

Voltage

This indicates that the dual stage system is on when it senses 2.5 V or less.

Next, by pressing the [ following screen is seen.

(step forward)] button, the

Typical voltage for the rotary sensor is as shown in graphic below (approximate values). 65V2E62024

Approximate voltage values Boom fully up=4.8 V

The screen should appear similar to what is shown. This is the voltage at which hibernate mode is changed to normal operation mode forcibly. Vni=Voltage normal idle. If the voltage is less than 26.7 VDC, 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

115ZV-2 FS EU 62-101 62 Function & Structure Electrical Group MODM

11. Lower kickout (for return to dig)

13. Calendar (Date and time)

Next, by pressing the [ following screen is seen.

(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.

115ZV-2 FS EU 62-102 62 Function & Structure Electrical Group MODM

Parameter change The parameter values can be changed when the both conditions below are satisfied: The engine is stopped (starter switch is ON). The parking switch is ON.

Press the [ (step forward)] button to add "1" to a numerical value. The numerical value will increase as you press the [ (step forward)] button as follows. 0  1  2 ..... 9  0 Press the [ (step back)] button to subtract "1" from a numerical value. The number decreases as follows.

A parameter value can be changed, however, only when the corresponding item is set to "VALID" in the specification setting monitor. (Refer to page 92-54) 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.

115ZV-2 FS EU 62-103 62 Function & Structure Electrical Group MODM

Specification Setting Monitor

1. Specification setting display

(Refer to page 92-55 and 92-56)

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.

115ZV-2 FS EU 62-104 62 Function & Structure Electrical Group MODM

2. Password entry and changing settings Note To make changes to entry settings, engine must be "OFF", and key switch in "ON" position with parking brake applied. Otherwise changes will not happen.

90ZV-262023

Every time the [ (step back)] button is pressed, the displayed content is changed "FR switch  Wheel type  Kickout  ..." in sequence. The following items can now be selected as "VALID" or "INVALID" by pressing and holding the [ ] button for 2 seconds or longer, and then selecting the [ (step forward)] or the [ (step back)] button to choose "VALID" or "INVALID" as required. When finished, press and hold the [ ] button for 2 seconds or longer to accept the change.

The password is a numerical password. Press the [ (step forward)] button to add "1" to a numerical value.

If you need to return without making a selection, press the [ ] button, and you will return to the previous screen without making a change of selection.

The numerical value will increase as you press the [ (step forward)] button as follows;

- Selection switch shift (shift lever or F/R switch) Valid/Invalid

0  1  2  3  4  5 ..... 9  0  1  2  3  4  5 ..... etc.

- Shift hold Valid/Invalid

Press the [ ] button to change the cursor position to continue password entry. When finished, press the [ ] button for longer than 2 seconds to get to the following screen.

- Ride control Valid/Invalid - Secondary steering Valid/Invalid - K-Lever (Stick steering) A Type/B Type/Invalid

80V2U62075

Every time the [ (step forward)] button is pressed and held for 2 seconds, the displayed contents are changed over "All setting reset  Specification group 1  Specification group 2  All setting reset" in sequence. Every time the [ (step back)] button is pressed and held for 2 seconds, the displayed contents are changed over "All setting reset  Specification group 2  Specification group 1  All setting reset" in sequence. For the display sequence, refer to "Outline of MODM (Machine Operation Diagnostic Module) Operation" page 92-48. 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)

115ZV-2 FS EU 62-105 62 Function & Structure Electrical Group MODM Specification group 2 Every time the [ (step forward)] button is pressed, the displayed content is changed "Downshift button  Auto brake  Engine speed  ..." in sequence. Every time the [ (step back)] button is pressed, the displayed content is changed "Downshift button  Brake oil level  Brake oil differential sw  ..." in sequence.

- Engine oil pressure sensor (for communication and monitor control) Valid/Invalid - Brake pressure differential switch Valid/Invalid - Brake oil level Valid/Invalid Use the table on page 62-108 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 !

115ZV-2 FS EU 62-106 62 Function & Structure Electrical Group MODM

All setting reset Item

Allows batch deletion or batch reset of information monitor, replacement monitor or fault log monitor. Specified Parameter

Comment

Kick down (downshift button)

SP1

Always valid

Selection switch shift (shift lever or F/R switch)

SP2

Optional

Shift hold

SP3

Always lnvalid

Autobrake

SP4

Valid 92~135ZV-2

Information monitor When this is performed, the following items will be reset. - Maximum engine coolant temperature

Ride control

SP5

Option

Engine speed

SP6

Sensor

Secondary steering

SP7

Option (EU always valid)

- Maximum hydraulic oil temperature - Number of cycles

- Maximum transmission oil temperature

K-Lever

SP8

Option

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

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

- Fuel filter timer

Engine coolant temperature switch

SP18

Invalid

- Coolant filter timer

Engine coolant temperature sensor

SP19

Net or Sensor

- Torque converter line filter timer

Engine oil pressure switch

SP20

Always valid

Engine oil pressure sensor

SP21

Sensor (INVALID)

- Hydraulic oil return filter timer

Brake pressure differential switch

SP22

50/60ZV-2 only

- Engine oil timer

Brake oil level

SP23

50/60ZV-2 only

Wheel type

SP24

A or B type

Replacement monitor - Engine oil filter 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.

115ZV-2 FS EU 62-107 62 Function & Structure Electrical Group MODM

All setting reset procedure (Start at screen shown)

80V2U62075

Press and hold the [ ] button for 2 seconds or more to display the all setting reset execution screen. See example below.

80V2U62076

When executing the all setting reset function, press and hold the [ ] button for 2 seconds or more. Then, the all setting reset function is executed, and the specification setting screen appears again. Press the [ ] button to return to the specification setting screen without executing the all setting reset function.

115ZV-2 FS EU 62-108 62 Function & Structure Electrical Group MODM

Default position of specification setting monitor (EU) ITEM

OPTION EITHER VALID OR INVALID

65ZV-2 65TMV-2

70ZV-2 70TMV-2

80ZV-2

85ZV-2

90ZV-2

92ZV-2

95ZV-2

115ZV-2

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

Net/ Sensor

Net

Net/ Sensor

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.

Note*** Concerning engine coolant temperature sensor, “Net” must be selected for the listed S/N machines in the following table, and “Sensor” must be selected for the machines prior to them. (The sensor wes no longer installed but temperature data was derived from the engine ECM on and after the listed S/N.)

Model

Serial number to use “Net”

65TMV-2/65ZV-2

Always “Net” (all S/N)

70TMV-2

Always “Net” (all S/N)

70ZV-2

70C5-9101~

80ZV-2

80C5-9101~

85ZV-2

85C5-9101~

90ZV-2

90C5-9201~

92ZV-2

Always “Net” (all S/N)

95ZV-2

97C5-9151~

115ZV-2

11C5-9051~

115ZV-2 FS EU 62-109 62 Function & Structure Electrical Group Electrical Detent Circuit

Electrical Detent Circuit Bucket leveler After dumping, if the control lever is set to the "rollback" position, the control lever will be held at that position until the bucket is tilted to the set angle. This is because the detent solenoid in the pilot valve is energized so that the fixing disc connected to the push rod is held by the magnetic force. When the bucket is positioned at the set angle, the rod will retract from the proximity switch. The proximity switch is turned off and the detent solenoid in the pilot valve is de-energized and demagnetized. The control lever is automatically returned to the neutral position by the spring. As a result, the bucket is set to the selected digging angle automatically.

Detent

Multiple control valve Bucket leveler Adjusting rod (detected object)

Proximity switch

Connector Bucket cylinder

85V2E62007

Proximity switch Adjusting the clearance Proximity switch Switch main circuit

LED

+24V

Br 1

Coil for detent inside pilot valve

B 2 L 3 +24V

Detection part Operation indicator lamp (LED) Detected object

1(Br)

View Z 3(L)

5±2 mm (0.197±0.079 in)

Adjust the clearance between the sensor and the adjusting plate to 5±2 mm (0.197±0.079 in). In this condition, the operation indicator lamp (LED) is on, and the circuit between the switches (2) – (3) is on.

2(B) 85ZV62015

115ZV-2 FS EU 62-110 62 Function & Structure Electrical Group Electrical Detent Circuit

Detent solenoid

Push rod

Detent solenoid Fixing disc

85V2E62035

Three detent solenoids are installed in the pilot valve. One detent solenoid, for the bucket leveler, is installed in the pilot valve bucket side. Two detent solenoids, for the boom kickout and float, are installed in the pilot valve boom side. Voltage

DC 24 V

Coil resistance

62±3 

115ZV-2 FS EU 62-111 62 Function & Structure Electrical Group Electrical Detent Circuit

Lift kickout & lower kickout Location

4 A 5

1 Detail A

1. Rotary sensor 2. Rod 3. Link 4. Cover 5. Cover 6. Boom

85V2E62008

Lift kickout

Lower 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.

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.

115ZV-2 FS EU 62-112 62 Function & Structure Electrical Group Electrical Detent Circuit

Sensor assy 4

3 3

5 A-A

Detail of grease applying

A 30 Position sensor detail

85V2E62009

1. Position sensor 2. Link 3. Plate 4. Shaft 5. Ball bearing

115ZV-2 FS EU 62-113 62 Function & Structure Electrical Group Electrical Detent Circuit

A B C

View A

A Position sensor detail

CCW

70T2U62008

70T2U62009

Resistance

5 k ± 1 k

Electrical rotation

128º (Theoretical)

Mechanical rotation

180º

Clockwise stop

90º from elect. center

Spring return

To clockwise end of rotation

115ZV-2 FS EU 62-114 62 Function & Structure Electrical Group Electrical Detent Circuit

Detent solenoid

Lever position: Lower kickout side

Preset height adjustment

Lever position: Lift kickout side

Push rod

Detent solenoid (for lift) Fixing disc

Detent solenoid (for lower) Fixing disc

Switch

115V2E62019

(Upper)

(Lower)

Hold

Reset

85V2E62017 65V2E62018

Two detent solenoids are installed in the pilot valve boom side. One is for the lift kickout and the other is for the lower kickout. Voltage

DC 24 V

Coil resistance

62±3 

1. Lift kickout preset height Raise the boom to the desired position and press the left side of the kickout control switch located on the console box to set the boom height for the lift kickout. 2. Lower kickout preset height Lower the boom to the desired position and press the right side of the kickout control switch located on the console box to set the boom height for the lower kickout.

115ZV-2 FS EU 62-115 62 Function & Structure Electrical Group Diode

Diode Open circuit, failed in open position.

Symbols

+24V Switch

Solenoid

[Anode]

[Cathode]

Surge voltage

(forward direction)

Current flow

(backward direction)

70ZV62051

Diode

Current flows while the diode is disconnected. (The solenoid is energized, however the surge voltage is not absorbed. This damages electrical parts.) 70T2U62011

A diode is an electronic part which makes the current flow in one direction.

Normal Current flow

+24V

The + side is called "anode", and the - side is called "cathode". The current can flow only in the direction from the anode to the cathode.

Switch

When a diode is connected in the current flow direction, it is called forward direction. When a diode is connected in the current non-flow direction, it is called backward direction.

Solenoid

Diode

Current flows while the diode is normal (The solenoid is energized.)

70ZV62052

Short-circuit, failed in closed position.

Some electrical parts, as solenoid valves, buzzers, relays, all equipped with electromagnetic coils may generate a surge voltage caused by counter electromotive force when the power is turned off. This surge voltage may cause malfunction of equipment. Diodes are provided to prevent such a malfunction.

+24V

Switch Solenoid

Diode

Current flows through the diode with smaller resistance. The solenoid is not energized. 95ZV62074

However, if a diode is damaged and short-circuited (or fails closed) in its inside, electronic parts may be harmed. Therefore, if a malfunction occurs in electrical equipment, electrical connection diagrams should be referred to first, to determine and repair the cause. If a diode is provided in the electrical equipment, the diode should be checked for damage.

115ZV-2 FS EU 62-116 62 Function & Structure Electrical Group Diode

Diode check method

Caution for diode check method Continuity check mode When checking the continuity by continuity check mode of volt-ohm-ammeter, only in case that the resistance is about 300  or smaller, the continuity is detected.

Coil

If the continuity check mode of volt-ohm-ammeter is used to check the continuity of diode with 500~600 , no continuity is detected both ways.

+ Analog type tester

Use a volt-ohm-ammeter with diode mode for checking diode continuity. 95ZV62129

12V

Diode check mode

12V

30A

Battery (1)

ECM F15

R1 BR B AC R2 C

(2) (3)

(2)(3): Diode unit

F13

F14

Suppression diode Charge circuit

From alternator I terminal

Neutral relay 115V2E62005

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

115ZV-2 FS EU 62-117 62 Function & Structure Electrical Group Diode

Resistance check mode Analog type tester

R1>0

R2=

Forward check

Backward check Digital type tester

R1>0

R2=

Forward check

Backward check

Forward check

Backward check

Judgement

R  (0<R<)



Normal



Open circuit

0

Short-circuit

115ZV-2 FS EU 62-118 62 Function & Structure Electrical Group Diode

Surge voltage and surge suppression diodes

Fig. 3

Fig. 1

Surge suppression diode

Coil

Current Switch or transistor Time [sec]

Load 115ZVE62032

Some electrical parts such as solenoid valves are equipped with a coil. When a coil is energized, an electromagnetic field is formed. See fig. 1. Fig. 2

Battery

Coil

When the switch opens, the field collapses across the coil windings. Voltage

Voltage [V] Current [A]

K70V2J62006

When the surge voltage was generated, it causes to increase wear on the switch points. During the coil is being activated by the transistor, when the excruciating high voltage is loaded on the transistor, the transistor may be broken. In order to absorb this surge voltage, connect the diode parallel to the coil in the reverse direction against the power supply. When the switch is off, the same amount of electric current, that was flown till now, flows through the diode. This electric current is attenuated gradually and finally it reaches zero. That means no surge voltage is generated in the circuit.

Current

Load

Coil

Voltage

Voltage [V] Current [A]

Current direction

Battery

Electromagnetic field forms when switch closes.

This diode is called as flywheel diode.

ON OFF Time [sec]

Surge voltage 115ZVE62033

When the solenoid coil is de-energized, the field collapses across the coil. The collapse of this electromagnetic field across the solenoid coil generates an unregulated voltage surge. See fig. 2. This can damage transistors, contacts, and other electronic parts. (See connection diagram.)

115ZV-2 FS EU 72-1 72 Function & Structure Operator Station Group

72 Function & Structure Operator Station Group Cabin ....................................................................... 72-2 Operator Seat.......................................................... 72-10 Steering and Transmission Shift Lever.................... 72-11 Air Conditioner ........................................................ 72-14 Troubleshooting....................................................... 72-70

115ZV-2 FS EU 72-2 72 Function & Structure Operator Station Group Cabin

Cabin Mounting drawing 2

Floor board

Rear chassis

The cabin equipped with the ROPS (Roll Over Protective Structure) is provided as standard. 1. Cabin 2. ROPS

115V2E72001

115ZV-2 FS EU 72-3 72 Function & Structure Operator Station Group Cabin Outline drawing

AB 3

7 6

B-B

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 8. ROPS

A-A

K115V2J72002

115ZV-2 FS EU 72-4 72 Function & Structure Operator Station Group Cabin

Glass

70V2E72001

1. Front glass 2. Front side glass 3. Rear glass

115ZV-2 FS EU 72-5 72 Function & Structure Operator Station Group Cabin

1. Part number 32011-21690

Clear glass (Outside)

2. Part number 32011-21700

Clear glass (Outside)

Laminate: 0.76 mm

T=3.0

Laminate: 0.76 mm

T=3.0

Green glass (Inside)

T=3.0

A-A

(mm) 327.5 (mm) R3

953

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.

115ZV-2 FS EU 72-6 72 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.

115ZV-2 FS EU 72-7 72 Function & Structure Operator Station Group Cabin

Wiper mount Front wiper

714 (Along surface)

angle 56º

ng surf ace)

Wipin g

R750(A lo

1 4

2 3

1 4

97ZV72004

1. Wiper motor 2. Wiper arm 3. Wiper blade

4. Intermittent wiper relay 5. Washer jet nozzle

Rear wiper

106

450

97ZV72005

1. Wiper motor 2. Wiper arm

3. Wiper blade 4. Washer jet nozzle

115ZV-2 FS EU 72-8 72 Function & Structure Operator Station Group Cabin

Wiper motor Front Cabin

(Automatic stop position) 12 159200 589 24V

100

e) ol rh ø5 the a re

115

80 70

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

DC 24 V

Rotating speed Load: 1.0 N-m (0.1 kgf-m)

Low

46±4 min-1

High

Rotating speed Load: 4.0 N-m (0.4 kgf-m)

High

68±7 min-1 > 32 min-1 = > 42 min-1 = < 16 V = > 32 V = <2A = < 15 A =

Low

No-load starting voltage (Minimum) Automatic stopping voltage (Maximum) No-load current Locked rotor current

115ZV-2 FS EU 72-9 72 Function & Structure Operator Station Group Cabin Rear

Wiping angle: 106º±3º Automatic stop position

L(+) LB (+1)

Y(S)

Cabin

AVS0.85 LB (+1) AVS0.85 L (+)

AVS0.85 WB ( )

MOTOR (Circuit breaker)

AVS0.85 Y (S)

M 2 LB

Cabin

L +

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

115ZV-2 FS EU 72-10 72 Function & Structure Operator Station Group Operator Seat

Operator Seat Armrests Rotate control knob (3) to select desired angle. Pivot up and parallel with backrest when not in use. Combined height and weight adjuster 3

1. Sit on the seat. 2. Turn handle (4) to adjust seat height. Clockwise to raise seat. Anti-Clockwise to lower seat.

2 1

3. Check ride indicator (5) shows green. If red, readjust seat height. Within the green band of the ride indicator there is 75 mm of height adjustment for any driver.

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.

115ZV-2 FS EU 72-11 72 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.

115ZV-2 FS EU 72-12 72 Function & Structure Operator Station Group Steering and Transmission Shift Lever

Tilt case 8

1 1

4 2

Lock release position

6 7

2 5 4 Operator stand

Slide quantity 85

Lock position

270 (355 when slid)

9 Operator stand

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)

115ZV-2 FS EU 72-13 72 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".

115ZV-2 FS EU 72-14 72 Function & Structure Operator Station Group Air Conditioner

Air Conditioner Air conditioner components

4 1-1

3 1-2

1 7 9

6 13

97ZV72020

1. Air conditioner assembly 1-1 Cooling unit assembly 1-2 Blower assembly 2. Air distributor assembly 3. 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)

115ZV-2 FS EU 72-15 72 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

115ZV-2 FS EU 72-16 72 Function & Structure Operator Station Group Air Conditioner

1. Cooling unit case (rear) 2. Cooling unit case (front) 3. — 4. Evaporator core 5. Heater core 6. Expansion valve 7. — 8. Tube 9. De-icing sensor (thermal resistor) 10. — 11. Door (upper) 12. Door (lower) 13. Door (foot) 14. Damper (vent) 15. Pressure switch (triple) 16. Liquid tube 17. Suction tube 18. — 19. —

20. — 21. — 22. — 23. Power integrated circuit assembly 24. Servo motor (A/M, air mixing) 25. Servo motor (mode) 26. — 27. — 28. — 29. — 30. — 31. — 32. — 33. — 34. — 35. — 36. — 37. Lever (face, door) 38. Lever (foot, door)

39. — 40. — 41. — 42. — 43. — 44. — 45. — 46. — 47. — 48. — 49. Lever (face, front) 50. Control lever (face, front) 51. Door (S/A) (face, front) 52. — 53. — 54. — 55. — 56. — 57. Thermo sensor (water temperature)

115ZV-2 FS EU 72-17 72 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)

115ZV-2 FS EU 72-18 72 Function & Structure Operator Station Group Air Conditioner

Air compressor (with magnetic clutch)

2-1 2

2-2

2-3

2-6

2-8 5~7 2-7 1 85V2U72001

3. — 4. — 5. Plate washer 6. Plate washer 7. Plate washer

1. Compressor 2. Magnetic clutch assembly 2-1 Magnetic stator coil 2-2 Magnetic clutch pulley 2-3 Clutch hub 2-6 Plate washer 2-7 Snap ring 2-8 Snap ring

Condenser unit 3 1

4 2

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

115ZV-2 FS EU 72-19 72 Function & Structure Operator Station Group Air Conditioner

Control unit

Control amplifier

Control panel

97ZV72027

Control panel

OFF switch

Inside/outside air selector switches

Blower switches

Temperature setting switches

Liquid crystal display (LCD) unit

Vent mode selector switch

AUTO switch

Air conditioner ON/OFF switch

97ZV72028

115ZV-2 FS EU 72-20 72 Function & Structure Operator Station Group Air Conditioner

Function of cooling mechanism Principle of cooling

Indoor

Evaporator

Expansion valve

Expansion Evaporation Condensation

Deprives heat of the adjacent area.

Condenser Releases heat to the outside.

Compression Refrigerant

Compressor Basic cooling cycle

contain some minor gas fractions, it is routed into the receiver drier. There it dries the refrigerant by use of a material we term a "desiccant", which means drying agent. A down tube in the receiver drier is submerged into the heavier liquid that is now at the bottom of the receiver drier. This tube will permit passage of only the heavier liquid that is at the bottom of the receiver drier. Then the high-pressure liquid passes through the thermal expansion valve that provides a restriction or throttles the flow of refrigerant. This restriction reduces the pressure of the liquid refrigerant thus reducing its boiling point. The expansion valve also meters the amount of refrigerant to the evaporator, by modulating the valve from wide open to closed, which varies with the heat load. The expansion valve separates the high-pressure side from the low-pressure side.

97ZV72029

Function and operation of air conditioning system Very often, things are much simpler than they may appear. This is also the case with an air conditioning system. Gas when compressed often heats as a result of molecular compression, and when decompressed it cools. Some gases are more prone to heat or cool to a greater degree when undergoing these changes than are others. We use these natural laws to make an air conditioning system work. Another factor to take into consideration is that we enhance the natural effects of hot and cold in these refrigerants by manipulating the gas temperature while it is undergoing the heating or cooling process. Note HFC 134A is a very effective "vehicle" to carry away heat. Explanation of function of air conditioning unit. As an example of manipulating refrigerant temperatures, imagine that you can very quickly make the refrigerant intensely hot. This is done by use of a compressor, as we just mentioned in paragraph one. If you course the heated refrigerant that just came from the compressor through a condenser that will cool it while it is very hot and in a compressed gaseous state, you will make it shed some of its heat that it gained in the compression process. This refrigerant then is converted into a liquid at this point, while still in the condenser. This is why it is called the condenser, as it has condensed the gas into a liquid. As a liquid that may still

The refrigerant is now at the evaporator. Temperatures in the evaporator are cold enough to cause the ambient air to cool when blown through it. This causes condensation to happen. The fan-charged air that rushes through the evaporator is now going to shed its humidity. This humidity, or condensed water, is routed through some tubing to be discharged to the outside of the cab as waste water that falls to the ground. The refrigerant is now on its way back to the compressor. It is still under pressure when compared to the atmospheric air pressure. However, because it is drawn along by the refrigerant compressor suction, we now say that is in the suction side (low-pressure side) of the circuit.

115ZV-2 FS EU 72-21 72 Function & Structure Operator Station Group Air Conditioner

Refrigerant A liquid object which circulates inside cooling circuit and transmits heat is called "refrigerant". The refrigerant changes repeatedly its state, from "liquid --> gas --> liquid --> gas ...", and carries heat from the low temperature side (inside the cab) to the high temperature side (outside the cab) while changing its status. There are many types of refrigerants. This air conditioner adopts refrigerant R134a which does not contain chlorine and does not destroy the ozone layer.

IMPORTANT Make sure to use the specified refrigerant (R134a). If any other refrigerant is used, following problems may occur: - The air does not become cool enough. - The equipment may be damaged. And never mix R134a with any other refrigerant. Chemical formula Molecular weight

CH2FCF3 102.03

Boiling point

-26.19ºC (-15ºF)

Critical temperature

101.14ºC (214ºF)

Critical pressure

4.1 MPa (41.45 kgf/cm2) (595 psi)

Critical density

511 kg/m3 (0.073 lbs)

Density of saturated liquid (at 25ºC/77ºF)

1,206 kg/m3 (595 psi)

Specific volume of saturated vapor (at 25ºC or 77ºF) Latent heat of evaporation (at 0ºC/32ºF) Combustibility Ozone decomposition modulus

0.0310 m3/kg 197.54 KJ/kg (186 BTU) (47.19 kcal/kg) Noncombustible 0

115ZV-2 FS EU 72-22 72 Function & Structure Operator Station Group Air Conditioner

Refrigerant characteristics

Generally, fluid (which is the generic name for compressed / condensed non-gas liquid) has following properties.

Refrigerant temperature (ºC) (ºF)

100 (212)

1. When the temperature of gas at a certain pressure decreases, the gas starts to condense and change into liquid at a certain temperature. For each substance (liquid), this temperature is fixed at a given pressure. This temperature determined by a given pressure is called the "saturated temperature".

80 (176) 60 (140) 40 (104) 35 (95) 20 (68) 15 (59) 0

(

20 4)

(

30 22) 0

3.6 5 8 10 353 490 785 981 51 71 114 142

15 1,471 213

20 1,961 284

25 2,452 355

30 2,942 426

35 3,432 497

Gauge pressure (kgf/cm2G) Relationship between saturated pressure and saturated temperature of R134a

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.

115ZV-2 FS EU 72-23 72 Function & Structure Operator Station Group Air Conditioner

Cooling circuit

The figure on the left shows the cooling circuit of the air conditioner.

Inside cab

Pressure bulb

Expansion valve

Evaporator Blower

Inside engine room

Compressor

Cooling fan Pressure switch

Receiver dryer Condenser

In this circuit diagram, the area which cools down the air inside the cab is the evaporator. The cooling circuit utilizes the fact that the refrigerant absorbs heat (latent heat of evaporation) from the adjacent area when evaporated, and cools down the air inside the cab. The area where the refrigerant is evaporated is the evaporator. The "cooling" effect can be obtained only when the air to be cooled down is continuously fed to the area around the evaporator by the blower fan and the liquid refrigerant (wet evaporation refrigerant with low degree of dryness) is supplied into the evaporator. For example, in order to cool down the air to 15ºC (59ºF), the refrigerant can absorb the latent heat of evaporation from the air only when it is evaporated at a temperature lower than 15ºC (59ºF). It can be seen from the figure in the previous page that the pressure of the refrigerant inside the evaporator should be 353 kPa (3.6 kgf/cm2G) (51 psi) or less to realize it. And in order to keep sufficient cooling effect, the supplied refrigerant quantity should be adjusted so that the refrigerant supplied to the evaporator is completely evaporated inside the evaporator into dry vapor or gas.

Structure of cooling circuit 85V2U72003

Accordingly, the cooling circuit should be constructed to reduce the pressure inside the evaporator and supply proper quantity of refrigerant into the evaporator so that the evaporator can cool down the air sufficiently. The supplied refrigerant quantity is adjusted by the expansion valve. The pressure inside the evaporator is kept at a low value by the closing action of the expansion valve and the suction action of the compressor. The compressor works as a pump which circulates the refrigerant. The refrigerant in the dry vapor status returns into liquid by the compression action of the compressor and heat change (heat radiation) of the condenser, which acts to change the state of the gas to liquid.

115ZV-2 FS EU 72-24 72 Function & Structure Operator Station Group Air Conditioner

Electrical circuit Control schematic drawing

Outside air sensor

Input signals

Set temperature, room temperature, water temperature, air temperature after evaporator

Insolation sensor Outside air sensor

e = Inside air temperature - Set temperature

Insolation sensor

Set temperature correction

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

115ZV-2 FS EU 72-25 72 Function & Structure Operator Station Group Air Conditioner

Air conditioner functions of components Control panel Name and function of each part on control panel (1) OFF switch

Indicator lamps

(2) Blower switches

(6) Inside/outside air selector switches

(3) Temperature setting switches

(7) Liquid crystal display (LCD) unit

- (1) OFF switch This switch stops the operation of the blower and the air conditioner. When OFF switch (1) is pressed, the set temperature and the air blow quantity displayed on LCD unit (7) as well as the indicator lamps above AUTO switch (5) and air conditioner ON/OFF switch (8) turned "off", and operation is stopped.

(4) Vent mode selector switch

Indicator lamps

(5) AUTO switch

(8) Air conditioner ON/OFF switch

97ZV72036

- (2) Blower switches These switches change over the air flow quantity in six steps. The air flow quantity is displayed on the LCD unit. When the switch is pressed, the air flow quantity increases. When the switch is pressed, the air flow quantity decreases. In the automatic mode, the air flow quantity is automatically changed over. Display on the LCD unit and the air blow quantity Display on LCD unit

Air blow quantity Air quantity "low" Air quantity "medium 1" Air quantity "medium 2" Air quantity "medium 3" Air quantity "medium 4" Air quantity "high"

115ZV-2 FS EU 72-26 72 Function & Structure Operator Station Group Air Conditioner - (3) Temperature setting switches These switches set the temperature inside the cab in the range from 18.0ºC (65ºF) to 32.0ºC (90ºF). When the switch is pressed, the set temperature increases. When the switch is pressed, the set temperature decreases. Usually, set the temperature to 23~25.0ºC (72~77ºF). Display on the LCD unit and the function Display on LCD unit

Set temperature

18.0ºC (65ºF)

Maximum cooling

18.5~31.5ºC (65~95ºF)

Temperature inside cab is controlled so that set temperature is realized.

32.0ºC (90ºF)

Maximum heating

- (4) Vent mode selector switch This switch changes over the vent mode. When vent mode selector switch (4) is pressed, the vent mode displayed on LCD unit (7) is changed over, and air is blown from the displayed vent positions. In the automatic mode, the vent mode is automatically changed over. Display on LCD unit

Vent mode

Vent positions (A)

(B)

Face (blow-off to upper portion of body mainly during cooling)

○

Face & foot

○

Foot (blow-off to feet mainly during heating)

(C)

(D)

Remarks

○

Foot & defroster

○

Defroster

○

This mode is not selected in automatic mode.

○

This mode is not selected in automatic mode.

- (5) AUTO switch This switch automatically changes over the air blow quantity, the vent mode and the inside/outside air in accordance with the set temperature. When AUTO switch (5) is pressed, the indicator lamp above it lights. Usually, press this switch, set the temperature by using temperature setting switches (3), and use the air conditioner in the automatic mode.

When the automatic mode is changed over to the manual mode, the indicator lamp above AUTO switch (5) is extinguished. In the manual mode, the air blow quantity, the vent mode and the inside/outside air can be changed over by manipulating each switch.

115ZV-2 FS EU 72-27 72 Function & Structure Operator Station Group Air Conditioner - (6) Inside/outside air selector switches These switches change over inside air circulation and outside air entry. When an either switch is pressed, the indicator lamp above it lights to indicate the selected air flow status. In the automatic mode, outside air introduction and inside air circulation are automatically changed over. Inside air recirculation

Outside air entry

The outside air is shut down, and the air inside the cab is circulated. Press this switch to rapidly cool or heat the air inside the cab or when the outside air is dirty. The outside air enters the cab. Press this switch to introduce clean air into the cab or defog the windows.

- (7) Liquid crystal display (LCD) unit This LCD unit indicates the set temperature, the air flow quantity and the vent mode during operation. When 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.)

115ZV-2 FS EU 72-28 72 Function & Structure Operator Station Group Air Conditioner

Operating method

2. Stopping the automatic operation

Normal use 1. Automatic operation

Set temperature

(1) OFF switch

(3) Temperature setting switches

(5) AUTO switch

97ZV72041

Air flow quantity

(8) Air conditioner ON/OFF switch 97ZV72040

(a) Set AUTO switch (5) to ON. Confirm that the set temperature and the air flow quantity are displayed on the LCD unit, and that the indicator lamps above AUTO switch (5) and the air conditioner ON/OFF switch (8) are lit. (b) Adjust temperature setting switches (3), and set arbitrary temperature. The air conditioner automatically changes over the air flow quantity, the vent mode and the inside/outside air to realize the set temperature. Note When the vent mode is set to or in the automatic operation, if the engine water temperature is low, the air flow quantity is restricted to prevent blow-off of cold air.

Press OFF switch (1). Then, the set temperature and the air flow quantity displayed on the LCD unit are extinguished, the indicator lamps above AUTO switch (5) and air conditioner ON/OFF switch (8) are extinguished, and the operation is stopped.

115ZV-2 FS EU 72-29 72 Function & Structure Operator Station Group Air Conditioner 4. Stopping the manual operation

3. Manual operation

(2) Blower switches

(3) Temperature setting switches

(6) Inside/outside air selector switch

(4) Vent mode selector switch

(1) OFF switch

(8) Air conditioner ON/OFF switch 97ZV72042

97ZV72041

(a) Press blower switches (2), and adjust the air flow quantity. Confirm that the set temperature and the air flow quantity are displayed on the LCD unit.

(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.

115ZV-2 FS EU 72-30 72 Function & Structure Operator Station Group Air Conditioner 2. Defroster operation

Other uses 1. Head cooling, feet heating (bi-level) operation

(2) Blower switches

(4) Vent mode selector switch

(4) Vent mode selector switch (2) Blower switches

(5) AUTO switch

(6) Inside/outside air selector switch (6) Inside/outside air selector switch

(3) Temperature setting switches 97ZV72044

(a) Press blower switches (2), and adjust the air flow quantity. Confirm that the set temperature and the air flow quantity are displayed on the LCD unit. (b) Press vent mode selector switch (4), and display the vent mode on the LCD unit. (c) Set to ON air conditioner ON/OFF switch (8). Confirm that the indicator lamp above the switch lights.

(3) Temperature setting switches 97ZV72045

(a) Press blower switches (2), and adjust the air flow quantity. Confirm that the set temperature and the air flow quantity are displayed on the LCD unit. (b) Press vent mode selector switch (4), and display the vent mode or on the LCD unit. (c) Set outside air introduction selector switch (6). (d) Press temperature setting switches (3), and display the set temperature "32.0" (maximum heating status) on the LCD unit.

(d) Arbitrarily set blower switches (2), temperature setting switches (3) and inside/outside air selector switches (6).

Adjust the louver at each vent position so that air flow reaches the windows.

Then, the air conditioner realizes the bi-level operation in which cold air is blown to the head and hot air is blown to the feet.

When defogging the windows or dehumidifying the air inside the cab in rainy season, set air conditioner ON/ OFF switch (8) to ON.

115ZV-2 FS EU 72-31 72 Function & Structure Operator Station Group Air Conditioner

Other functions

3. Failure code deletion

Self-diagnosis function Each sensor and equipment used in the air conditioner can be diagnosed for failure.

(1) OFF switch

After completing the inspection and/or the repair, delete the failure codes memorized in the computer. If not removed, the failure codes memorized in the computer continue to display on the LCD whenever diagnosing. To delete the failure codes, press and hold both air intake control switches (6) for 3 seconds or more. <Display on the LCD unit and the failure mode> Display

(6) Inside/outside air selector switches

(3) Temperature setting switches Press and hold both the " " and " " switches together 97ZV72035 (for 3 seconds or more).

1. Press the OFF switch to stop the operation. (The set temperature and the air flow quantity displayed on the LCD are extinguished.) 2. When the both temperature setting switches " " and " " (3) are pressed and held together for 3 seconds or more, the failure mode is displayed on the LCD unit. (a) If two or more failure are detected, the displayed contents can be scrolled through by pressing either one of the temperature levels (3) " " or " ". (b) Press OFF switch (1) again to finish the self diagnosis function and return to the normal display.

Failure mode

E-

No failure

E11

Wire breakage in inside air sensor

E12

Short-circuit in inside air sensor

E13

Wire breakage in outside air sensor

E14

Short-circuit in outside air sensor

E15

Wire breakage in water temperature sensor

E16

Short-circuit in water temperature sensor

E18

Short-circuit in insolation sensor

E21

Wire breakage in vent sensor

E22

Short-circuit in vent sensor

E43

Abnormality in vent damper

E44

Abnormality in air mixing damper

E45

Abnormality in inside/outside air

E51

Abnormality in refrigerant pressure

Celsius-Fahrenheit selector function for the set temperature display While the blower is operating, press and hold both temperature setting switches (3) " " and " " together for 5 seconds or more to change over the unit of the displayed value between Celsius and Fahrenheit. However, the unit type (C or F) itself is not displayed. Only the set value is displayed. Value displayed on LCD unit Celsius (ºC)

18.0~32.0

Fahrenheit (ºF)

65~90

115ZV-2 FS EU 72-32 72 Function & Structure Operator Station Group Air Conditioner

Air conditioner unit

Air mixing damper

[In the case of maximum cooling] Air mixing damper A (completely opened) Heater coil Evaporator coil

Cold air Co

air

Air mixing damper B (completely closed) [In the case of maximum heating] Air mixing damper A (completely closed)

Ho ta ir

Blower motor Inside/outside air selection damper Air mixing damper A

ld a

Inside air

Outside air

Fan

Blower motor Heater radiator

Evaporator Air mixing damper B

80ZVE72001

The air conditioner unit has the cooling, heating and air blowing functions to perform conditioning of the air inside the 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.

115ZV-2 FS EU 72-33 72 Function & Structure Operator Station Group Air Conditioner

Evaporator

(7)

(5)

Evaporator

The evaporator is an important heat exchanger which evaporates liquid refrigerant set to low temperature and low pressure by an expansion valve, utilizes its latent heat, and absorbs heat from air (target) inside the cab. Accordingly, heat should be smoothly transmitted between the target and the refrigerant in the evaporator.

(4)

For this purpose, fins are provided on the air side of the evaporator to extend the heat transmission area on the air side so that heat can be smoothly transmitted between the refrigerant and the air.

(2)

By cooling, the moisture contained in the air condenses, changes into water drops, and adheres to the outside of the evaporator. If these water drops are frozen, the cooling effect deteriorates. To prevent this, attention should be paid also to proper drainage of condensed water.

(8) (1)

(6)

The refrigerant quantity supplied to the evaporator is adjusted by the expansion valve described next. In order to ensure that the refrigerant quantity is accurately adjusted, pressure drop of the refrigerant inside the evaporator should be minimal.

(3)

Refrigerant flow inside evaporator ( From expansion valve(1) to (8) Compressor

)

Accordingly, reduction of pressure drop is an element to enhance the performance of the evaporator. 97ZV72048

Troubleshooting the evaporator Item Gas leak

Symptom

Cause

Both high pressure and low pressure are low, and air bubbles can be seen through sight glass.

- Joint portion of supply area - Cracks in evaporator main body

Action - Tightening - Repair/replacement

Blockage in circuit

Both high pressure and low pressure are low.

- Blockage inside

- Cleaning/replacement

Blockage in fins

Air quantity is small. (Filters may be clogged.)

- Blockage in fins

- Cleaning

Freezing

Air quantity is small, and low pressure is low.

- Blockage in filter (Evaporator is not preforming inadequately.)

- Cleaning/replacement

115ZV-2 FS EU 72-34 72 Function & Structure Operator Station Group Air Conditioner

Expansion valve (box type)

(Evaporator)

Expansion valve operation

Diaphragm Evaporator

Spring Temperature sensing rod Diaphragm

Temperature sensing rod Needle valve (To compressor) (From receiver)

Needle valve From receiver (High pressure)

Structural drawing of box type expansion valve

To compressor (Low pressure)

97ZV72049

97ZV72050

The expansion valve offers the following two functions.

The temperature sensing rod detects the temperature of the refrigerant, and transfers the detected temperature to the refrigerant gas chamber.

1. By injecting the liquid refrigerant at high temperature and high pressure which has gone through the receiver from a small hole, the expansion valve expands dramatically the liquid refrigerant into mist refrigerant at low temperature and low pressure. 2. Promptly in accordance with the vaporized status of the refrigerant inside the evaporator, the expansion valve adjusts the refrigerant quantity. In order to ensure that the evaporator offers its full performance, the liquid refrigerant should be kept in a state in which it deprives heat of the adjacent area and its evaporation is always completed at the exit of the evaporator. To realize this, the expansion valve automatically adjusts the refrigerant quantity in accordance with fluctuation of the temperature inside the cab (cooling load) and fluctuation of the rotation speed of the compressor. The expansion valve consists of a needle valve, a diaphragm and a temperature sensing rod. The temperature sensing rod detects the temperature of the refrigerant which has gone through the evaporator, and transfers the detected temperature to the refrigerant gas chamber located in the upper portion of the diaphragm chamber.

The gas pressure changes in accordance with the detected temperature, the temperature sensing rod directly connected to the diaphragm is moved, then the needle valve opening is adjusted. - When the temperature at the exit of the evaporator is low or when cooling load is small, following occurs. The gas pressure inside the diaphragm chamber becomes low, the volume decreases, the temperature sensing rod moves to the right, and the needle valve is closed. - When the temperature at the exit of the evaporator is high or when cooling load is great, following occurs. The gas pressure inside the diaphragm chamber becomes high, the volume increases, the temperature sensing rod moves to the left, the needle valve is opened, and more quantity of refrigerant is supplied to the evaporator.

115ZV-2 FS EU 72-35 72 Function & Structure Operator Station Group Air Conditioner Troubleshooting the expansion valve Item

Symptom

Cause

Action

Blocked expansion Both high pressure and low pressure are low, valve or defective and air bubbles cannot be seen through sight adjustment (too closed) glass.

- Expansion valve

- Cleaning/adjustment or replacement

Defective adjustment (too open)

Low pressure is too high, and compressor head is cold.

- Expansion valve

- Adjustment or replacement

Freezing caused by moisture

Cooling is disabled during operation. Frosting is not detected in evaporator. Both high pressure and low pressure are low, and air bubbles cannot be seen through sight glass.

- Expansion valve

- Replace receiver tank, evacuate air, then charge gas again.

115ZV-2 FS EU 72-36 72 Function & Structure Operator Station Group Air Conditioner

Heater radiator coil

Fin

Heater core

97ZV72051

The heater radiator utilizes the engine cooling water as the heat source. When going through the heater radiator, the air receives heat from the heater radiator fins and is warmed. The hot water inside the heater radiator is forcedly circulated by the engine water pump. Troubleshooting the heater radiator Item Water leak

Symptom Water leaks from heater core.

Cause

Action

- 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

115ZV-2 FS EU 72-37 72 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

115ZV-2 FS EU 72-38 72 Function & Structure Operator Station Group Air Conditioner

Blower motor assembly

Blower motor assembly specifications

Fan

Blower motor

Voltage

DC 24 V

Number of rotations of motor

3,100 min-1

Power consumption

225 W (9.4 amps) ± 10%

Fan outer diameter

ø150 (5.9")

Note This unit can be bench tested with 24 V DC by using normal test methods. Determine if excessive amperage is required to turn it. It is controlled by the speed control (BLC) below. Air Air 97ZV72053

The blower motor assembly consists of a DC motor and a fan, and blows air. Troubleshooting the blower motor Item Blower motor operation is defective.

Symptom Air is not blown at all.

Cause - Blower motor - Control unit

Action - Repair/replacement

BLC (blower linear control)

85V2U72004

97ZV72054

This resistor changes over the air quantity of the blower motor. Troubleshooting the blower linear control Item

Symptom

Cause

Action

Wire in BLC is broken.

Air quantity does not change.

- BLC - Control unit

- Replacement

Blower motor operation is defective.

Air is not blown at all.

- Blower motor - Control unit

- Repair/replacement

115ZV-2 FS EU 72-39 72 Function & Structure Operator Station Group Air Conditioner

De-icing sensor (Thermistor (or thermal resistor))

Evaporator

Appearance of thermistor 8,000 7,000

Resistance ()

6,000

Thermistor

5,000

Heater radiator

4,000

97ZV72056

3,000 2,000 1,000 0

10 (14)

5 (23)

0 (32)

5 (41)

10 (50)

15 (59)

20 (68)

25 (77)

30 (86)

Temperature (ºC) (ºF) Characteristics curve between temperature 85V2U72005 and resistance of thermistor

The thermistor, a kind of semi-conductor, offers the characteristics as shown in the curve on the above. When the temperature becomes high, its resistance becomes small. When the temperature becomes low, its resistance becomes large.

The thermistor mounted on the blowoff port side of the evaporator detects the temperature of the air cooled by the evaporator, and transmits it as a signal to the control amplifier. If the air at the vent is 3ºC (37ºF) or less, the control amplifier turns off the compressor clutch relay. If the air at the blowoff port becomes 4ºC (39ºF) or more, the control amplifier turns on the compressor clutch relay again to restart cooling. Because the air temperature at the vent is detected and the compressor clutch relay is turned on and off accordingly, freezing of the evaporator is prevented.

Troubleshooting the thermistor Item

Symptom

Cable in thermistor is broken.

Compressor clutch does not work.

Thermistor is short-circuited.

Air not blowing.

*Note For temperature reference between ºC and ºF please see references below. Temp ºC

Temp ºF

-10ºC 0ºC 10ºC 20ºC 25ºC 30ºC

14ºF 32ºF 50ºF 68ºF 77ºF 86ºF

Cause - Thermistor

Action - Replacement

115ZV-2 FS EU 72-40 72 Function & Structure Operator Station Group Air Conditioner

Water temperature sensor

Foot/defroster selection box

Air conditioner unit

Foot Def 97ZV72057

97ZV72059

This sensor detects the temperature of the engine cooling water flowing into the heater core, and feeds it back to the control panel.

This selection box changes over the vent positions between the foot side and the defroster side.

This sensor is installed on the rear side of the heater core, and can be taken out when being pulled out. Temperature

Resistance value

-30ºC (-22ºF)

91.4 k

25ºC (77ºF)

5 k

100ºC (212ºF)

0.321 

Inside air temperature sensor

97ZV72058

This sensor detects the air temperature inside the cab, and feeds it back to the control panel. This sensor is installed in the inside are suction port, and can be taken out when the clamp is removed. Temperature

Resistance value

0ºC (32ºF)

16.45 k

25ºC (77ºF)

5 k

When the vent mode selector switch (MODE) on the control panel is pressed, the servo motor in this selection box changes over the vent selection damper to the foot side or the defroster side by way of a link and lever.

115ZV-2 FS EU 72-41 72 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]

115ZV-2 FS EU 72-42 72 Function & Structure Operator Station Group Air Conditioner

Magnetic clutch

Magnet clutch specifications Model S

Pulled force Stator Switch Iron piece (rotor)

Power supply Magnetic force N

Principle of magnetic clutch

97ZV72062

The magnetic clutch controls mechanical connection between the engine and the compressor. When the engine is rotating and the air conditioner ON/OFF switch is ON, if the temperature inside the cab reaches or exceeds the temperature set by the temperature setting switches, the magnetic clutch stops or drives the compressor.

Suction face

Pulley Stator coil

Hub

Rotor

Stator Ball bearing

Magnet clutch 97ZV72063

The hub of the magnetic clutch is fitted onto the shaft of the compressor. While the compressor is not driven, the hub is separated from the rotor and only the pulley is rotating. When the air conditioner switch is set to ON, the current flows in the stator coil, the stator works as a magnet and engages the hub, then the compressor rotates together with the pulley. When the current applied on the stator coil is set to OFF, the hub is not immediately separated but rotates together with the pulley because the pulley has residual magnetism. Accordingly, clearance is provided between the hub and pulley so that they are not in close contact with each other during disengagement. This clearance is called air gap.

L50T

Voltage

DC 24 V

Power consumption

40 W (1.67 amps)

Drive belt

V-ribbed belt (six ribs)

Air gap

0.5±0.15 mm (0.020" ± 0.006")

115ZV-2 FS EU 72-43 72 Function & Structure Operator Station Group Air Conditioner Troubleshooting the compressor and magnetic clutch Item

Symptom

Suction or exhaust valve is damaged. *

- Compressor temperature is abnormally high. - High pressure is abnormally low, and low pressure is abnormally high. - Air bubbles cannot be seen through sight glass.

Cause

Action

- Suction or exhaust valve

- Repair/replacement

Clutch draw voltage is low.

- Stator coil

- Replacement

Power is not supplied to stator coil.

- Wiring on main body - Control amplifier - Pressure switch

- Repair - Replacement - Replacement

- Magnetic clutch

- Replacement

Compressor main body is defective (seized, etc.).

- Shaft, piston

- Repair/replacement

Clutch bearing is damaged.

- Clutch bearing

- Replacement

- Magnetic clutch

- Replacement

V belt is slack.

- V belt

- Adjustment/replacement

Compressor main body is defective.

- Internal compressor trouble

- Repair/replacement

- V belt

- Adjustment/replacement

- Abnormal sounds are made while clutch is turned on.

Gap between hub and rotor is large.

Contact or slippage caused by too small gap between hub and rotor.

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.

115ZV-2 FS EU 72-44 72 Function & Structure Operator Station Group Air Conditioner

Condenser unit

Condenser fan motor The condenser fan motor used to cool down the condenser is mounted on the condenser together with a fan shroud.

Condenser Blower assembly Resistor Cover

Fan motor 95V2U72002

Each condenser unit consists of a condenser, a condenser fan motor and a resistor. Two condenser units are arranged in series with the piping. The condenser units cool down the gaseous refrigerant at high temperature and high pressure sent from the compressor, and change it into liquid refrigerant.

Condenser The condenser consisting of tubes and fins cools down the gaseous refrigerant at high temperature and high pressure (70ºC, 1,618 kPa (16.5 kgf/cm2)) (158ºF (235 psi)) sent from the compressor, and change it into liquid refrigerant during passing tubes.

Condenser specifications Voltage

DC 24 V

Power consumption

80 W (3.4 amps) x 10%

Air quantity

1,750±10 m3/Hr (61,800"3/Hr)

Number of rotations of motor

2,200 min-1 (rpm)

115ZV-2 FS EU 72-45 72 Function & Structure Operator Station Group Air Conditioner

Resistor The resistor controls rotation of the condenser fan motor in two steps in accordance with a command given by the fan control pressure switch (medium pressure switch). Resistor specifications 4.0 

Resistance

Troubleshooting the condenser unit Item

Symptom

Heat radiation quantity is insufficient due to blockage*. Both high pressure and low pressure are abnormally high, and air does not become Rotation of condenser fan cool enough. motor is defective.

Cause

Action

- Blockage or crushed fins

- Clean or replace condenser

- Fan motor

- Repair or replace motor

Blockage / condenser airflow

High pressure is abnormally high, low pressure is abnormally low, and air does not become cool enough. Air bubbles can be seen through sight glass.

- Internal to condenser fins

- Clean or replace condenser

Gas leak

Both high pressure and low pressure are abnormally low, and air bubbles can be seen through sight glass.

- Leaks at joints - Cracks in main body

- Tightening - Repair or replacement

* It is important to check the fan blades also as these can become bent or packed with dirt, making them ineffective.

115ZV-2 FS EU 72-46 72 Function & Structure Operator Station Group Air Conditioner

Receiver dryer

Desiccant

Refrigerant inlet Refrigerant outlet

Desiccant

If moisture is present inside the cooling circuit, the compressor valve and oil may deteriorate, metal parts within the circuit may corrode, or moisture may be frozen inside expansion valve which may clog the circuit. To prevent such failure, synthetic zeolite (drying agent) is positioned inside the air conditioner and acts as a desiccant suitable to the circuit so that it absorbs moisture entering the circuit during installation or refrigerant charging. When the expansion valve is often frozen by moisture (icing), the desiccating agent does not have enough absorption ability. When this happens, the receiver must be replaced.

Strainer

Desiccant specifications

Receiver tube

Receiver tank

97ZV72065

The receiver dryer consists of a receiver tank, desiccant, strainers, and a receiver tube.

Receiver tank In the air conditioner, the number of rotations of the compressor changes and the proper refrigerant quantity in the cooling circuit fluctuates in accordance with fluctuation of the number of revolution of the engine. The receiver tank receives such fluctuation. When the cooling circuit does not require much refrigerant, the receiver stores temporarily excess refrigerant. When the cooling circuit requires much refrigerant, the receiver tank supplies refrigerant from its receiver tube to the circuit. In addition, the receiver tank stores a reserve of refrigerant in order to take balance of charging of the refrigerant and respond to any minute leaks of the refrigerant caused by permeation through rubber hoses.

Capacity

550 cm3

Desiccating agent

Synthetic zeolite

Desiccating agent capacity

290 g

IMPORTANT If parts of the cooling circuit are removed and left for a long time for repair or another reason, the desiccant absorbs moisture contained in the air and loses its absorption performance, and the receiver dryer should be replaced. To prevent this, after parts are removed, all openings should be plugged.

115ZV-2 FS EU 72-47 72 Function & Structure Operator Station Group Air Conditioner

Strainers If dusts enter the circuit, the expansion valve may be clogged, the compressor may be damaged, and the cooling function may be deteriorated. Strainers are provided to prevent dusts from flowing with in the refrigerant. The strainers cannot be cleaned. When they are considerably clogged (in this case, the high pressure increases and the low pressure decreases), the entire receiver dryer should be replaced. Troubleshooting the receiver tank Item

Symptom

Cause

Action

Icing

- At first, air in cab will cool down, but after a short time no longer will cool properly.

- Desiccating agent in receiver

- Replacement of receiver dryer

Blockage in strainers

- High pressure is excessively high, low pressure is excessively low, and air does not become cool enough*.

- Blockage in strainers

- Replacement of receiver dryer

*A means to test this is to check the temperature between the inlet and outlet of receiver dryer. If it drops more than it should the dryer is plugging and should be replaced.

115ZV-2 FS EU 72-48 72 Function & Structure Operator Station Group Air Conditioner

Sight glass

Pressure switches

Sight glass

Terminal

Receiver joint

Contact area

Receiver dryer

97ZV72066

97ZV72067

This sight glass is installed on the receiver joint located on the top of the receiver dryer. Only through this sight glass, the refrigerant quantity inside the circuit can be visually checked.

The pressure switch detects the pressure on the high pressure side of the cooling circuit, and stops the compressor when detecting any abnormality so that damage of the equipment in the cooling circuit can be prevented.

WARNING Possible freezing of eye tissue. Always wear protective eyewear when doing a visual inspection.

There are three types of pressure switches, high pressure type, medium pressure type and low pressure type, which function as shown in the table below.

115ZV-2 FS EU 72-49 72 Function & Structure Operator Station Group Air Conditioner

Switch

Switching pressure kPa (kgf/cm2) (psi)

Function

Switch operation confirmation method

Causes of abnormal pressure

Pressure switch coupler

High pressure switch

When pressure between compressor and expansion valve becomes abnormally high, this switch shuts down power supplied to compressor magnetic clutch to protect circuit.

2,550 (26) (370)

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 Refrigerant leak from a part in pressure switch coupler shown of circuit. above.

OFF 196 (2.0) (28)

Troubleshooting the pressure switch Item Insufficient cooling

Gas leak

Symptom

Cause

Action

- Condenser fan motor does not change its speed (to high speed).

- Medium pressure switch

- Replacement

- Even when abnormal high pressure (3,136 kPa (32 kgf/cm2) (455 psi)) occurs, compressor does not turn off. - Even when gas (refrigerant) has run short, compressor does not turn off.

- High or low pressure switch*

- Replacement

*If abnormally high pressure occurs while the high pressure switch is non-functioning, the equipment in the cooling circuit may be damaged. The pressure relief valve releases the refrigerant to the atmosphere in order to prevent equipment or personnel damage.

115ZV-2 FS EU 72-50 72 Function & Structure Operator Station Group Air Conditioner

Pressure relief valve

Flow rate (L/min) 113

Gas discharge route while valve is operating 97ZV72071

This valve mounted on the high pressure side of the compressor service valve releases the refrigerant to the atmosphere when abnormal high pressure occurs.

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.

115ZV-2 FS EU 72-51 72 Function & Structure Operator Station Group Air Conditioner

Relay A

Relay B

(Condenser fan, condenser fan high, compressor clutch)

(Evaporator fan motor, low/high)

97ZV72072

Relay A specifications

97ZV72099

Relay B specifications

Rated voltage

DC 24 V

Rated voltage

Rated current

16 A

Rated current

DC 24 V 11 A

Rated coil current

0.1 A

Rated coil current

0.075 A

Troubleshooting the relay Item

Coil wire is broken. Contact is melted down.

Symptom

Cause

- Blower motor does not rotate at all. - Blower motor remains rotating.

- Blower motor main relay

- Blower motor does not rotate at high speed. - Blower motor remains rotating at high speed.

- Blower motor Hi relay

- Blower motor does not rotate at medium speed Me2. - Blower motor speed does not change from Me2 to Me1.

- Blower motor Me2 relay

- Blower motor does not rotate at medium speed Me1. - Blower motor speed does not change from Me1 to low speed.

- Blower motor Me1 relay

- Both condenser fans do not rotate. - Both condenser fans remain rotating.

- Condenser fan relay

- When condenser fan is at high pressure, it does not rotate at high speed. - When condenser fan is at low pressure, it remains rotating at high speed.

- Condenser fan relay 1

- Compressor magnetic clutch does not turn on. - Compressor magnetic clutch remains ON.

- Compressor clutch relay

Action

- Replacement

115ZV-2 FS EU 72-52 72 Function & Structure Operator Station Group Air Conditioner

Refrigerant hose

WARNING Burst hazard These hoses operate at high pressure for HVAC systems and must not be replaced with substandard hoses.

Outer layer Reinforcing layer

Use only OEM replacement hoses or hoses of the same rating as OEM replacement hoses. Mouth ring Inner layer Intermediate layer 97ZV72073

White line and "R134a" indication

97ZV72074

As shown in the figure on the above, the refrigerant hose consists of the outer layer, the reinforcing layer, the intermediate layer and the inner layer, and the mouth ring is crimped. Region

Material

Outer layer

Ethylene propylene rubber

Reinforcing layer

Polyester

Intermediate layer

Chlorinated butyl rubber

Inner layer

Nylon

The mouth ring of this hose is changed and the symbol "R134a" is indicated on this hose as shown in the figure on the right.

IMPORTANT Never use any other hose or any other refrigerant. Otherwise, refrigerant may leak.

115ZV-2 FS EU 72-53 72 Function & Structure Operator Station Group Air Conditioner

Charge of refrigerant WARNING WARNING Serious accidents may occur in the refrigerant charging work. Observe the following contents. - Only trained or experienced specialists having sufficient knowledge on the contents of the work should be allowed to perform the refrigerant charging work. - If the refrigerant comes into contact with your eyes, you may lose your eyesight. Make sure to wear protective goggles. - The refrigerant in the liquid status is at low temperature (approximately -30ºC (-22ºF)). If it splashes on your skin, you may suffer from frostbite. Pay close attention when handling it. - If the refrigerant (Refrigerant R134a) touches a hot object (approximately +400ºC or more), it decomposes and generates harmful substances. Never release the refrigerant in a room where ventilation is bad and there is a hot object or a fire (such as in the presence of a stove). - In order to protect the environment, do not release the gaseous refrigerant to the atmosphere.

Serious accidents may occur during storage and transportation of a service can. Observe the following contents. - A service can accommodates high pressure gas in the saturated liquid status. If the temperature rises, the pressure may increase drastically and the can may burst. Keep the temperature of the service can at 40ºC (104ºF) or less. Make sure to keep the can away from hot objects or fire. - During storage, make sure to avoid direct sunlight, and store the can in a dark and cool place. - Inside the closed cab (including trunk), the air temperature may rise considerably due to solar heat, etc., and may become dangerously temperature even in winter if the closed cab is exposed to direct sunlight. Never put the can inside the cab. - If the service can suffer from flaws, dents and deformations, its strength deteriorates. Never hit or drop it. And never throw or drop a package of cans while loading or unloading it. - Keep the can away from the reach of children.

IMPORTANT CAUTION Serious accidents may occur during the refrigerant charging work. Observe the following contents. - When warming a service can to charge the refrigerant, make sure to open the low pressure valves of the service can and the gauge manifold, then warm it with hot water of 40ºC (104ºF) or less (temperature at which you feel warm when putting your hand into it). Never warm the can with boiling water or overheat it with open fire. If the can is treated in such a way, it may burst. - When charging the refrigerant after having started the engine, never open the high pressure (Hi) valve. If it is opened, the high pressure gas may flow in the reverse direction, and the service can and the hose may burst.

- It is prohibited by law to reuse service cans. Never reuse them. - Pay close attention so that air and dusts do not enter into the cooling circuit. - Never charge the refrigerant excessively. - The air conditioner is so designed as to be used with Refrigerant R134a. Never charge any other refrigerant such as Freon R12. - If the compressor oil (ND-OIL 8) adheres to the painting face or the resin area, the painting may peel off or the resin may be damaged. If so, wipe it off soon. - Tighten the piping at the specified torque.

115ZV-2 FS EU 72-54 72 Function & Structure Operator Station Group Air Conditioner

Work procedure

Charging procedure

The refrigerant charging process is mainly divided into "refrigerant evacuation procedure" and "gas charging procedure" as shown below.

1. Charge the system with the required amount of gas by weight, and check for leaks by letting the HVAC system sit static and permit pressure to equalize. 2. Check the system pressure in comparison to the ambient temperature. If acceptable, go to the 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.

115ZV-2 FS EU 72-55 72 Function & Structure Operator Station Group Air Conditioner

Charging procedure chart

Start evacuation. 20~30 min Refrigerant evacuation process

Stop evacuation.

-750 mmHg (-30" Hg) or less If too little vacuum, repair leaking connection*

Leave system untouched for 5 min. Check pressure.

*It is possible that system may need pressurized and tested for leaks.

Stop when gage indicates excessive pressure (air entry)

When gage indicates a normal value Charge refrigerant gas.

Check for gas leak. Gas charging process

Charge gaseous refrigerant until gauge pressure reaches 98 kPa (1 kgf/cm2) (14 psi). Check for leaks.

Note A full charge should be about 2±0.1 lbs (900±50 g) of refrigerant.

Charge refrigerant.

Check for gas leak.

As a general guideline, with engine off and HVAC system static, the pressure in the system should be about 85 psi (588 kPa) (6.0 kgf/cm2) with the pressure has equalized between the low and high pressure side.

Performance test 95ZVE72042

115ZV-2 FS EU 72-56 72 Function & Structure Operator Station Group Air Conditioner

Refrigerant charging tools

Charging hose and quick connectors

Recovery and recycling unit

Gauge manifold*

Low pressure charging hose (blue) 95ZV72024

It is against Federal Regulations* in the United States to release refrigerant to atmosphere. A recovery and recycling unit must be used to capture the refrigerant so as not to release it into the atmosphere. *Refer to section 609 of the clean air act at www.epa.gov.

It is used for the following; 1. Recover the refrigerant. 2. Filter the refrigerant. 3. Measure the refrigerant weight. 4. Remove trapped non compressible gases (air). 5. Measure the refrigerant to install in system by weight. 6. Measure the pressure of the refrigerant in system. 7. Measure ambient temperature. 8. View bubbles in system if there are any. Read and understand the Operation Manual for the recovery and recycling machine.

IMPORTANT Only use a vacuum pump if the system is already open to atmosphere and refrigerant has completely left the system.

High pressure charging hose (red)

Quick connector (Lo)

Center charging hose (green or yellow) Quick connector (Hi)

97ZV72077

These different colored hoses are used to evacuate the air and charge the gas. (The colors may be different depending on the manufacturer.) Red hose Connects the high pressure valve of the gauge manifold and the high pressure charging valve (with "H" mark on its cap) of compressor outlet hose. Blue hose Connects the low pressure valve of the gauge manifold and the low pressure charging valve (with "L" mark on its cap) of the compressor inlet hose. Green or yellow hose Connects the center valve of the gauge manifold and the vacuum pump (or the service can valve). *Gauge manifold may be used with vacuum pump or recovery unit.

115ZV-2 FS EU 72-57 72 Function & Structure Operator Station Group Air Conditioner

Gauge manifold

Leak detector

Many recovery and recycling units are equipped with a gauge manifold, which is very similar to the gauge manifolds that were used for earlier application refrigerant handling systems. Typically, the low pressure side hose color is blue, the charging hose color is yellow (may be light green), and the high pressure side hose color is red. These are generally integrated into the recovery and recycling unit. 85V2U72007

Low pressure gauge

High pressure gauge

A leak detector find areas where refrigerant traces are leaking and sounds an alarm to alert the technician of areas of leakage. Gauge manifold

Low pressure valve Low pressure charging hose Center valve mounting nipple Center charging hose mounting nipple

High pressure valve High pressure charging hose mounting nipple 97ZV72078

It is used to evacuate the air and charge the gas, and equipped with a high pressure gauge, a low pressure gage, plus valves and hose mounting nipples as shown in the figure on the above. Some gauge manifolds are equipped with sight glasses. These are used to check for bubbles in the refrigerant. Excessive flow of bubbles may indicate: 1. Low pressure. 2. Leak to atmosphere (air ingestion) when in vacuum. 3. Boiling action, perhaps due to pressure changes.

115ZV-2 FS EU 72-58 72 Function & Structure Operator Station Group Air Conditioner

Cautions on handling of quick connector and charging valve When discharging the refrigerant, use a quick connector.

Precautions

Quick connector

1. Connecting the quick connector.

Screwdriver, etc. Sleeve

"Click" sound (OK) Valve pin

(A) Spring

Charging valve

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 the quick connector against the 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.

115ZV-2 FS EU 72-59 72 Function & Structure Operator Station Group Air Conditioner

Refrigerant charging procedure

Valve setting

Air evacuation work

Lo Hi Closed Closed High pressure valve

WARNING If hoses are connected incorrectly, serious accidents may occur. Observe the following. - Never confuse connection of hose to the high pressure side and the low pressure side of the gauge manifold.

Low pressure valve

(red) (blue) (green)

(Hi)

Recovery and recycling unit (Lo)

Charging valve on high pressure side (located on receiver dryer) Vacuum pump shown Compressor (stopped) A refrigerant recycle and recovery unit may be used. 95ZVE72045

95ZV72024

With system "OFF"; (a) Close both the high pressure (Hi) valve and the low pressure (Lo) valve of the gauge manifold. (b) Connect the charging hose.

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.

115ZV-2 FS EU 72-60 72 Function & Structure Operator Station Group Air Conditioner 2b. Evacuating the system with a recycling and recovery unit.

2a. Evacuating the system with a vacuum pump When pulling a vacuum with a vacuum pump on a system that has been open due to replacing major components.

Valve setting

After air evacuation Valve setting Lo Hi Lo Hi for 30 minutes OpenedOpened Closed Closed High pressure valve

Low pressure valve 95ZV72024

(red) (blue) (green)

(Hi) (Lo) Charging valve on high pressure side Vacuum pump (operating) Compressor (stopped)

(stopped) 95ZVE72046

(a) Open both the high pressure (High) valve and the low pressure (Low) valve of the gauge manifold. (b) Turn on the switch of the vacuum pump, and evacuate until the degree of vacuum becomes -750 mm Hg (-30" Hg) for about 20~30 minutes. (c) After finishing evacuation, close both the high pressure valve and the low pressure valve of the gauge manifold. Then, turn off the switch of the vacuum pump.

IMPORTANT If you stop the vacuum pump before closing each valve of the gauge manifold, refrigerant from vacuum unit and tank is released to the atmosphere. It is important to first close both high and low side valves.

Each manufacture of recycling and recovery units provide operating instructions for their units. Read, understand and closely follow operating instructions as provided.

115ZV-2 FS EU 72-61 72 Function & Structure Operator Station Group Air Conditioner 3. Checking for leaks after vacuum has been drawn Valve setting

Leave for 10 minutes or more as per EPA regulations Lo Hi Pointer of low Closed Closed pressure gauge moves toward "0". Low pressure gauge 0

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)

115ZV-2 FS EU 72-62 72 Function & Structure Operator Station Group Air Conditioner

Valve setting Lo Hi OpenedOpened

1. Charging the refrigerant from the high pressure side with the engine in the "OFF“ position.

Valve setting

After 1~1.5 service cans are charged

Lo Hi Closed Closed

High pressure valve

(a) After evacuation, disconnect the charging hose (green or yellow) of gauge manifold from vacuum pump, and connect it to the service canister. (b) Purging air from lines

Low pressure valve (red)

(blue)

(green)

(Hi)

Open the service canister valve very slightly with low and high pressure manifold valves closed. Open both high and low side valves so that lines are charged. Connect lines to HVAC system. A small amount of trapped air will escape from the lines, as air is discharged by the refrigerant pressure. EPA says that release of this tiny bit of air that is very small is ok.

(Lo) Charging valve on high pressure side

Compressor (stopped) R134a

Service can valve (opened charge closed) 95ZVE72052

WARNING If the refrigerant were changed from the high pressure side, the refrigerant would flow in reverse direction and the can and the hose may be burst if you start the engine and operate the compressor. Never start the engine in this condition.

IMPORTANT If you charge refrigerant with refrigerant canister placed upside down liquid will exit canister, refrigerant is sucked into the compressor in a liquid state. This will damage the compressor. Charge only with refrigerant gas.

(c) WITH ENGINE "OFF"; Open tank canister valve and charge the gaseous refrigerant until gauge pressure read 98 kPa (1 kgf/cm2) (14 psi). (This should take about one to one and half one lb service cans. If using scale, add one to one and a half lbs.) (d) After charging, close the low and high pressure valves of the gauge manifold and the service can valve. 2. Check for gas leak with a leak detector Check for gas leak in the circuit using a leak tester, etc. If a leak is detected, repair leak as required. If located at connections, tighten the connection area.

IMPORTANT Make sure to tighten the connection areas of the piping at a specified tightening torque. For the tightening torque, refer to the volume "Maintenance Standard". Do not overtighten or it will worsen.

115ZV-2 FS EU 72-63 72 Function & Structure Operator Station Group Air Conditioner 3. Charging the refrigerant - low pressure side - e/g "ON". Valve setting Lo Hi Opened Closed

Charge the refrigerant until air bubbles seen through the sight glass disappear.

(c) Start the engine, and increase the number of rotations to approximately 1,500 min-1(rpm). (d) On the control panel, set the fan speed to high and set the air flow volume to maximum cold, and set the vent port temperature switches to the coldest status.

Valve setting Lo Hi Closed Closed

High pressure valve

Low pressure valve

(e) Open the low pressure valve of the gauge manifold and service canister valve to charge the refrigerant. When air bubbles seen through the sight glass of the receiver dryer disappear, charge the refrigerant further more by 150~250 g.

(red)

(blue)

(green)

IMPORTANT (Hi)

(Lo) Charging valve on high pressure side

Compressor (On-load) R134a

Service can valve (opened charge closed) 95ZVE72052

When replacing service canister while charging refrigerant, connect the line as described earlier so as to not have air in the line. (f)

After charging, close the low pressure valve of the gage manifold and the service can valve. Then, stop the engine. Refrigerant quantity to be charged (guideline) 900±50 g (2.0±0.1 lb)

Refrigerant quantity

Proper

Gas bubbles are few. (When the number of rpm’s of the engine is gradually increased from the idle status to 1,500 min-1, gas bubbles disappear.)

Too much

Gas bubbles are not seen in the flow at all. System is over-pressurized. (In this case, both the high pressure and the low pressure are high, and the cooling ability is deteriorated.)

Insufficient

Many gas bubbles are seen in the flow. (Gas bubbles visibly seen constantly.)

Sight glass

Receiver joint

Receiver dryer

97ZV72066

(a) Make sure that the high and low pressure valves of the gauge manifold and service canister valve are closed. (b) If the inside of the cab becomes cold during the charging process, the compressor magnetic clutch turns off and system charging is disabled. When charging, completely open the cab doors. This will keep the system from turning off and on.

Sight glass situation

115ZV-2 FS EU 72-64 72 Function & Structure Operator Station Group Air Conditioner 4. Guidelines to determine quantities of refrigerant charge

5. Disconnecting the gauge manifold

Use the following table to determine the refrigerant charge quantity. Sleeve Item

Criteria

Doors

Completely open

Temperature control switches

Maximum cooling

Blower speed

High

Inside/outside air selection

Inside air

Number of rotations of engine

1,500 min-1

Air conditioner switch

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.

115ZV-2 FS EU 72-65 72 Function & Structure Operator Station Group Air Conditioner

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)

115ZV-2 FS EU 72-66 72 Function & Structure Operator Station Group Air Conditioner

When the refrigerant charge quantity is insufficient <Low pressure side> 49~98 kPa (0.5~1.0 kgf/cm2) (7~14 psi)

<High pressure side> 686~981 kPa (7~10 kgf/cm2) (100~144 psi)

When the refrigerant does not circulate (due to clogging in the cooling circuit) <Low pressure side> Negative value

<High pressure side> 490~588 kPa (5~6 kgf/cm2) (71~85 psi)

97ZV72092

Symptom

Cause

- Pressure is low on both low and high pressure sides.

- Refrigerant quantity is insufficient.

- Gas bubbles go through sight glass continuously.

- Gas is leaking.

- Temperature of blown air is not cold.

Inspection/action point - Find and repair leaks. - Repair leak. Add refrigerant. - If pressure indicated by gage is around "0", detect and repair leaks, vacuum system and recharge.

97ZV72093

Symptom

Cause

Inspection/action point

- If cooling circuit is completely blocked, needle on low pressure side indicates a vacuum immediately.

Clogging in cooling circuit

- Inspect receiver dryer, expansion valve, etc. (Temperature is different between IN and OUT of failing part.)

- If cooling circuit is partially blocked, needle on low pressure side slowly indicates a vacuum.

- After finishing work, evacuate system and recharge.

115ZV-2 FS EU 72-67 72 Function & Structure Operator Station Group Air Conditioner

When the moisture has entered into the cooling circuit. <Low pressure side> Abnormal status Vacuum

<Low pressure side> 392~588 kPa (4~6 kgf/cm2) (57~85 psi)

<High pressure side> 686~981 kPa (7~10 kgf/cm2) (100~144 psi)

Normal status 215~275 kPa (2.2~2.8 kgf/cm2) (31~40 psi)

When the compression in compressor is defective. <High pressure side> 686~981 kPa (7~10 kgf/cm2) (100~144 psi)

1,470~1,765 kPa (15~18 kgf/cm2) (213~255 psi)

97ZV72095

97ZV72094

Symptom

Cause

Inspection/action point

- Air conditioner operates normally for a while after startup, but pressure on low pressure side indicates a vacuum value later.

Expansion valve is frozen due to entry of moisture.

- Inspect expansion valve, replace if needed. - Replace receiver dryer. - After finishing work, evacuate system completely and recharge.

Symptom

Cause

Inspection/action point

- Pressure on low pressure side is unusually high, and pressure on high pressure side is unusually low.

Compressor is defective.

- Review 2nd symptom.

- Shortly after air conditioner turns off, pressure becomes equal between high pressure side and low pressure side.

- If pressure in compressor is low, compressor will not build much heat due to lack of pressure. - Replace compressor. - After finishing work, evacuate system and recharge.

115ZV-2 FS EU 72-68 72 Function & Structure Operator Station Group Air Conditioner

When there is too much refrigerant or cooling in the condenser is insufficient <Low pressure side> 245~343 kPa (2.5~3.5 kgf/cm2) (35~50 psi)

When air has entered into the cooling circuit

<Low pressure side> 245~294 kPa (2.5~3.0 kgf/cm2) (35~43 psi)

<High pressure side> 1,961~2,452 kPa (20~25 kgf/cm2) (284~355 psi)

97ZV72097

97ZV72096

Symptom

Cause

Inspection/action point

Symptom

Cause

Inspection/action point

- Pressure is high on both low pressure side and high pressure side.

- Refrigerant quantity is too much.

- Check and correct refrigerant charge pressure.

- Pressure is high on both low pressure side and high pressure side.

Air has entered system.

- Refrigerant is bad.

- Plugged or bent condenser fins.

- Inspect and repair condenser fins.

- Even when engine rpm’s (min-1) are reduced, gas bubbles cannot be seen at all in sight glass. - Air in cab does not become cool enough.

- Bad fan motor or fan blade. - Heat transfer does not occur in evaporator has plugged fins

- Repair or replace fan or fan motor - Inspect and repair evaporator fins.

- Low pressure piping is not cold.

- Evacuate system completely.

- Gas bubbles go through sight glass.

- Replace refrigerant.

115ZV-2 FS EU 72-69 72 Function & Structure Operator Station Group Air Conditioner

When the expansion valve is opened too much <Low pressure side> 294~392 kPa (3.0~4.0 kgf/cm2) (43~57 psi)

<High pressure side> 1,961~2,452 kPa (20~25 kgf/cm2) (284~355 psi)

97ZV72098

Symptom

Cause

Inspection/action point

- Pressure is high on both low pressure side and high pressure side.

Expansion valve is defective.

- Temperature sensing rod may be sticking. - Inspect expansion valve. Check temp in and out of valve to determine if it is operating correctly.

- Condensation forms on low pressure side pipes.

Thermal expansion valve

To and from evaporator

Diaphragm

Spring

Temperature sensing rod Needle valve Compressor return From receiver dryer

97ZV72049

115ZV-2 FS EU 72-70 72 Function & Structure Operator Station Group Troubleshooting

Troubleshooting  Error code table

Air conditioner Fault diagnosis procedure

Display

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

E-

No failure

E11

Wire breakage in inside air sensor

E12

Short-circuit in inside air sensor

E13

Wire breakage in outside air sensor

E14

Short-circuit in outside air sensor

E15

Wire breakage in water temperature sensor

E16

Short-circuit in water temperature sensor

E18

Short-circuit in insolation sensor

E21

Wire breakage in vent sensor

E22

Short-circuit in vent sensor

E43

Abnormality in vent damper

E44

Abnormality in air mixing damper

E45

Abnormality in inside/outside air

E51

Abnormality in refrigerant pressure

115ZV-2 FS EU 72-71 72 Function & Structure Operator Station Group Troubleshooting 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

Examine the cause of over-voltage before taking the corrective measure.

See D-2 .

See D-1 .

See C-3 .

Check the wiring. Replace the servo motor with a new one. Remove the foreign matter.

Replace the V-belt with a new one. Replace the compressor with a new one. Repair the magnet switch, or replace it with a new one. Check the wiring.

Operation of low-pressure cut function

Wiring failure, disconnection, disengaged connector Servomotor failure Blocked foreign matter

Magnet clutch failure Clutch engagement failure due to electrical system failure

Broken or slipped belt Compressor failure (locking)

Insufficient refrigerant.

See C-3 . See C-4 . See C-5 .

High pressure both at high-pressure side and low-pressure side Low pressure both at high-pressure side and low-pressure side

See C-2 .

Too low pressure at high-pressure side(Pressure is not increased to approx. 981kPa[10kgf/cm2] or over) Too low pressure at low-pressure side(Pressure is decreased to approx. 49kPa[0.5kgf/cm2] or less

Close the window and door. Adjust the inside/outside air changeover damper. Re-set the link.

∗ Examine the cause before taking the corrective measure,and then replace the fuse with that of the same capacity. See B-1 . Replace the blower main relay with a new one. Replace the blower motor with a new one. Correct the interference. Replace the panel with a new one. Earth the body securely. Check the wiring. Replace the motor with a new one.

Too high pressure at low-pressure side(approx. 294kPa[3kgf/cm2] or over)

Disengaged A/M link

Mixing of outside air

Wiring failure, disconnected connector Operation of BLC protective function due to locked motor

Blown fuse Blower main relay failure Blower motor failure Interference of blower with case Blower switch failure Body earth failure

Operation of BLC over-voltage protective function

Check the battery charging system. Correct the contact failure. Replace the blower motor with a new one. Replace the BLC with a new one.

See A-1 .

See C-1 .

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

Decreased supply voltage Battery terminal contact failure Blower motor rotation failure BLC failure

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

115ZV-2 FS EU 72-72 72 Function & Structure Operator Station Group Troubleshooting

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

115ZV-2 FS EU 72-73 72 Function & Structure Operator Station Group Troubleshooting

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

115ZV-2 FS EU 72-74 72 Function & Structure Operator Station Group Troubleshooting

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

Excessively high pressure [2452 kPa(25kgf/cm2)or over]

Replace the control panel with a new one.

Compressor clutch relay failure

High-pressure error

Replace the control panel with a new one.

Blower switch failure

Re-charging

Battery voltage drop

Air conditioner switch failure

Replacement

Rare-short in coil

Disassembling/repair

Remove the oil.

Foreign matter caught between rotor and stator

Replace the key with a new one.

Stained clutch surface due to oil

Repair or replacement Slippage due to broken key or key insertion failure

Excessive air gap between rotor and stator

Slipped clutch

Replacement

Disconnected stator coil

115ZV-2 FS EU 72-75 72 Function & Structure Operator Station Group Troubleshooting

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"

115ZV-2 FS EU 72-76 72 Function & Structure Operator Station Group Troubleshooting

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

115ZV-2 FS EU 72-77 72 Function & Structure Operator Station Group Troubleshooting

80V2E01018

115ZV-2 FS EU 72-78 72 Function & Structure Operator Station Group

MEMO

115ZV-2 FS EU 73-1 73 Check & Adjustment Operator Station Group

73 Check & Adjustment Operator Station Group Air Conditioner ........................................................ 73-2

115ZV-2 FS EU 73-2 73 Check & Adjustment Operator Station Group Air Conditioner

Air Conditioner Adjustment of lubricating oil quantity when components of air conditioner are replaced

WARNING In order to protect the environment, do not release refrigerant to atmosphere when removing components from air conditioner system. It not illegal to do so.

IMPORTANT

Fig. 1 97ZV73002

- When replacing components of the air conditioner, if the lubricant oil quantity is too small, the compressor may seize. And if the lubricating oil quantity is too much, the cooling ability may lessen. Use the correct amount of compressor lube oil. - When connecting a joint, apply compressor oil (ND-OIL 8) on the O ring before tightening (Fig. 1). - If the compressor oil (ND-OIL 18) is applied to paint, paint may peel or otherwise be damaged. If it gets on a painted surface, quickly wipe it off. - Tighten the piping, etc. at the recommended torque. Tightening torque table Connection area

Nut type (Fig. 2) Fig. 2 97ZV73003

Block joint (Fig. 3)

Fig. 3

97ZV73004

Pipe size or bolt size

Tightening torque N-m (kgf-cm) (lb-ft)

ø8 pipe

14.7 (150) (7)

1/2 pipe

24.5 (250) (18)

5/8 pipe

34.3 (350) (25)

M6 bolt in receiver (4T)

6.9 (70) (5)

Any M6 bolt other than above (6T)

11.8 (120) (9)

115ZV-2 FS EU 73-3 73 Check & Adjustment Operator Station Group Air Conditioner

When the compressor is replaced

New compressor

Old compressor to be replaced

Compressor mounting bolt 29 N-m (3.0 kgf-m) (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) Example

Oil quantity remaining inside circuit

Suppose that the oil quantity (A) removed from the compressor to be replaced is 100 cm3. See figure 1.

(B)

Oil quantity remaining inside circuit (B) = 180 cm3 - (100 + 20) = 60 cm3

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. Torque values

Remove 60 cm3 from the new compressor to avoid overloading the circuit.

115ZV-2 FS EU 73-4 73 Check & Adjustment Operator Station Group Air Conditioner

When the evaporator is replaced

When the condenser is replaced Quantity of lubricating oil lost by replacement of condenser is approximately 40 cm3 (1.35 oz).

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)

115ZV-2 FS EU 73-5 73 Check & Adjustment Operator Station Group Air Conditioner

Adjustment of air gap (between hub and rotor) in compressor magnetic clutch

1. Remove the front cover of the magnetic clutch. 2. Measure dimension A between rotor end face and hub end face while magnetic clutch is "OFF". 3. Apply the battery voltage directly on the connector of the magnetic clutch, and measure the size of B in the same way as step 2 above. Note the difference.

Position while magnetic clutch is OFF

A (OFF status) Position while magnetic clutch is ON

Reference plane Air gap 0.50±0.15 mm (0.020±0.006 in)

Standard (normal dimension) of air gap (A - B) 0.50±0.15 mm (0.020±0.006 in) If the obtained value does not agree with the criteria, loosen the head bolt, remove the hub, and adjust the air gap by adjusting the thickness of the washer plate between the hub and the shaft.

B (ON status)

Hub Head bolt Washer plate

Rotor

95ZVE73002

WARNING Shut off the engine to do this procedure. If you try to adjust air gap while engine is "ON", a serious accidents would occur. Turn starter switch "OFF", stop rotation of engine tag out unit, pull out starter key, then start adjustment. Use a "Do Not Start" tag on the machine when performing this work.

115ZV-2 FS EU 73-6 73 Check & Adjustment Operator Station Group Air Conditioner

Compressor V-belt adjustment A

A 1

2 6 5 4 3

1 2

4 3 7

Engine

A-A 1. Compressor 2. Bracket mounting bolt 3. Lock nut 4. Adjusting nut 5. V-belt 6. Bracket 7. Bolt

K115V2U73002

115ZV-2 FS EU 73-7 73 Check & Adjustment Operator Station Group Air Conditioner

Belt adjustment procedure 1. Loosen four bracket mounting nuts (2). : Bracket mounting nut (2): 53.0 N-m (5.4 kgf-m) (39 lb-ft) 2. Turn adjusting nut (4) counterclockwise to tighten V-belt (5) by sliding bracket (6) upward. Turn adjusting nut (4) clockwise to loosen the Vbelt. : Lock nut (3): 53.0 N-m (5.4 kgf-m) (39 lb-ft) Adjusting nut (4): 53.0 N-m (5.4 kgf-m) (39 lb-ft) 3. After the adjustment, tighten the lock nut, adjusting nut and the bracket mounting nuts securely.

Belt adjustment value

85V2E73002

Adjust the V-belt tension so that the belt tension at A part is 353±88 N (36±9 kgf) (79±20 lbf) by using tension gauge. Note The V-belt tension should be 559±108 N (57±11 kgf) (125±24 lbf) when the belt is replaced with new one.

115ZV-2 FS EU 73-8 73 Check & Adjustment Operator Station Group Air Conditioner

Parts to be replaced periodically

Receiver dryer

Air filters

Replacement Once every 3 years or 6,000 hours

Air filter for outside air Cleaning Once every 2 weeks or when required. However, if the operating environment is severe (with much sand, dust, etc.) and the air filter is easily clogged, clean it more frequently. To clean, blow filter with compressed air of 196~294 kPa (2~3 kgf/cm2) (28~43 psi) mainly from inside of filter. Replacement Once each year or when required. When air flow volume is so small as to affect air movement even after the filter has been cleaned, or when the air filter has been cleaned 20 times, replace it.

Air filters for inside air Cleaning Once each month However, if the air filters are easily clogged, clean them more frequently. To clean, blow filter with compressed air of 196~294 kPa (2~3 kgf/cm2) (28~43 psi) mainly from inside of the filter. Replacement Once every 3 years When air flow volume is so small as to affect air movement even after the filter has been cleaned, or when the air filter has been cleaned 6 times, replace it.

Note When replacing the receiver dryer, do not release the refrigerant into the atmosphere.

INDEX A Accelerator pedal ............................................................62-33 Accelerator pedal installation ..........................................62-35 Accumulator ......................................................................52-9 Accumulator (for ride control) .........................................42-62 Accumulator assembly ....................................................32-37 Accumulator function ......................................................42-62 Accumulator low pressure sensor .....................................52-8 Accumulator structure .....................................................32-37 Adapter (Orifice) .............................................................42-52 Adjustable declutch preset switch ...................................62-50 Adjusting set pressure ....................................................42-44 Adjusting shim ..................................................................13-6 Adjusting tooth contact .....................................................23-9 Adjustment ........................................................................13-5 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) ............................72-18 Air Conditioner ...................................................... 72-14, 73-2 Air conditioner components ............................................72-14 Air conditioner functions of components .........................72-25 Air conditioner specifications (system performance) ......72-14 Air conditioner unit ..........................................................72-32 Air conditioner .................................................................72-70 Air distributor (hood & defroster selection box) ...............72-17 Air filters ............................................................................73-8 All setting reset .............................................................62-106 Alternator ........................................................................62-21 Alternator I terminal wire .................................................62-17 Auto Brake ......................................................................52-33 Auto brake ......................................................................62-54 Auto brake circuit ............................................................52-33 Auto brake operation set value .......................................52-33 Automatic shift ................................................................62-44 Automatic shift (with lock-up solenoid) ................. 32-6, 62-45 Axle ...................................................................................23-5 Axle Assembly ...................................................... 22-12, 92-2 Axle nut tightening procedure ...........................................23-5 Axle Support ...................................................................22-14

B Back-up alarm .................................................................62-51 Battery relay ....................................................................62-16 Battery relay operation ....................................................62-16 Bearing installation ...........................................................23-8 Belt adjustment procedure ................................................73-7 Belt adjustment value .......................................................73-7 Bleeding air from brake pipes and axle housing hubs ....................................................................................52-21 Bleeding air from parking brake housing ........................52-21 Bolt tightening torque ......................................................00-12 Boom cylinder .................................................................42-21 Boom spool operation .....................................................42-49

Brake Circuit ..................................................................... 92-6 Brake circuit air bleeding procedure ............................... 52-20 Brake Circuit Check Valve .............................................. 52-32 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 ............................................................... 42-21 Bucket hinge pin section (#1) ........................................... 13-3 Bucket leveler ............................................................... 62-109 Bucket link pin section (#2) .............................................. 13-4 Bucket spool operation ................................................... 42-47

C Cabin ................................................................................ 72-2 Caution for diode check method ................................... 62-116 Cautions on Hydraulic Parts Replacement ....................... 42-3 Cautions on installing brake discs .................................... 53-8 Cautions on Safety ........................................................... 03-2 Cautions regarding parts removal .................................. 00-17 Cautions regarding reassembly ...................................... 00-17 Cautions regarding welding repair service ..................... 00-19 Center Pin ............................................................... 12-7, 13-6 Changing display from one function to next ................... 62-71 Charge of refrigerant ...................................................... 72-53 Check valve ........................................................... 42-6, 42-57 Clear active fault log (error pop up) (S/N 9001~9216, 9218~9222, 9224~9226) ................ 62-86 Clear fault log ................................................................. 62-85 Clutch combination ........................................................... 32-9 Clutch Oil Pressure and Time Lag ................................... 33-2 Clutch oil pressure measurement procedure ................... 33-3 Clutch Pack .................................................................... 32-14 Clutch solenoid valve assembly ..................................... 32-33 Clutch specifications ....................................................... 32-10 Clutch valve assembly .................................................... 32-36 Column shaft .................................................................. 72-13 Compressor and magnetic clutch ................................... 72-41 Compressor V-belt adjustment ......................................... 73-6 Condenser unit .................................................... 72-18, 72-44 Connection diagram ....................................................... 62-22 Connector ....................................................................... 62-37 Continuity check mode ................................................. 62-116 Control panel .................................................................. 72-25 Control schematic drawing ............................................. 72-24 Control unit ..................................................................... 72-19 Control Valve Assembly ................................................. 32-31 Conventional type ........................................................... 22-16 Coolant ............................................................................. 00-9 Coolant specification ........................................................ 00-9 Cooling circuit ................................................................. 72-23

Cooling unit .................................................................... 72-15 Cylinder natural drift ....................................................... 43-14 Cylinders .......................................................................... 42-4

D Denso air conditioner structure ...................................... 72-15 Detent solenoid ............................................... 62-110, 62-114 Differential Gear ............................................................. 22-16 Differential gear adjustment procedure ............................ 23-6 Diode ............................................................................ 62-115 Diode check method .................................................... 62-116 Diode check mode ....................................................... 62-116 Diode unit ....................................................................... 62-17 Direct charge valve ........................................................ 32-38 Directional control valve ................................................... 42-6 Display language ............................................................ 62-83 Downshift button operation ................................... 32-9, 62-47 Dust seal .......................................................................... 12-9

E ECM (Engine Controller) ................................................ 62-22 ECM safety features ....................................................... 62-16 Efficient Loading System ................................................ 42-87 Efficient loading system ................................................... 42-9 Efficient loading system operation ................................. 42-90 Efficient loading system outline ...................................... 42-87 Electrical Cable Color Codes ........................................... 62-8 Electrical circuit .............................................................. 72-24 Electrical Circuit Diagram (Cabin Air Conditioner) ......... 92-29 Electrical Circuit Symbols ................................................. 62-9 Electrical Connection Diagram (1/2) (S/N 9001~9050) .................................................................................... 92-31 Electrical Connection Diagram (1/2) (S/N 9051~9100) .................................................................................... 92-33 Electrical Connection Diagram (1/2) (S/N 9101~9200) .................................................................................... 92-35 Electrical Connection Diagram (1/2) (S/N 9201~) .......... 92-37 Electrical Connection Diagram (2/2) (S/N 9001~9050) .................................................................................... 92-32 Electrical Connection Diagram (2/2) (S/N 9051~9100) .................................................................................... 92-34 Electrical Connection Diagram (2/2) (S/N 9101~9200) .................................................................................... 92-36 Electrical Connection Diagram (2/2) (S/N 9201~) .......... 92-38 Electrical Detent Circuit ................................................ 62-109 Electrical Equipment Layout ........................................... 92-39 Electrical Wiring Diagram ............................................... 92-22 Electrical Wiring Diagram (1/3) (S/N 9001~9006) ............ 92-7 Electrical Wiring Diagram (1/3) (S/N 9007~9050) .......... 92-10 Electrical Wiring Diagram (1/3) (S/N 9051~9100) .......... 92-13 Electrical Wiring Diagram (1/3) (S/N 9101~9200) .......... 92-16 Electrical Wiring Diagram (1/3) (S/N 9201~) .................. 92-19 Electrical Wiring Diagram (2/3) (S/N 9001~9006) ............ 92-8 Electrical Wiring Diagram (2/3) (S/N 9007~9050) .......... 92-11 Electrical Wiring Diagram (2/3) (S/N 9051~9100) .......... 92-14 Electrical Wiring Diagram (2/3) (S/N 9101~9200) .......... 92-17 Electrical Wiring Diagram (2/3) (S/N 9201~) .................. 92-20 Electrical Wiring Diagram (3/3) (S/N 9001~9006) ............ 92-9 Electrical Wiring Diagram (3/3) (S/N 9007~9050) .......... 92-12

Electrical Wiring Diagram (3/3) (S/N 9051~9100) .......... 92-15 Electrical Wiring Diagram (3/3) (S/N 9101~9200) .......... 92-18 Electrical Wiring Diagram (3/3) (S/N 9201~) .................. 92-21 Electrical Wiring Diagram (CAB) ....................................92-26 Electrical Wiring Diagram (Cabin Air Conditioner) .......... 92-28 Electrical wiring diagram abbreviation chart ................... 92-24 Engine ..............................................................................23-2 Engine / Transmission ...................................................... 22-3 Engine / transmission mount ............................................22-3 Engine diagnostic switch (option) ................................... 62-24 Engine fault log navigation .............................................62-85 Engine Start Circuit ......................................................... 62-13 Engine start circuit diagram ............................................ 62-13 Equipment Operation Table (Cabin Air Conditioner) ......92-30

F Failure diagnosis ............................................................ 62-24 Failure diagnostic chart ..................................................62-25 Fan motor ..................................................................... 42-100 Fan Motor Line ............................................................... 42-92 Fan motor specifications ............................................... 42-104 Fan Motor System .......................................................... 42-91 Fan motor system .............................................................42-9 Fault log history check .................................................... 62-83 Fault Log Monitor ............................................................ 62-83 First propeller shaft assembly ........................................... 22-9 Flanged hexagon bolt .....................................................00-15 Floor board ....................................................................... 12-6 Floor board mount ............................................................ 12-6 Flow amplifier notch and pilot orifice .............................. 42-82 Flow control valve .............................................................42-5 Flushing Hydraulic Circuit ................................................. 42-2 For high, low, reverse and speed clutches ..................... 32-35 Forward 1st speed power flow path ................................ 32-15 Forward 2nd speed power flow path .............................. 32-16 Forward 3rd speed power flow path ...............................32-16 Forward 4th speed power flow path ...............................32-17 Forward/reverse (F/R) shifting and speed change ......... 62-42 Friction plate: mm (in) .....................................................32-11 From accumulator to clutch valve ................................... 32-23 From clutch solenoid valve to clutch valve assembly ..... 32-22 From cooler to lubrication circuit .....................................32-22 From direct charge valve to clutch valve ........................ 32-23 From torque converter gear pump to clutch solenoid valve assembly ..................................................................... 32-22 From torque converter gear pump to lock-up clutch (option) ....................................................................................32-22 From torque converter gear pump to torque converter ....................................................................................32-22 From torque converter to cooling circuit .........................32-22 Front Chassis ...................................................................12-2 Front differential – Transmission ....................................22-10 Front wiper ........................................................................72-7 Fuel gauge circuit ...........................................................62-69 Fuel tank ...........................................................................12-5 Function of differential gear ............................................ 22-19 Function of ECM ............................................................. 62-22 Fuse ................................................................................ 62-11 Fuse box .........................................................................62-11 Fusible link ......................................................................62-12

G Gauge circuit ...................................................................62-67 Gear pump specifications .................................................32-7 Gear train and number of teeth .......................................32-10 Glass .................................................................................72-4

H Heater and accessories ..................................................72-17 Hexagon bolt ...................................................................00-12 Hose band tightening torque ...........................................00-16 How to assemble .................................................... 13-3, 13-4 How to Use Electrical Wiring Diagram ..............................62-2 How to Use Manual ..........................................................00-2 How to wind a seal tape ..................................................00-18 Hydraulic & Brake Circuit ..................................................92-5 Hydraulic circuit (fan motor normal rotation) ...................42-94 Hydraulic circuit (Reverse rotation) ...............................42-107 Hydraulic Circuit Diagram ...............................................32-20 Hydraulic Circuit Symbols .................................................42-4 Hydraulic Cylinder ............................................... 42-21, 43-14 Hydraulic cylinder specifications .....................................42-23 Hydraulic lines ..................................................................42-4 Hydraulic oil level check .................................................42-16 Hydraulic Pump ..............................................................42-17 Hydraulic pump bushing lubrication ................................42-20 Hydraulic pump oil amount and steering force ...............42-69 Hydraulic pump principle ................................................42-19 Hydraulic pump wear plate .............................................42-20 Hydraulic System Diagram .............................................32-19 Hydraulic System Operation .............................................42-8 Hydraulic system operation outline ...................................42-8 Hydraulic Tank ................................................................42-11 Hydraulic Tank (S/N 9001~9150) ...................................42-11 Hydraulic Tank (S/N 9151~) ...........................................42-13 Hydraulic tank breather valve (tank cap) (S/N 9001~9150) ....................................................................................42-12 Hydraulic tank breather valve (tank cap) (S/N 9151~) ....42-14 Hydraulic tank specifications ..........................................42-15

I Increment decrement switch (option) ..............................62-26 Information Monitor .........................................................62-73 Information monitor display .............................................62-73 Input/Output Monitor .......................................................62-90 Input/Output monitor display ...........................................62-90 Inspection and maintenance table ....................................00-5 Installing bearing cover .....................................................13-6 Installing bearing outer ring ..............................................13-7 Instrument panel .............................................................62-63 Instrument Panel and Switch ..........................................62-63 Instrument panel rear surface .........................................62-65 Interior schematic (simple explanation) ..........................32-27 Items to be monitored and operation condition ...............62-60

L Layout of Hydraulic Units ................................................42-10 Layout of main components ..............................................00-4 Left turn position .............................................................42-74

Lift kickout .................................................................... 62-111 Lift kickout & lower kickout ........................................... 62-111 Limit switch ..................................................................... 32-23 Limited Slip Differential (option) (S/N 9054~) ................. 22-21 Liner ................................................................................. 13-2 Linkage Pin ....................................................................... 13-2 Liquid gasket and screw lock agent ............................... 00-17 Loading and pilot and brake pump ................................. 42-17 Loading circuit relief valve setting pressures .................... 43-2 Loading linkage ................................................................ 12-2 Loading linkage pin .......................................................... 12-4 Loading System .............................................................. 42-24 Loading system ................................................................ 42-8 Loading/Steering Circuit Relief Valve/Ride Control Circuit Reducing Valve (OPT) ....................................... 43-2 Location ........................................................................ 62-111 Lock-up clutch function (only forward) .............................. 32-5 Lock-up clutch solenoid valve ........................................ 32-39 Lock-up clutch structure ................................................... 32-5 Lower center pin ............................................................... 12-8 Lower kickout ............................................................... 62-111 LSD function ................................................................... 22-22 LSD operation ................................................................ 22-22 LSD structure ................................................................. 22-21 Lubrication chart ............................................................. 00-10

M Machine control unit (MCU) ............................................ 62-36 Machine control unit (MCU) failure warning ................... 62-57 Machine control unit (MCU) function .............................. 62-42 Machine fault log navigation ........................................... 62-85 Machine speed sensor ................................................... 62-46 Magnetic switch .............................................................. 62-19 Main relief valve operation ............................................. 42-43 Make-up valve ................................................................ 42-94 Make-up valve operation ..................................... 42-46, 42-80 MCU connection diagram (S/N 9001~9200) .................. 62-38 MCU connection diagram (S/N 9201~) .......................... 62-40 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 reducing valve 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 ............................................................................ 62-70 MODM function .............................................................. 62-70 MODM: Input/Output Monitor - Input/Output Signal Correspondence Table ............................................... 92-57 Modulation at clutch switching ........................................ 62-48 Modulation Mechanism .................................................. 32-28 Modulator valve function ................................................ 32-28 Modulator valve operation ................................... 32-29, 62-49 Modulator Valve Unit ...................................................... 32-25 Monitor Changeover ....................................................... 62-70

Monitor lamp test ............................................................ 62-23 Monitoring system .......................................................... 62-60 Mounting of fan motor .................................................... 42-91 Mounting of the ELS valve ............................................. 42-88 Mounting of the variable kickout sensor ......................... 42-89 Multiple Control Valve (KML35A/2T103) ........................ 42-41 Multiple control valve boom spool .................................. 42-49 Multiple control valve bucket spool ................................ 42-47 Multiple control valve main relief valve ........................... 42-43 Multiple control valve make-up valve ............................. 42-46 Multiple control valve overload relief valve (with make-up function) ...................................................................... 42-45 Multiple control valve specifications ............................... 42-42

N Neutral ............................................................................ 42-66 Neutral position (steering spool in "Neutral") ................. 42-73 Neutral relay ................................................................... 62-18 Neutral starter ................................................................ 62-14

O Oil Flow .......................................................................... 32-22 Oil flow in the torque converter line ................................ 32-22 Oil flow in the transmission line ...................................... 32-22 Oil seal installation ........................................................... 23-8 Operation methods ........................................................... 42-5 Operation monitor lamps ................................................ 62-62 Operation of differential gear .......................................... 22-19 Operation of parking brake ............................................. 52-25 Operator Seat ................................................................. 72-10 Orbit rotor operation principle ......................................... 42-70 Orbitrol® .......................................................................... 42-64 Orbitrol® feed-back mechanism operation ..................... 42-68 Orbitrol® operation .......................................................... 42-66 Orbitrol® specifications ................................................... 42-65 Orbitrol® structure ........................................................... 42-64 Outline .............................................................................. 00-4 Outline of MODM (Machine Operation Diagnostic Module) Operation .................................................................... 92-48 Overload relief valve operation ........................... 42-45, 42-80

P Parameter change ........................................................ 62-102 Parameter Setting Monitor ............................................. 62-94 Parameter setting monitor display .................................. 62-94 Parking Brake ........................................................ 52-22, 53-9 Parking brake ........................................................ 52-2, 62-52 Parking brake friction disc .............................................. 52-28 Parking Brake Manual Release ...................................... 52-30 Parking brake operation ................................................. 52-25 Parking brake performance check ................................... 53-9 Parking brake solenoid valve ......................................... 52-29 Parking brake steel plate ................................................ 52-28 Part number 32011-21500 ............................................... 72-6 Part number 32011-21690 ............................................... 72-5 Part number 32011-21700 ............................................... 72-5 Parts to be replaced periodically ...................................... 73-8 Pilot valve (S/N 9001~9100) .......................................... 42-26 Pilot valve (S/N 9101~9105) .......................................... 42-31

Pilot valve (S/N 9106~) ...................................................42-36 Pilot valve function ................................... 42-28, 42-33, 42-38 Pilot valve operation (modulated position) ............................................................. 42-28, 42-33, 42-38 Planetary gear ..................................................................32-9 Power flow path ................................................................32-3 Power Flow Path in the Transmission ............................32-15 Power Generating/Charging Circuit ................................ 62-21 Power Line ........................................................................22-2 Power transmission ........................................................22-19 Pre-detent and detent magnet solenoid ............................................................. 42-30, 42-35, 42-40 Preload adjustment ........................................................... 23-7 Preparation mode (ride control switch is OFF) ............... 42-54 Preset height adjustment .............................................. 62-114 Pressure control valve ...................................................... 42-5 Pressure relief valve ....................................................... 72-50 Pressure sensor (for Declutch) .......................................52-38 Pressure sensor (for declutch) .......................................52-36 Pressure Sensor (for stop lamp and declutch) ............... 52-36 Pressure sensor (for stop lamp) .....................................52-36 Pressure switches .......................................................... 72-48 Principle of cooling ......................................................... 72-20 Propeller Shaft .........................................................22-8, 23-3 Propeller shaft phase ........................................................ 23-3 Propeller shaft tightening torque .......................................23-4 Proportional relief valve (S/N 9001~9050) ......................42-96 Proportional relief valve (S/N 9051~) .............................. 42-98 Proportional relief valve operation ..................................42-96 Proximity switch ............................................................ 62-109 Pump specifications ........................................................42-17 Pumps & motors ............................................................... 42-4 Purpose of flushing ........................................................... 42-2

Q Quantum fault code information .....................................62-27

R Radiator (S/N 9001~9050) ................................................ 22-4 Radiator (S/N 9051~) ........................................................ 22-6 Radiator mount ................................................................. 22-5 Rear Chassis .................................................................... 12-5 Rear wiper ........................................................................72-7 Receiver dryer .......................................................72-46, 73-8 Recommended lubricants ................................................. 00-8 Recommended mixture of antifreeze ................................ 00-9 Reducing valve ............................................................... 42-57 Reducing valve (for Autobrake circuit) ............................52-34 Reducing Valve (for Orbitrol®) ........................................ 42-85 Reducing Valve (for Pilot Pressure) ...............................42-25 Refrigerant ......................................................................72-21 Refrigerant characteristics .............................................. 72-22 Refrigerant charging procedure ...................................... 72-59 Refrigerant charging tools .............................................. 72-56 Refrigerant hose ............................................................. 72-52 Relay A ........................................................................... 72-51 Relay B ........................................................................... 72-51 Replacement interval pop-up ..........................................62-82 Replacement interval set (timer reset) ............................62-81

Replacement Monitor ......................................................62-77 Replacement time check ................................................62-77 Resistance check mode ................................................62-117 Reverse 1st speed power flow path ................................32-17 Reverse 2nd speed power flow path ..............................32-18 Reverse 3rd speed power flow path ...............................32-18 Reversing fan control chart ...........................................42-106 Reversing fan motor (OPT) ...........................................42-104 Reversing fan motor function ........................................42-103 Reversing Fan Motor Line (OPT) ..................................42-103 Ride Control (OPT) .........................................................42-53 Ride control circuit reducing valve setting pressures (OPT) ......................................................................................43-7 Ride control function .......................................................42-53 Ride control hydraulic circuit ...........................................42-53 Ride control operation .....................................................42-54 Ride control system (OPT) ...............................................42-9 Ride control valve assembly (Accumulator circuit) .........42-59 Ride control valve assembly (Reducing valve circuit) .....42-56 Rotor part ........................................................................42-65 Running mode (ride control switch is ON) ......................42-55

S Safety precautions ............................................................00-2 Screw lock agent application procedure .........................00-18 Second propeller shaft alignment .....................................23-3 Second propeller shaft assembly ....................................22-10 Secondary Steering ......................................................42-108 Secondary steering circuit ............................................42-108 Secondary steering function (OPT) ................................62-58 Secondary steering motor and pump ............................42-110 Secondary steering operation .......................................42-109 Selection of machine fault log and engine fault log ........62-84 Selector valve .................................................................42-61 Sensor assy ..................................................................62-112 Sensor Mount .................................................................62-10 Service Brake ....................................................... 52-14, 53-6 Service brake ....................................................................52-2 Service brake friction disc ...............................................52-15 Service brake friction plate wear measurement ................53-7 Service brake operation ..................................................52-14 Service brake pedal stroke adjusting mechanism ..........52-18 Service brake performance check ....................................53-6 Service brake piston .......................................................52-17 Service brake steel plate ................................................52-16 Shift lever ........................................................................72-13 Shift lever forward/reverse (F/R) position .......................62-14 Shift lever neutral (N) position ........................................62-14 Shift lever position ............................................................32-9 Shuttle valve ...................................................................42-60 Sight glass ......................................................................72-48 Solenoid specifications ...................................................52-35 Solenoid valve .................................................... 42-58, 42-60 Solenoid valve (for Autobrake circuit) .............................52-35 Solenoid valve operation ................................................52-29 Solenoid valve specifications ..........................................52-29 Specification Setting Monitor ........................................62-103 Specification setting monitor display .............................62-103 Standard Measurement Values for Performance Check ......................................................................................03-3

Starter switch .................................................................. 62-15 Steel plate: mm (in) ........................................................ 32-12 Steering and Transmission Shift Lever .......................... 72-11 Steering circuit relief valve setting pressures ................... 43-9 Steering cylinder ............................................................. 42-22 Steering Line Filter ......................................................... 42-86 Steering pilot circuit and its operation ............................ 42-81 Steering pump ................................................................ 42-18 Steering pump specifications ......................................... 42-18 Steering speed and flow rate control .............................. 42-69 Steering spool variable throttle ....................................... 42-75 Steering System ............................................................. 42-63 Steering system ................................................................ 42-8 Steering Valve (KVS32-A4.0/21) .................................... 42-71 Steering valve flow control spool .................................... 42-76 Steering valve main relief valve ...................................... 42-77 Steering valve operation ................................................. 42-73 Steering valve overload relief valve ................................ 42-79 Stop Valve ........................................................... 42-83, 43-16 Stop valve adjustment procedure ................................... 43-16 Stop valve function ......................................................... 42-84 Stop valve operation ....................................................... 42-84 Straight ........................................................................... 22-19 Surge voltage and surge suppression diodes .............. 62-118 Symbols ............................................................................ 00-3

T T/C and T/M Oil Circulation ............................................ 32-24 The operation condition of ELS ...................................... 42-87 Third propeller shaft assembly ....................................... 22-11 Tilt case .......................................................................... 72-12 Time lag measurement procedure ................................... 33-4 Tolerance ring ................................................................ 52-19 Torque Converter ............................................................. 32-2 Torque Converter (Lock-up) (Option) ............................... 32-4 Torque Converter and Transmission ................................ 92-4 Torque Converter Gear Pump .......................................... 32-7 Torque Converter structure .............................................. 32-3 Torque multiplication ........................................................ 32-3 Traction Control Switch Mount ....................................... 92-58 Transmission .................................................................... 32-8 Transmission – Rear differential ..................................... 22-11 Transmission – Torque converter ..................................... 22-9 Transmission Control Circuit and Monitor Circuit ........... 62-36 Troubleshooting .............................................................. 72-70 Troubleshooting using the gauge manifold .................... 72-65 Turn ..................................................................... 22-20, 42-67

U Unit conversion and language selection ......................... 62-76 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 ....................................................................... 42-64 Valve Unit ......................................................................... 52-7

Viscous mount .................................................................. 12-6 Voltage relay .................................................................. 62-20

W Way of looking at connectors ......................................... 92-22 Weight of main components ........................................... 00-11 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 ................ 42-78 When the pressure is at the preset value or less ........... 42-77 While the ELS is not operating ....................................... 42-90 While the ELS is operating ............................................. 42-90 While the valve is not operating ..................................... 52-12 Wiper motor ...................................................................... 72-8 Wiper mount ..................................................................... 72-7 Work procedure .............................................................. 72-54

MEMO

Maintenance Log Date

Machine hours

Service performed

Date

Machine hours

Service performed

Date

Machine hours

Service performed

Date

Machine hours

Service performed

Notes

115ZV-2 FS EU 92-1 92 Drawing & Diagrams

92 Drawing & Diagrams Axle Assembly ......................................................................................................................... 92-2 Torque Converter and Transmission........................................................................................ 92-4 Hydraulic & Brake Circuit......................................................................................................... 92-5 Brake Circuit ............................................................................................................................ 92-6 Electrical Wiring Diagram (1/3) (S/N 9001~9006) ................................................................... 92-7 Electrical Wiring Diagram (2/3) (S/N 9001~9006) ................................................................... 92-8 Electrical Wiring Diagram (3/3) (S/N 9001~9006) ................................................................... 92-9 Electrical Wiring Diagram (1/3) (S/N 9007~9050) ................................................................. 92-10 Electrical Wiring Diagram (2/3) (S/N 9007~9050) ................................................................. 92-11 Electrical Wiring Diagram (3/3) (S/N 9007~9050) ................................................................. 92-12 Electrical Wiring Diagram (1/3) (S/N 9051~9100) ................................................................. 92-13 Electrical Wiring Diagram (2/3) (S/N 9051~9100) ................................................................. 92-14 Electrical Wiring Diagram (3/3) (S/N 9051~9100) ................................................................. 92-15 Electrical Wiring Diagram (1/3) (S/N 9101~9200) ................................................................. 92-16 Electrical Wiring Diagram (2/3) (S/N 9101~9200) ................................................................. 92-17 Electrical Wiring Diagram (3/3) (S/N 9101~9200) ................................................................. 92-18 Electrical Wiring Diagram (1/3) (S/N 9201~) ......................................................................... 92-19 Electrical Wiring Diagram (2/3) (S/N 9201~) ......................................................................... 92-20 Electrical Wiring Diagram (3/3) (S/N 9201~) ......................................................................... 92-21 Electrical Wiring Diagram ...................................................................................................... 92-22 Electrical wiring diagram abbreviation chart .......................................................................... 92-24 Electrical Wiring Diagram (CAB)............................................................................................ 92-26 Electrical Wiring Diagram (Cabin Air Conditioner)................................................................. 92-28 Electrical Circuit Diagram (Cabin Air Conditioner)................................................................. 92-29 Equipment Operation Table (Cabin Air Conditioner).............................................................. 92-30 Electrical Connection Diagram (1/2) (S/N 9001~9050) ......................................................... 92-31 Electrical Connection Diagram (2/2) (S/N 9001~9050) ......................................................... 92-32 Electrical Connection Diagram (1/2) (S/N 9051~9100) ......................................................... 92-33 Electrical Connection Diagram (2/2) (S/N 9051~9100) ......................................................... 92-34 Electrical Connection Diagram (1/2) (S/N 9101~9200) ......................................................... 92-35 Electrical Connection Diagram (2/2) (S/N 9101~9200) ......................................................... 92-36 Electrical Connection Diagram (1/2) (S/N 9201~) ................................................................. 92-37 Electrical Connection Diagram (2/2) (S/N 9201~) ................................................................. 92-38 Electrical Equipment Layout .................................................................................................. 92-39 Outline of MODM (Machine Operation Diagnostic Module) Operation.................................. 92-48 MODM: Input/Output Monitor - Input/Output Signal Correspondence Table ......................... 92-57 Traction Control Switch Mount............................................................................................... 92-58

115ZV-2 FS EU 92-2 92 Drawing & Diagrams Axle Assembly

Axle Assembly (S/N 9001~9202) The only difference between the front and rear axles is the differential housing (1) and axle housing (2). Other parts are the same as the rear axle assembly.

48 49 Brake adjustment mechanism

14 13

4 25

A-Detail

1. Differential assembly 2. Axle housing assembly 3. Wheel hub 4. Spider 5. Cover 6. Axle shaft 7. Sun gear 8. Disc gear 9. Planetary gear 10. Internal gear 11. Internal gear hub 12. Snap ring 13. Planetary pin 14. Wear ring 15. Wear ring 16. Brake piston 17. Separation disc 18. Friction disc 19. Brake backing plate 20. Plate 21. Axle nut 22. Taper roller bearing (inner) 23. Taper roller bearing (outer) 24. Separation disc 25. Needle cage 26. Axle lock plate

PT3/8 (Brake oil inlet)

39 33 52 38 9 5 27 7 8 20 15 51 37

2 32

26 41

30 21

34,35,36

37 115V2E92001

27. Snap ring 28. Floating seal 29. D-ring 30. D-ring 31. O-ring 32. O-ring 33. O-ring 34. Socket bolt 35. Spring 36. U-nut 37. Magnet plug 38. Bolt 39. Socket bolt 40. Air bleeder screw 41. Spring pin 42. Ring 43. O-ring 44. Spring pin 45. Plug 46. Spring 47. Sleeve 48. Bushing 49. Socket bolt 50. Bolt 51. Bolt 52. Flange bolt

115ZV-2 FS EU 92-3 92 Drawing & Diagrams Axle Assembly (S/N 9203~) The only difference between the front and rear axles is the differential housing (1) and axle housing (2). Other parts are the same as the rear axle assembly.

48 49 Brake adjustment mechanism

14 13

A-Detail

11 42 43

PT3/8 (Brake oil inlet)

33 52 38 9 5 27 7 8 20 15 51 37 32

26 41

30 21

34,35,36

37 115V2E92034

28. Floating seal 29. D-ring 30. D-ring 31. O-ring 32. O-ring 33. O-ring 34. Socket bolt 35. Spring 36. U-nut 37. Magnet plug (Square socket head) 38. Bolt 39. Socket bolt 40. Air bleeder screw 41. Spring pin 42. Ring 43. O-ring 44. Spring pin 45. Plug (Square socket head) 46. Spring 47. Sleeve 48. Bushing 49. Socket bolt 50. Bolt 51. Bolt 52. Flange bolt

115ZV-2 FS EU 92-4 92 Drawing & Diagrams Torque Converter and Transmission

Torque Converter and Transmission (T/M model: PS400D01~04)

- !* ' ("'& *)#, ! )#

2 !3( ' - !" !

' ("'& / ,, 0 *& !*1 !, ' ("'& / ,, 0 *& !*1 , ' ("'& / ,, 0 *& !*1

, ' ("'& *)#, ! )#

*" ' ("'& )#*"

! " # ! $ %

# & ! ' ("'& )#*"

$ ' ("'& )#*"

' () " !3( ' - !" !

" **

,$ !, ' ("'& )#*"

! " # !. % . + !# . (")(" *& %". & (*#

1. Pump impeller 2. Turbine impeller 3. Stator 4. Turbine shaft 5. Stator shaft (Fixed) 6. Drive cover 7. Ring gear 8. P.T.O. drive gear 9. P.T.O. driven gear 10. P.T.O. driven gear 11. Torque converter output flange 12. Transmission input flange 13. Transmission input gear 14. Transmission input shaft 15. High range clutch 16. Reverse clutch 17. Low range clutch 18. 3rd speed clutch 19. 2nd speed clutch 20. 1st speed clutch 21. Output gear 22. Output shaft 23. Output flange (2nd propeller shaft side) 24. Output flange (3rd propeller shaft side) 25. Modulator valve 26. Clutch solenoid valve 27. Clutch valve 28. Lock-up clutch 29. Lock-up piston

115ZV-2 FS EU 92-5 92 Drawing & Diagrams Hydraulic & Brake Circuit

Hydraulic & Brake Circuit

PA PA

105

(FM) 09701-03271A 115V2E92017

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. Pilot valve (stick) 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. Slow return check valve 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. Reducing valve (for auto-brake) 38. Reducing valve (pilot, parking brake) 39. — 40. — 41. — 42. — 43. — 44. — 45. — 46. — 47. — 48. — 49. Pressure sensor (for brake oil pressure)

(for secondary steering) (for efficient loading system) 50. — 51. Pressure sensor (for inching & 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)

115ZV-2 FS EU 92-6 92 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. Reducing valve (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 inching & 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. — 83. Suction strainer

Stop lamp turns on when pressure rises. 0.26 0.1 MPa2 (2.6 1 kgf/cm ) (38 14.5 psi) Inching is variable.

On when pressure drops. 3.9 0.5 MPa2 (40 5 kgf/cm ) (567 71 psi)

Capacity: 3.0 L Gas charging pressure: 2.94 0.1 MPa2 (30 1 kgf/cm ) (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 2 (70 10 kgf/cm ) (995 142 psi)

3.5 MPa 2 35.7 kgf/cm (512 psi)

0.3 0.06 MPa2 (3 0.6 kgf/cm ) (43.5 8.7 psi)

1.3 MPa 2 13.3 kgf/cm (185 psi)

1.0 kPa (0.01 kgf/cm2) (0.14 psi)

29.4 kPa 2 (0.3 kgf/cm ) (4.3 psi) 105 150

105 150

0.1 0.02 MPa2 (1 0.2 kgf/cm ) (14 2.8 psi)

(FM) 09701-03611 K115V2U92002

115ZV-2 FS EU 92-7 92 Drawing & Diagrams Electrical Wiring Diagram (1/3) (S/N 9001~9006)

Electrical Wiring Diagram (1/3) (S/N 9001~9006) FUEL EFFICIENT MODE SELECTION

(+)

8 5

8 RO RO BP B911 A815 G803 321 K101 323 RBr RBr BP B910 A814 G803 322 K103 323

3 8

Lg D103 013 GyW S823 200

5 Lg D103 013 GL S822 265

8 BW BrB D105 H747 012 722

3/4

SS WTM TTM

1/2

−

1/4

EMP GND

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 H749 H735 H763 S524 S734 S721 013 241 235 731 732 730 224 401 402 10

COMBINATION S/W FOR LAMPS

P RBr RO RW G703 A103 A106 F401 320 322 321 304

RB RY F601 F501 301 302

LR LBr B S911 S904 126 128 LW B S912 120 LY LG LO S910 S903 S905 121 122 123 RB A611 300

BW F005 271

BrG F004 255

R G B O Y V

DATA LINK CONNECTOR C7

REMOTE THROTTLE (EU:STANDARD)

SLIP CONTROL (EU:STANDARD)

AIR PROBE (TH AM )

3 8

YV S918 231

R RGy D109 C306 002 H728 R RGy D109 A801 002 310

RG RLg D113 C302 006 K105 RG RGy D113 A801 006 310 4

TORQUE SELECTION RELAY

E/G OIL PRESS. S/W RELAY

LgY F002 167 YO F003 176

Hi-BEAM RELAY

HEAD LAMP RELAY

6 RW R K108 D108 308 001 RY RY RW A813 F504 B912 K102 305 304

Gy GyR S816 H729 750 751 B B 1

Sb SbP H704 S509 205 202 RLg B H738 206 1

SbY SbR H737 S608 209 208 B B

(BLACK)

(BLUE)

WIDTH LAMP RELAY

NEUTRAL RELAY

BY G S707 S732 114 415

1 168 T606 B LP 271 167 T706 T608 BW LgY 255 176 T708 T601 BrG YO BrG YO S922 B001 255 176 BW LgY S813 A803 271 167 B LP S915 168

MCU FAULT RELAY

R R D108 D108 001 001 RY RY F402 B915 305 302

C403 K106 H756 300 4 303

LIFT KICKOUT RELAY

(BLACK)

LOWER KICKOUT RELAY

4 SPEED INDICATOR RELAY

(BLUE)

(BLACK)

SECONDARY EMERGENCY STEERING STEERING RELAY RELAY (EU: STANDARD) (EU:STANDARD)

L YGy E706 E704 005-a 242 B R H804 243 1

LG LW S502 S508 142 144 B LG A709 132 1

BrR L G202 D205 272 005-a B L S610 273 1

BrB L G402 D205 257 005-a B BrB S611 258 1

SbW L H703 D205 207 005-a RLg SbW H738 S615 206 203 1

Lg Lg D103 D103 013 013 LgSb LgBr G601 S609 112 104 1

LgW L A508 D205 102 005-a B LgW S612 101

DOWNSHIFT BUTTON

(BLUE)

(BLACK)

PILOT VALVE MAGNETS

4 YL YO H757 S2S H706 H758

8 Lg V703 013 GW V701 210

CAB ALARM BUZZER

S2L H759

AIR-SUS. OY D114 007

S2H W H760 D506 6

B 8

DIAG INC/DEC S/W

1 1

YSb S917 125

Br D110 003

1 (BLUE) Br

BrB

BrW

G D107 010

2 BP G A101 D107 A108 010 B

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

P R B909 D111 320 004 B

L 2

LgSb X504 112

C607 C608 C609 C610 LO GW BY BrY

H0 1

D804 D802 H709 H723 R RB RW Y

C501 C510 BG BL

D803 D701 H722 C508 C504 C503 C502 C509 RG RL YR PL WG OL BrW BR 18

B 10

HAZARD

E R

G V805

AIRCON UNIT

TURN SIGNAL

BrR

KICK FLOAT LEVELER OUT

SHIFT HOLD S/W (OPT)

PG PW H745 H731 739 740 BrG B H718 738 2

G G D107 D107 010 010 GW GL K107 B801 329 328 1

G L D102 D205 014 005-a RL SbP H761 S618 703 145

OSb V704 211

R R D108 D108 001 001 RB RB B914 301

E/G DROOP SELECTION RELAY

BUZZER RELAY

GR BG V708 V711 742 744 2 GY V707 743 1

HORN RELAY

AIR TEMP. PROBE (MCU)

1 LP F001 168

H742 306 H767 A102 F403 A107 B RBr RY RO 311 H756 329 308 B108 F604 F804 F404 RLg RB GW RW

H2 K1

1 1

3 BY V Br S707 S709 D110 H724 H708 003 LgL BrR BrW S504 S826 G302 261 251 250 4

H8 7

H6 4

B PB LgR LP S920 S605 S517 152 150 149 LB LBr LY LG LO LR S518 S502 S505 S613 S601 S604 141 142 143 146 147 148

BR Y C509 C611

WY V PB YB VW P H920 H919 H918 H917 H916 H914

B J

LO GW BY BrY Y RL 12 H901 H902 H903 H904 C801 D701

2 1

V BY S709 S707 100 114 LgR S727 166

RY RBr RO F403 A102 A107 307 326 324 LgY RGy F002 B101 167 B201

2 −

GyB B S514 103 LgR GY WL S521 S520 S624 130 169 400

4 GyY GyW BL H746 H732 H717 736 737 741 YV BLg BrW H719 H705 H733 734 735 733

DECLUTCH SENSOR

WP LgR PL BR BL 10 C5 H910 H913 H015 C802 H008 H011 B WG OL BrW BG H014 H013 H012 H007

8 8

THROTTLE PEDAL

RB BrB LgY F604 H912 H911 300

DECLUTCH SET-UP

1 3 4 6

C3 C0

Sb GO WR 6 H907 H908 H909

L C101 801 L C102 802

CAB (AIRCON) 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 H764 H765 D609 D608 D607 D606 500 506 019 018 017 016

S2L S2H H759 H760 S720 S729 1

B7 CAB

LIFT KICKOUT SET-UP/ LOWER KICKOUT SET-UP

B6 6

S2S H758

L B402 802 L B401 801

LLg

CAN (RESISTOR)

E/G IDLE SELECTION RELAY

DECLUTCH S/W

S921

6 L LgG D206 H753 005-b 162 GO SbW B S901 A712 164 163 1 3 4

F003

B8 L

G Y B

GND

F801

PARKING S/W

R D602 023 R D601 024 TB

1 3 4 6

HORN S/W

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

SHIFT LEVER

20 7

GyG Gy LgY LgW S515 S519 S528 F903 753 749 173 102 Sb WG LgW GyL S513 H710 S527 S516 194 705 192 190

EG2 EG1 EG3

257 T903 BrB

250 K206 BrW

GND

272 T003 BrR

YSb S506 403

F/R S/W SELECTION (EU STANDARD)

1 3 4 6

INSTRUMENT PANEL

COLD STARTER S/W

REAR WORKING LAMP

1 3 4 6

S914

HAZARD

FRONT WORKING LAMP

EFFICIENT LOADING SYSTEM (ELS)

1 6

910 D301 R 911 D402 R

1 912 D401 R 913 D901 R

BY R E701 V404 114 243 SbR V E702 E703 240 100

1 914 D002 R 915 D001 R

901 E201 W

8 330 744 062 172 705 S709 S510 V211 D504 S722 A503 H003 K202 V RL BG BW SbY WG RW 312 743 181 171 S707 B208 V207 S811 S730 K203 H004 H016 Y YR RGy GY BrY SbY BY 327 742 220 170 F204 209 267 K103 V208 S723 S614 X604 F103 S501 RBr GR GyO WR RLg SbY GB 221 266 F604 180 182 162 K106 S731 S806 B506 S702 S801 RB GyL LgL LgG LgB GyB 331 754 019 325 707 506 500 S619 S625 D609 K101 S724 C308 C307 PB RG GyG OR RO WL PL 70 64

1 212 748 735 205 207 405 409 S525 T402 C002 F203 X603 S817 S821 GW YO BLg Sb SbW YR YG 140 160 734 738 741 406 015 S507 S716 C001 G004 C004 S828 D101 YV BrG BL LLg Y YB WR 732 159 733 737 740 407 751 A606 S708 C003 C005 G002 S820 F302 BrW Y BrW GyW PW YL GyR 731 184 722 736 739 408 161 A607 S815 A008 C006 G003 S829 S715 BrB Sb BrB GyY PG YBr W 730 183 703 T406 T405 T404 747 A605 S814 F704 C201 C202 C203 T403 BrR SbO RL S2H S2L S2S YL 63 57

This page illustrates the transmission is in neutral and key switch is in OFF position. (FM) 115ZV2-09709-08431 EU 1/3 115V2E92019

115ZV-2 FS EU 92-8 92 Drawing & Diagrams Electrical Wiring Diagram (2/3) (S/N 9001~9006)

Electrical Wiring Diagram (2/3) (S/N 9001~9006) 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

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

A10

A11

A12

A13

A14

A15

A16

A17

A18

A19

A20

A21

A22

A23

A24

A25

A26

(WHITE)

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

A27

A28

A29

A30

A31

A32

A33

A34

B12.X_R B13.F_SO B14.B_SO B15.EG_SW2 B16.RIN1 B17.OUT_MD2 B18.N_R B19.BR_L B20.CAN_R1 B21.CAN_R2 B22.DOUT1 B23.OUT_FEW B24.MT B25.ET_SE B26.TXD1

B10

B11

B12

B13

B14

B15

B16

B17

B18

B19

B20

B21

B22

B23

B24

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

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

E31.TT_SE E32.OT_SE E33.OUT_RSE E34.ET_M

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

E10

E11

E12

E13

E14

E15

E16

E17

E18

E19

E20

E21

E22

E23

E24

E25

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

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

D12.SL_A D13.SS_N D14.KD D15.INCH_S D16.OD_SW D17.SH D18.SS_SW D19.SS_F D20.TMP D21.INCH D22.KO_S D23.SC D24.AR D25.SM_SW D26.SS_R

D2 D8

C10 C11 C12 C13 C14 C15 C16 C17

D3 D9

D10 D11 D12 D13

C18 C19 C20 C21 C22 C23 C24 C25

D14 D15 D16 D17 D18 D19

E34

C26 C27 C28 C29 C30 C31 C32 C33 C34

D20 D21 D22 D23 D24 D25 D26

YG YB LgR S2H SbY GyL G C703 C201 H725 H755 C901 T302 A603 166 171 180 415 116 401 G S2L BrW SbY GyO WL YL E003 C202 A602 H711 H740 H766 T304 234 402 172 220 707 117 L L W Y G D203 D204 H743 H720 D107 005-C 005-D 161 160 010 V B BR LgB L L B BY Y E002 H751 D201 D202 H734 236 221 005-A 005-B 159

B BrR SbR YB YBr Y GyW LgY 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 Gy YR BW SbO Sb BrY R H726 T203 F005 H762 H748 F303 H702 181 106 271 183 184 750 405 GyB P PL LgL H750 S102 S103 H754 266 107 108 182

PB LLg BrG GW LB PW YW 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 B LY LR LW B703 B709 B706 121 126 120 GO PG LG LBr LO B503 S401 B702 B708 B701 164 109 122 128 123

E26

E27

E28

E29

E30

E31

E32

E33

(BLUE) B

EU 3

SPEEDOMETER DIVIDING RATIO ODOMETER SELECTION SELECTION

JPN PL P 2 S803 S802 108 107 B

A/M SELECTION

PW S925 111

1 (BLUE)

PB S916 110 1

PG S902 109 1

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 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 H209 E502 E001 147 278 148 150 225 237 9

(BLACK)

(BLUE)

SbO LgW LgY GR OSb YBr RL YB A612 A502 A507 A701 V204 A618 A608 A616 193 192 173 135 211 413 235 411 YG LgB GW LY Gy GY LgR YL A708 A506 A807 A808 A617 A619 A604 H707 H201 749 169 130 412 414 224 V212 0 YR Sb GyB GyG GyL LP RL H714 A615 A609 A504 A809 A505 A501 H208 T801 410 241 194 103 753 190 149 GB LG YGy LgL LO YSb LLg LW SbP H736 H202 E804 K204 A710 A901 H721 A711 F202 267 V303 242 261 H203 403 140 V302 202

100 C702 E803 E004 K202 T101 H708 9

C701 E007 C902 K203 E801 T102 114 H724

S9 T3

WR RL

4 RL RG LR LW YR YW

003 G201 G301 G401 K201

R1 BR S2L B ACC R2 C

BW BG

STARTER S/W

WRx2 WBx2

W D506 060 W H601 901

WR WR D501 D503 063 065 G D502 064

1 4

G Br

LW B

R R

R H301 910

R H302 911 R H401 912

OG D606

OL OR O D608 D609 D610

5 V801 W

RL 1

(EU:STANDARD)

R R D602 D601

L V808

6 BW W H712 E202 062 T407 WR G WR E107 E101 E106 065 064 063

G W

RG RB 2 H018 H002

R H402 913

R H501 914 R H502 915

BACK LAMP (OPT)

YO E405 232

8 YW E412 233

RS232C

R Y S812 S830 106 105

DIAG. S/W CONNECTION

R H001 1 4

DC-DC CONVERTOR (EC : STANDARD)

C612 H915 H017

V906 V804 V908 V909 V910 OG Y OL OR O 10

OUT IN

G G501

L V904

O 10 OG OW OL OR C312 C311 C310 C309 C301 016 017 018 H768 020 WBr R R C303 B301 B302 022 023 024 5

Y D607

W D604 1

D0 V8

1 3 4 6

V902 V901 R R

R5 R5

FR SWITCH (EU : STANDARD) 2

V GL S616 S709 810 100 GR BY S622 S707 811 114

MCU SELECTION

T2 1

O WR

14 R Br R RG OY L B102 T501 B202 G702 004 B207 B107 007 WR BW Lg G A007 F703 H715 012 014 015 7 C304 1 013 F802 3 4 5 A207 V203 1 6 F803 2 A307 X502 L G501 L L L L L A610 X503 E008 G802 S703 S704 S711 S712 E806 B504 A706 S717 005-A 005-B 005-C 005-D F702 005-b E601 010 F902 D1 T902 T002 X602 005-a

STARTER SWITCH

2 R

001 8 R F406 F502 F503 F602 G F603

W3 W 5

1 W

1 YB YG YBr S623 S733 S617 115 116 119 YO B YL S725 S626 117 118

FUSE BOX (MAIN) R5

FUSE BOX (CAB)

RL S510 330

RIDE CONTROL S/W

REVERSAL FAN S/W 3

Lg LgL S825 S606 222 225 B LgY S834 223

SECONDARY EMERGENCYSTEERING STEERING (EU: (EU :STANDARD) STANDARD) 4

GyW S833 260 B Lg D103 013 1

YGy V V402 H803 242 100 SbR B H802 240 BY L V403 H801 005-a 114

YGy V S709 S503 100 242 SbR B S827 240 BY L S707 D205 114 005-a

FR SWITCH (EU : STANDARD)

B 6

YW E308 233 12

F/R SWITCH/ STICK STEERING

TRACTION CONTROL (EU : STANDARD) 6

BL BR G V YO LB S607 S701 S719 S709 S919 S924 237 236 234 100 232 230 YW B L BY S926 D205 S707 233 005-a 114

YO E306 232

PRESS. INTENSIFYING

GB GB S603 S824 278 277 2

1 7

6 GW V602 210 GW

Lg OSb V607 V604 013 211 BG B GR GY V502 V503 V501 212 744 742 743

OSb Lg GW S530 D103 S923 211 013 210 GY GR B BG GW H727 H741 H713 S525 743 742 744 212 12

This page illustrates the transmission is in neutral and key switch is in OFF position.

(FM) 115ZV2-09709-08431 EU 2/3 115V2E92020

115ZV-2 FS EU 92-9 92 Drawing & Diagrams Electrical Wiring Diagram (3/3) (S/N 9001~9006)

Electrical Wiring Diagram (3/3) (S/N 9001~9006)

1 B

PB 1

RW RY K108 K102 308 306 B

2 R B W

JPN:CONNECT EU :DISCONNECT

COMBINATION LAMP

K106

RBr

K103

K801 K802

LBr H206 148

−

LY H201 141

AUTO BRAKE SOLENOID

PARKING SOLENOID

LG H202 142

−

LLg H721 140

B Sb H748 184

X1 2

L9 2

LO H203 143

−

Y Y H720 H734 160 159

ETHER INJECTION VALVE

WATER LEVEL SENSOR

GROUND SPEED SENSOR

YV H719

BrR K205 251

V K202 100 BY K203 114

R 1

SPPC

L2 1

AIR CLEANER

PB P H210 J902 152 153

PRESS. S/W 2

ELECT. FAN CONDENSER

B LgL L401 261 3

YR B H702 405 YB YG H716 H701 406 409 YL YBr H730 H744 407 408

1/4 R

E/G WATER TEMP. SENSOR

E Y

3/4 B

V BY H708 H724 100 114 SbY H711 172

N601 BrR

H747

B 2 1

P0 STARTER C

−

FUSIBLE LINK

SECONDARY EMERGENCY STEERING STEERING OIL OIL PRESS. PRESS. SENSOR SENSOR

30A

+ −

SECONDARY EMERGENCY STEERING STEERING MOTOR MOTORPUMP PUMP

PG H745

WP P601 708

R 1

WL N901 H766 706 707

W N303 900

W H601 P50A P50B P50F 901 081 085

BL H717 Sb H704

N3 BATTERY RELAY

W N102 900

SbW H703

BW P001 702 2

R N504 3 701

2 B

BrW H735

RL N906 703

WG N801 704

WG N704 N905 704 705

R H301 H302 H401 H402 H501 H502 910915 BW H712 062

700 N301 WV 015 708 P601 P602 WR WP 1

2 015 708 N401 N402 WR WP B

WL N901 706

WG B H710 705 RL WL H761 M701 703 706

WR WP H715 M702 015 708 1

DIODE UNIT

15 SbY H737

23 12

312

REAR WORKING LAMP

RGy R102

312

REAR WORKING LAMP

RL RGy H714 H728 330 312 RB B H756 303

This page illustrates the transmission is in neutral and key switch is in OFF position.

1 330 R103 RL

R501

RB R104 303

R502

BACK UP ALARM

LICENSE LAMP

LH BATTERY −

1 303 R501 RB B 330 R301 R401 R201 RL RGy

1 703 706 N701 N804 RL WL 705 N801 WG B

22 11

BrR H763

10 3

4 4

9 2

BrB H749

8 19

RGy R102

YR H722

N8 VOLTAGE RELAY 1

31 30

BrG H718

WV N403 700

W H743

RLg H738

S R

ECM

M7 ALTERNATOR

GyY H746

FUEL LEVEL SENSOR

BrW H733

N7 MAGNETIC S/W

BRAKE OIL PRESS. (MAIN)

COMPRESSOR CLUTCH (EC C )

SECONDARY EMERGENCY STEERING STEERING MOTOR MOTOR PUMP PUMP

BW N702 702

FUSIBLE LINK

F E

R N703 701

−

T D

REAR COMBINATION LAMP (R.H)

REAR COMBINATION LAMP (L.H)

1 1

E/G WATER TEMP. S/W (COLD STARTER)

BrB

LgB H751 221 2

1/8 G

1/2 W

V BY H708 H724 100 114 SbY H725 171

BLg H705

PW H731

R H804 243

70A

FAN SPEED CONTROL SOL. VALVE

GyW H732

R H804 243

70A

LgL K204 261

LgL R801 R803

M3 1

70A

LgL L401 261

J8 L4

CAN (RESISTOR)

P J701 153

PRESS. S/W

GyG BY H769 H724 754 114

N004 N002 H760 S2H H758 N003 S2S H759 S2L

GyL BY H755 H724 180 114

RIDE CONTROL SOLENOID (OPT)

T/M OIL TEMP. SENSOR

V BY H803 H801 100 114 SbR H802 240

V L301 BrR 100 L302 BY 251 L303 114

T/M OIL FILTER

R1 R7

LgR H209 150

LU LOCK UP SOLENOID

V L201 100 BrR L203 251 BY L202 114

BG H713

U C

LP H208 149

GyR H729

GW H707

P4 BOOM ANGLE SENSOR

V J B

B L802

GY H727

+ −

X GR H741

−

2 B

BrR M002 721

+ −

BO 745

8 7

182 L002 LgL

L903 B

K M

−

DATA LINK CONNECTOR

YO H706

−

LgG H753 162

RW Y L803 L804

Br K201 003 BrW B K206 250

1 B

K803

L902 L901 RW Y

327

WASHER MOTOR

303

WR H739 170

BUCKET LEVELER

1 B

3 (BLUE)

RW Y H709 H723

PL H765 506 B

FRONT HEAD LAMP (OUTSIDE)

OR H768 019 PB H764 2 500

LgL H754 182

311

K105

B C

YL H757

6 B

WORKING LAMP (INSIDE)

LB H205 147

−

W N101 901

R N201 915 R N201 914

W N001

S2L 2 S2H P902 S2S P901 P903

R N201 913 R N201 912

3 4

−

R N201 911 R N201 910

L7 K6

RLg

114 L601 M301 L702 M502 M201 M602

B GW K701 K703

GW K601 329

2 B

K7 HORN (H)

1 2

GB H736 267

BrY H726 181

−

LR H204 146

GW K601 329

329 K107 GW

HORN (L)

GyO BY H740 H724 220 114

GyB H750 266 V BY H724 H708 114 100

L602 M202 M302 100 H7

W N001

R103 R602 R702 330

T/M SOLENOID VALVE

WR H715

311

K105

Br V BY L103 L201 L202 003 100 114 BrW BrR LgL L102 L203 L401 250 251 261

LgL L806 182

RLg

W N001

WORKING LAMP (INSIDE)

12 −

240 100 P403 P402 V SbR 114 X301 P401 P301 BY R

LR LB LBr J102 J202 J302 146 147 148 LgR LP J001 R901 150 149

R B

HYD. OIL LEVEL S/W

6 LY LG LO J402 J502 J602 141 142 143 B PB J702 152

RW RY K108 K102 308 306 B

2 1

57 BrR SbO RL S2H S2L S2S YL P816 X101 N906 P901 P902 P903 N001 730 183 703 747 BrB Sb BrB GyY PG YBr W P817 X201 M001 P809 P823 J804 P831 731 184 722 736 739 408 161 BrW Y BrW GyW PW YL GyR P818 M902 P820 P810 P824 J803 P70A 732 159 733 737 740 407 751 LLg Y YV BrG BL YB WR N502 M901 P821 P801 P811 J802 P50H 140 160 734 738 741 406 P602 GW YO BLg Sb SbW YR YG P70O N008 P822 P812 P813 J801 J805 212 748 735 205 207 405 409 7 1

325 330 H767 H714 RO RL 303 331 H756 H770 RB RG

K503

FRONT HEAD LAMP (OUTSIDE)

EFFICIENT LOADING SYSTEM (ELS) SOLENOID VALVE

64 PB RG GyG OR RO WL PL R605 M601 M801 R603 M701 M803 M802 R705 754 019 325 707 506 500 RB GyL LgL LgG LgB GyB M501 L806 M101 P101 L603 221 266 180 182 162 RBr GR GyO WR RLg SbY GB R703 P70L L701 X401 P808 P814 L501 327 742 220 170 206 209 267 RGy GY BrY SbY BY Y YR R102 P70M M401 M203 L804 P201 312 743 181 171 RL BG BW SbY WG RW V P70N N201 M303 N905 L803 744 062 172 705 14 8

327 330 H742 H714 RBr RL 303 331 H756 H770 RB RG

K502

70 303 R104 R604 R704

SbO H762

325

HYD. OIL TEMP. SENSOR

−

K101

K501

K106

303

RLg RB GW RW K401 K501 K601 K303 K901 K801 329 K003 B RBr RY RO K802 K302 K502 327 K002 325

EFFICIENT LOADING SYSTEM (ELS) OIL PRESS. SENSOR

JPN:CONNECT EU :DISCONNECT

COMBINATION LAMP

RH BATTERY 1

− +

(FM) 115ZV2-09709-08431 EU 3/3 115V2E92021

115ZV-2 FS EU 92-10 92 Drawing & Diagrams Electrical Wiring Diagram (1/3) (S/N 9007~9050)

Electrical Wiring Diagram (1/3) (S/N 9007~9050)

4 6

(+)

8 GyG Gy LgY LgW S515 S519 S528 F903 753 749 173 102 Sb WG LgW GyL S513 H710 S527 S516 194 705 192 190

8 5

8 RO RO BP B911 A815 G803 321 K101 323 RBr RBr BP B910 A814 G803 322 K103 323

3 8

Lg D103 013 GyW S823 200

5 Lg D103 013 GL S822 265

3 8

BW BrB D105 H747 012 722

WTM TTM

1/2

1/4

−

3/4

EMP GND

PARKING S/W

P RBr RO RW G703 A103 A106 F401 320 322 321 304

RB RY F601 F501 301 302

LR LBr B S911 S904 126 128 LW B S912 120 LG LO LY S910 S903 S905 121 122 123

CAB

Sb GO WR H907 H908 H909

LLg

BW F005 271

O Y V

DATA LINK CONNECTOR C7

REMOTE THROTTLE (EU:STANDARD)

SLIP CONTROL (EU:STANDARD)

BR Y C509 C611

YV S918 231

8 RG RLg D113 C302 006 K105 RG RGy D113 A801 006 310

8 R RGy D109 C306 002 H728 R RGy D109 A801 002 310

A 1

Hi-BEAM RELAY

LP F001 168

(BLACK)

LgY F002 167 YO F003 176

Gy GyR S816 H729 750 751 B B 1

Sb SbP H704 S509 205 202 RLg B H738 206 1

HEAD LAMP RELAY

6 RW R D108 K108 308 001 RY RY RW A813 F504 B912 K102 305 304

WIDTH LAMP RELAY

C403 K106 H756 300 4 303

BrG YO S922 B001 255 176 BW LgY S813 A803 271 167 B LP S915 168

SECONDARY EMERGENCY STEERING STEERING RELAY RELAY (EU: STANDARD) (EU:STANDARD)

(BLACK)

GR BG V708 V711 742 744 2 GY V707 743 1

LIFT KICKOUT RELAY

LOWER KICKOUT RELAY

2 2

3 3 LgB LgR H751 H209 221 150 LgB LgR S702 S605 226 154

LG LW S502 S508 142 144 LG B A709 132 1

BrR L G202 D205 272 005-a B L S610 273 1

BrB L G402 D205 257 005-a B BrB S611 258 1

SbW L H703 D205 207 005-a RLg SbW H738 S615 206 203 1

Lg Lg D103 D103 013 013 LgSb LgBr G601 S609 112 104 1

LgW L A508 D205 102 005-a B LgW S612 101 1

G G D107 D107 010 010 GW GL K107 B801 329 328

VOLTAGE RELAY

(BLACK)

(BLUE)

(BLACK)

(BLUE)

BACK RELAY (OPT)

DOWNSHIFT BUTTON

FLOAT 4

4 YL YO H757 S2S H706 H758

8 Lg V703 013 GW V701 210

OSb V704 211 4

CAB ALARM BUZZER

PILOT VALVE MAGNETS

S2L H759

1 B 8

5 OY D114 007

S2H W H760 6 D506

PG PW H745 H731 739 740 BrG B H718 738

B 2

DIAG INC/DEC S/W 2 3

AIR-SUS.

1 1

TURN SIGNAL

YSb S917 125

Br D110 003

1 (BLUE) Br

BrR

BrW

BrB

L 2

G D107 010

LgSb X504 112

P R B909 D111 320 004 B

Lg LB D103 S510 013 138 RL B H714 T801 1

(BLUE)

(BLACK)

WG WL H710 H766 705 707 B B

HAZARD

E G V805

KICK OUT

LEVELER

SHIFT HOLD S/W (OPT)

2 BP G A101 D107 A108 010 B

AIRCON UNIT

G8 H9

C607 C608 C609 C610 LO GW BY BrY

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

8 5

H8 7

LgB LgR X803 X802 221 150 LgB LgR X804 X801 226 154

226 154 X904 X901 LgB LgR 221 150 X903 X902 LgB LgR

L YGy E706 E704 005-a 242 R B H804 243

4 SPEED INDICATOR RELAY

1 H742 306 H767 A102 F403 A107 B RBr RY RO 311 H756 329 308 B108 F604 F804 F404 RLg RB GW RW 4

(BLACK)

1 6

910 D301 R 911 D402 R

1 912 D401 R 913 D901 R

BY R E701 V404 114 243 SbR V E702 E703 240 100

1 914 D002 R 915 D001 R

901 E201 W

8 330 744 062 172 N803 S709 X704 V211 D504 S722 A503 H003 K202 BG BW SbY WG RW V RL 312 743 181 171 S707 B208 V207 S811 S730 K203 H004 H016 Y YR RGy GY BrY SbY BY 327 742 220 170 F204 209 267 K103 V208 S723 S614 X604 F103 S501 RBr GR GyO WR RLg SbY GB 221 266 F604 180 182 162 K106 S731 S806 B506 X803 S801 RB GyL LgL LgG LgB GyB 331 754 019 325 S724 506 500 S619 S625 D609 K101 N802 C308 C307 RG GyG OR RO WL PL PB 70 64

H6 1

PB LgR LP S920 X802 S517 152 150 149 LY LG LO LR LB LBr S518 S502 S505 S613 S601 S604 141 142 143 146 147 148

3 3

E/G DROOP SELECTION RELAY

BUZZER RELAY

BY V Br S707 S709 D110 H724 H708 003 LgL BrR BrW S504 S826 G302 261 251 250

MCU FAULT RELAY

HORN RELAY

2 4

1 3

(BLACK)

1A 1

R R D108 D108 001 001 RB RB B914 301

(BLACK)

FUSE

2 G L D102 D205 014 005-a RL SbP H761 S618 703 145

R R D108 D108 001 001 RY RY F402 B915 305 302

(BLUE)

BY G S707 S732 114 415

AIR TEMP. PROBE (MCU)

E/G OIL PRESS. S/W RELAY

1 168 T606 B LP 271 167 T706 T608 BW LgY 255 176 T708 T601 BrG YO

2 1

B J

WY V PB YB VW P H920 H919 H918 H917 H916 H914

BrG F004 255

AIR PROBE (TH AM )

R G B

1 V BY S709 S707 100 114 LgR S727 166

TORQUE SELECTION RELAY

SbY SbR H737 S608 209 208 B B

4 GyY GyW BL H746 H732 H717 736 737 741 YV BLg BrW H719 H705 H733 734 735 733

DECLUTCH SENSOR

LO GW BY BrY Y RL 12 H901 H902 H903 H904 C801 D701

1 3 4 6

E/G IDLE SELECTION RELAY

RB BrB LgY F604 H912 H911 300 1

THROTTLE PEDAL

10 BR BL WP LgR PL C5 H910 H913 H015 C802 H008 H011 WG OL BrW BG B H014 H013 H012 H007

DECLUTCH SET-UP

16 RY RBr RO F403 A102 A107 307 326 324 LgY RGy F002 B101 167 B201

CAB (AIRCON) 4

1 3 4 6

S921

G WBr RLg O RGy RB B208 A611 D107 D604 B108 D610 520 300 010 022 521 020 PB PL OR OL OW OG H764 H765 D609 D608 D607 D606 500 506 019 018 017 016

S2L S2H H759 H760 S720 S729

NEUTRAL RELAY

B6 6

S2S H758

L B402 802 L B401 801

F003

GyB B S514 103 LgR GY WL S521 S520 S624 130 169 400

DECLUTCH CUT-OFF S/W

RB A611 300

L C101 801 L C102 802

LIFT KICKOUT SET-UP/ LOWER KICKOUT SET-UP

L LgG D206 H753 005-b 162 GO SbW B S901 A712 164 163 1 3

CAN (RESISTOR)

R D602 023 R D601 024

G Y B

F801

GND

COMBINATION S/W FOR LAMPS

TB GW

HORN S/W

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

N P

SHIFT LEVER

1 3 4 6

B3 1

20 7

YL YBr YG RB SbO YR YB B601 S526 S511 S533 S522 S531 S523 410 411 412 413 414 C305 193 O RL BrB BrW BrR LgB YB BrW Lg D103 S512 S532 H749 H735 H763 S524 S734 S721 013 241 235 731 732 730 224 401 402

EG2 EG1 EG3

257 T903 BrB

250 K206 BrW

COLD STARTER S/W

GND

2 5

272 T003 BrR

1 3 4 6

YSb S506 403

INSTRUMENT PANEL

1 3 4 6

HAZARD

1 3 4 6

F/R S/W SELECTION (EU STANDARD)

REAR WORKING LAMP

FRONT WORKING LAMP

EFFICIENT LOADING SYSTEM (ELS)

S914

FUEL EFFICIENT MODE SELECTION

212 748 735 205 207 405 409 S525 T402 C002 F203 X603 S817 S821 GW YO BLg Sb SbW YR YG 140 160 734 738 741 406 015 S507 S716 C001 G004 C004 S828 D101 YB WR LLg Y YV BrG BL 732 159 733 737 740 407 751 A606 S708 C003 C005 G002 S820 F302 BrW GyW PW YL GyR BrW Y 731 184 722 736 739 408 161 A607 S815 A008 C006 G003 S829 S715 BrB Sb BrB GyY PG YBr W 730 183 703 T406 T405 T404 747 A605 S814 F704 C201 C202 C203 T403 BrR SbO RL S2H S2L S2S YL 63 57

D804 D802 H709 H723 R RB RW Y

C501 C510 BG BL

D803 D701 H722 C508 C504 C503 C502 C509 RG RL YR PL WG OL BrW BR

This page illustrates the transmission is in neutral and key switch is in OFF position. (FM) 115ZV2-09709-08432A EU 1/3 115V2E92022

115ZV-2 FS EU 92-11 92 Drawing & Diagrams Electrical Wiring Diagram (2/3) (S/N 9007~9050)

Electrical Wiring Diagram (2/3) (S/N 9007~9050) MCU

OPT

A11

A12

A13

A14

A15

A16

A17

A18

A19

A20

A21

A22

A23

A24

A25

A26

(WHITE)

A10

A27

A28

A29

A31

A30

A32

A33

A34

B10

B11

B12

B13

B14

B15

B16

B17

B18

B19

B20

B21

B22

B23

B24

B25

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

B26

E31.TT_SE E32.OT_SE E33.OUT_RSE E34.ET_M

E16.SPD E17.BATT E18.CANL1 E19.SS_P E20.CANLO E21.TM_M E22.B_SE2 E23.WT_SE E24.ALT E25.RXD1 E26.TGSP E27.INCH_SE E28.ASUB2 E29.CANHO E30.B_SE1

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_SW3 B 1.H_SO B 2. B 3.IP_SO B 4.R_SO B 5.MO_SO B 6.FR_SO B 7.SSL_SO B 8.ISW_R B 9.BZ B10.BSL_R B11.KO_R

A16.TT_L A17.D_SO A18.1_SO A19.EP_L A20.AB_L A21.A_L A22.1/2_L A23.E_L A24.SS_L A25.SC_SW A26.TF_L A27.AC_L A28.BP_L A29.N_L A30.SC_L

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

E33

E34

C11

C12

C13

C14

C15

C16

C17

C18

C19

C20

C21

C22

C23

C24

C25

C27

C28

C29

C30

C31

C32

C33

C10

C26

D12.SL_A D13.DSUB2 D14.KD D15.INCH_S D16.OD_SW D17.SH D18.SS_SW D19.SS_F D20.TMP D21.INCH D22.KO_S D23.SC D24.AR D25.SM_SW D26.SS_R

C31.BSL C32.DSUB3 C33.DD_S C34.AFR D 1.PRK D 2.AM_SW D 3.SL_2 D 4.SL_R D 5.SL_3 D 6.S_UP D 7.S_DOWN D 8.EG_SW D 9.M_SW D10.SL_1 D11.SL_F

C16.EP C17.F C18.ASUB1 C19.TMP_SE C20.1/2 C21.1/8 C22.2S C23.EGM C24.IP_SW C25.FR C26.KO_P C27.ES_SE C28.3/4 C29.1/4 C30.DC

C34

D10

D11

D12

D13

D14

D15

D16

D17

D18

D19

D20

D21

D22

D23

D24

D25

D26

(BLUE) B

ODOMETER SELECTION

JPN 3

PL P 2 S803 S802 108 107 B 1 (BLUE)

A/M SELECTION

PB S916 110

PG S902 109 1

SbO LgW LgY GR OSb YBr RL YB A612 A502 A507 A701 V204 A618 A608 A616 193 192 173 135 211 413 235 411 YG LgB GW LY Gy GY LgR YL A708 A506 A807 A808 A617 A619 A604 H707 H201 749 169 130 412 414 224 V212 YR Sb GyB GyG GyL LP 0 LB X702 A615 A609 A504 A809 A505 A501 H208 138 410 241 194 103 753 190 149 GB LG YGy LgL LO YSb LLg LW SbP H736 H202 E804 K204 A710 A901 H721 A711 F202 267 V303 242 261 H203 403 140 V302 202

1 (BLACK)

GR YB WL GyG YO T103 T303 A806 H769 T305 811 115 400 754 118 WR SbW GL YBr SbP RG H739 X601 T104 T301 F701 H770 170 203 810 119 145 331 L BrB LgW LR SbR LgBr F102 X501 T001 T901 F901 H204 208 104 273 258 101 146 LB GB LBr LgR LgL BL H205 V101 H206 X801 E502 E001 147 278 148 154 225 237 9

YG YB LgR S2H SbY GyL G C703 C201 H725 H755 C901 T302 A603 166 171 180 415 116 401 G S2L BrW SbY GyO WL YL E003 C202 A602 H711 H740 H766 T304 234 402 172 220 707 117 L L W Y G D203 D204 H743 H720 D107 005-C 005-D 161 160 010 V BR LgB L L B BY Y B E002 X804 D201 D202 H734 236 226 005-A 005-B 159 7

100 C702 E803 E004 K202 T101 H708 9

B Y GyW LgY 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

YW PB LLg BrG GW LB E012 H210 B002 F004 V201 E006 152 165 255 210 230 233 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

C701 E007 C902 K203 E801 T102 114 H724

S9 T1

T3 3

FUSE BOX (CAB) R5

FUSE BOX (MAIN) R5

WR RL

4 RL RG LR LW YR YW

003 G201 G301 G401 K201

R1 BR S2L B ACC R2 C

BW BG

STARTER S/W

WRx2 WBx2

W D506 060 W H601 901

WR WR D501 D503 063 065 G D502 064

1 4

G Br

LW B

MCU SELECTION

WR L

R H301 910

R H302 911 R H401 912

OG D606

BW W E202 H712 062 T407 WR G WR E107 E101 E106 065 064 063 3

OL OR O D608 D609 D610 L V808

RL 1

(EU:STANDARD)

5 V801 W

R R D602 D601

RG RB 2 H018 H002

R H402 913

R H501 914 R H502 915

R H001

R Y S812 S830 106 105

DIAG. S/W CONNECTION

1 4

DC-DC CONVERTOR (EC : STANDARD)

C612 H915 H017

OUT

G G501

L V904

O 10 OG OW OL OR C312 C311 C310 C309 C301 016 017 018 H768 020 WBr R R B301 B302 C303 022 023 024

YW E412 233

RL X704 330

RIDE CONTROL S/W

REVERSAL FAN S/W 3

8 YO E405 232

RS232C

Y D607

W D604 1

D0 V8

BACK LAMP 8

V906 V804 V908 V909 V910 O 10 Y OL OR 6 OG

1 3 4 6

1 B

R5 R5

V902 V901 R R

FR SWITCH (EU : STANDARD) 2

1 GL V S616 S709 810 100 GR BY S622 S707 811 114

O WR

14 RG OY R Br R L B202 G702 B102 T501 004 B207 B107 007 G WR BW Lg F703 H715 A007 D2 012 014 015 7 C304 1 013 F802 3 4 5 A207 V203 6 1 F803 2 A307 X502 L G501 L L L L L A610 X503 E008 G802 S703 S704 S711 S712 E806 B504 A706 X703 S717 005-D 005-C 005-B 005-b 005-A E601 F702 010 F902 D1 T902 T002 X602 005-a

STARTER SWITCH

2 R

001 8 R F406 F502 F503 F602 G F603

W3 W 5

1 W

1 YG YBr YB S623 S733 S617 115 116 119 YL YO B S725 S626 117 118

Lg LgL S825 S606 222 225 B LgY S834 223

SECONDARY EMERGENCYSTEERING STEERING (EU: (EU :STANDARD) STANDARD) 4

GyW S833 260 Lg B D103 013 1

YGy V V402 H803 242 100 B SbR H802 240 BY L V403 H801 005-a 114

YGy V S709 S503 100 242 B SbR S827 240 BY L S707 D205 114 005-a

FR SWITCH (EU : STANDARD)

6 B

B 6

YW E308 233 12

F/R SWITCH/ STICK STEERING

TRACTION CONTROL (EU : STANDARD) 6

BL BR G V YO LB S607 S701 S719 S709 S919 S924 237 236 234 100 232 230 YW B L BY S926 D205 S707 233 005-a 114

YO E306 232

PRESS. INTENSIFYING

GB GB S603 S824 278 277 2

1 7

6 GW Lg OSb V602 V607 V604 210 013 211 GW BG B GR GY V502 V503 V501 212 744 742 743

OSb Lg GW S530 D103 S923 211 013 210 GY GR B BG GW H727 H741 H713 S525 743 742 744 212 12

This page illustrates the transmission is in neutral and key switch is in OFF position.

(FM) 115ZV2-09709-08432A EU 2/3 115V2E92023

115ZV-2 FS EU 92-12 92 Drawing & Diagrams Electrical Wiring Diagram (3/3) (S/N 9007~9050)

Electrical Wiring Diagram (3/3) (S/N 9007~9050)

HYD. OIL LEVEL S/W

+ −

1 RLg

−

311

K105

LY H201 141

−

2 2

K103

K0 + 1

−

303

K801

327

K802

LO H203 143

1 B

LgG H753 162

V L301 BrR 100 L302 BY 251 L303 114

BrR K205 251

V K202 100 BY K203 114

3 S

AUTO BRAKE SOLENOID

P J701 153 2

RIDE CONTROL SOLENOID (OPT) 2

LgL H754 182

LgL L401 261

LgL K204 261

LgL R801 R803

−

LgL L401 261 3

SECONDARY EMERGENCY STEERING STEERING OIL OIL PRESS. PRESS. SENSOR SENSOR

T/M OIL FILTER

M7 ALTERNATOR

3 2

AIR CLEANER WP P601 708

ELECT. FAN CONDENSER

LOCK UP SOLENOID

WL N901 H766 706 707

W N303 900

W H601 P50A P50B P50F 901 081 085

R H301 H302 H401 H402 H501 H502 910915 BW H712 062

D E

O R

ETHER INJECTION VALVE

WATER LEVEL SENSOR

BLg H705 PG H745

GyW H732

BrW H733 GyY H746

PW H731

SbW H703

20 8

30 19 BrW H735

BrG H718

BL H717 Sb H704

W H743

RLg H738

BrB H749

28 16

2 B

BW P001 702 2

N004 N002 H760 S2H H758 N003 S2S H759 S2L

RGy R102

312

REAR WORKING LAMP

312

REAR WORKING LAMP

RGy R102

COMPRESSOR CLUTCH (EC C )

R N304 701

RL N906 703

WG N905 705

015 708 N401 N402 WR WP B 2

WG B H710 705 RL WL H761 M701 703 706 1

YR 3

WR WP H715 M702 015 708

DIODE UNIT

YR H722 1

1 703 N701 RL 705 N704 WG

This page illustrates the transmission is in neutral and key switch is in OFF position.

N4 700 N301 WV 015 708 P601 P602 WR WP

24 25

ECM

W BATTERY N102 RELAY 900

23 12

N7 MAGNETIC S/W

WV N403 700

22 11

5 15

SbY H737

10 3

BrR H763

21 9

N601

3/4 B

LgL L806 182 R

E Y

70A

BrR

H747 BrB

YV H719

−

BW N702 702

FUSIBLE LINK

Sb H748 184

P0 STARTER

SECONDARY EMERGENCY STEERING STEERING MOTOR PUMP MOTOR PUMP

30A 2

B L802

+ −

RW Y L803 L804

1/2 W

Q 2

SECONDARY EMERGENCY STEERING STEERING MOTOR MOTOR PUMP PUMP

N6 1 BrR M002 721

FUEL LEVEL SENSOR

E/G WATER TEMP. S/W (COLD STARTER)

1/8 G

R N703 701

L9 E/G WATER TEMP. SENSOR

1/4 R

GyG BY H769 H724 754 114

−

182 L002 LgL 6

LLg H721 140

CAN (RESISTOR)

+ −

L902 L901 RW Y

S 4

GyL BY H755 H724 180 114

−

SECONDARY EMERGENCY STEERING STEERING MOTOR MOTOR RELAY RELAY

BG H713 GW H707

R H804 243

L903 B

T/M OIL TEMP. SENSOR

SECONDARY EMERGENCY STEERING STEERING MOTOR MOTOR RELAY RELAY

RW Y H709 H723

PARKING SOLENOID

GyR H729

BRAKE OIL PRESS. (MAIN)

V BY H803 H801 100 114 SbR H802 240

6 B

PRESS. S/W

6 YR B H702 405 YB YG H716 H701 406 409 YL YBr H730 H744 407 408

PB P H210 J902 152 153

V BY H708 H724 100 114 SbY H711 172

70A

L3 1

J8 1

PRESS. S/W

LgB H751 221 1

V BY H708 H724 100 114 SbY H725 171

M3 1

1 B

WR H739 170

SPPC

M9 1

V J B

GY H727

LgR H209 150

V L201 100 BrR L203 251 BY L202 114

X K

Y Y H720 H734 160 159

GB H736 267

LP H208 149

Br K201 003 BrW B K206 250

BO 745

DATA LINK CONNECTOR

K803

GyO BY H740 H724 220 114

BrY H726 181

FAN SPEED CONTROL SOL. VALVE

GR H741

GyB H750 266 BY V H724 H708 114 100

Br 1

K106

−

JPN:CONNECT EU :DISCONNECT RBr

LG H202 142

K M

GROUND SPEED SENSOR

70A

(BLUE)

−

RW RY K108 K102 308 306 B

BOOM ANGLE SENSOR

R −

PB PL

PL H765 506

6 3

FRONT HEAD LAMP (OUTSIDE)

WASHER MOTOR

BUCKET LEVELER

EFFICIENT LOADING SYSTEM (ELS) SOLENOID VALVE

330 R103 RL

R501

RB R104 303

R502

BACK UP ALARM

LICENSE LAMP

LH BATTERY −

1 303 R501 RB B 330 R301 R401 R201 RL RGy RL RGy H714 H728 330 312 RB B H756 303

REAR COMBINATION LAMP (R.H)

B C

YO H706

OR PB H764 H768 500 019

LBr H206 148

YL H757

W N101

S2L 2 S2H P902 S2S P901 P903

5 1

REAR COMBINATION LAMP (L.H)

RH BATTERY 1

329 K107 GW

GW K701 K703

HYD. OIL TEMP. SENSOR

W N101

3 4

−

EFFICIENT LOADING SYSTEM (ELS) OIL PRESS. SENSOR

WORKING LAMP (INSIDE)

−

114 L601 M301 L702 M502 M201 M602

COMBINATION LAMP

GW K601 329

L602 M202 M302 100 H7

W N101 WR H715

−

LB H205 147

−

K7 HORN (H)

R103 R602 R702 330

GW K601 329

W N101 901

+ 4

−

HORN (L)

−

3 Br V BY L103 L201 L202 003 100 114 BrW BrR LgL L102 L203 L401 250 251 261

LR H204 146

R N201 915 R N201 914

1 1

311

K105

R N201 913 R N201 912

3 RLg

R N201 911 R N201 910

WORKING LAMP (INSIDE)

H2 T/M SOLENOID VALVE 4

RW RY K108 K102 308 306 B

240 100 P403 P402 SbR V 114 X301 P401 P301 BY R

325 330 H767 H714 RO RL 303 331 H756 H770 RB RG

K503

FRONT HEAD LAMP (OUTSIDE)

57 BrR SbO RL S2H S2L S2S YL P816 X101 N906 P901 P902 P903 N001 730 183 703 747 W BrB Sb BrB GyY PG YBr P817 X201 M001 P809 P823 J804 P831 731 184 722 736 739 408 161 BrW GyW PW YL GyR BrW Y P818 M901 P820 P810 P824 J803 P70A 732 159 733 737 740 407 751 Y YB WR LLg YV BrG BL N502 M902 P821 P801 P811 J802 P50H 140 160 734 738 741 406 P602 GW YO BLg Sb SbW YR YG P70O N008 P822 P812 P813 J801 J805 212 748 735 205 207 405 409 7 1

K502

64 RG GyG OR RO WL PL PB R605 M601 M801 R603 M701 M803 M802 R705 754 019 325 707 506 500 RB GyL LgL LgG LgB GyB M501 L806 M101 P101 L603 221 266 180 182 162 RBr GR GyO WR RLg SbY GB R703 P70L L701 X401 P808 P814 L501 327 742 220 170 206 209 267 RGy GY BrY SbY BY Y YR R102 P70M M401 M203 L804 P201 312 743 181 171 BG BW SbY WG RW RL V P70N N201 M303 N905 L803 744 062 172 705 14 8

303 R104 R604 R704

327 330 H742 H714 RBr RL 303 331 H756 H770 RB RG

325

K101

K501

−

303

K106

6 LG LR LB LBr LY LO J402 J502 J602 J102 J202 J302 141 142 143 146 147 148 PB LgR LP B J702 J001 R901 152 150 149

SbO H762

JPN:CONNECT EU :DISCONNECT

RLg RB GW RW K401 K501 K601 K303 K901 K801 329 K003 B RBr RY RO K802 K302 K502 327 K002 325

COMBINATION LAMP

− +

(FM) 115ZV2-09709-08432A EU 3/3 115V2E92024

115ZV-2 FS EU 92-13 92 Drawing & Diagrams Electrical Wiring Diagram (1/3) (S/N 9051~9100)

Electrical Wiring Diagram (1/3) (S/N 9051~9100)

(+)

5 7

8 Lg D103 013 GyW S823 200

8 Lg D103 013 GL S822 265

8 BW BrB D105 H747 012 722

LR LBr B S911 S904 126 128 LW B S912 120 LG LO LY S910 S903 S905 121 122 123

P RBr RO RW G703 A103 A106 F401 320 322 321 304

RB RY F601 F501 301 302

F003

B7 CAB

BW F005 271

BrG F004 255

LP F001 168

LgY F002 167 YO F003 176

R G B

O Y V

DATA LINK CONNECTOR

1 V BY S709 S707 100 114 LgR S727 166

+ S

SLIP CONTROL (EU:STANDARD)

REMOTE THROTTLE (EU:STANDARD)

AIR PROBE (THAM)

YV S918 231

8 RG RLg D113 C302 006 K105 RG RGy D113 A801 006 310

8 R RGy D109 C306 002 H728 R RGy D109 A801 002 310

A 1

E/G OIL PRESS. S/W RELAY

Sb SbP H704 S509 205 202 RLg B H738 206 1

NEUTRAL RELAY

Hi-BEAM RELAY

HEAD LAMP RELAY

WIDTH LAMP RELAY

BY G S707 S732 114 415

6 RW R D108 K108 308 001 RY RY RW A813 F504 B912 K102 305 304 3 1

Gy GyR S816 H729 750 751 B B 1

(BLACK)

(BLUE)

R R D108 D108 001 001 RY RY F402 B915 305 302 4

C403 K106 H756 300 4 303

MCU FAULT RELAY

HORN RELAY

(BLACK)

GR BG V708 V711 742 744 2 GY V707 743 1

LIFT KICKOUT RELAY

LgB LgR X803 X802 221 150 LgB LgR X804 X801 226 154

3 3

2 2 LgB LgR H751 H209 221 150 LgB LgR S702 S605 226 154

LgW L A508 D205 102 005-a B LgW S612 101 1

G G D107 D107 010 010 GW GL K107 B801 329 328 4

Lg Lg D103 D103 013 013 LgSb LgBr G601 S609 112 104 4

SbW L H703 D205 207 005-a RLg SbW H738 S615 206 203 1

BrB L G402 D205 257 005-a B BrB S611 258 1

BrR L G202 D205 272 005-a B L S610 273

LG LW S502 S508 142 144 LG B A709 132 1

VOLTAGE RELAY

(BLACK)

(BLUE)

(BLACK)

(BLUE)

YL YO H757 S2S H706 H758

8 Lg V703 013 GW V701 210

OSb V704 211 4

CAB ALARM BUZZER

DOWNSHIFT BUTTON PILOT VALVE MAGNETS

AIR-SUS.

S2L H759

S2H W H760 D506

5 OY D114 007

PG PW H745 H731 739 740 BrG B H718 738

B 2

DIAG INC/DEC S/W

1 1

FLOAT

SHIFT HOLD S/W (OPT)

LEVELER

TURN SIGNAL

Br D110 003

1 (BLUE) Br

BrR

BrW

G V805

BrB

G D107 010

LgSb X504 112

P R B909 D111 320 004 B

E L

(BLUE)

2 WG WL H710 H766 705 707 B B

HAZARD

YSb S917 125

KICKOUT

BP G A101 D107 A108 010 B 4

AIRCON UNIT

G8 H9

C607 C608 C609 C610 LO GW BY BrY

C404 C405 C406 C506 Sb GO WR WP

C606 C605 C604 C603 C602 D701 C601 C507 C402 C401 P LgR BrB LgY WY V PB YB VW RL 11

8 5

H8 7

226 154 X904 X901 LgB LgR 221 150 X903 X902 LgB LgR

L YGy E706 E704 005-a 242 R B H804 243

4 SPEED INDICATOR RELAY

LOWER KICKOUT RELAY

1 4

(BLACK)

1 6

910 D301 R 911 D402 R

1 912 D401 R 913 D901 R

BY R E701 V404 114 243 SbR V E702 E703 240 100

1 914 D002 R 915 D001 R

901 E201 W

8 330 744 062 172 N803 S709 X704 V211 D504 S722 A503 H003 K202 BG BW SbY WG RW RL V 312 743 181 171 S707 B208 V207 S811 S730 K203 H004 H016 RGy GY BrY SbY BY Y YR 327 742 220 170 F204 209 267 K103 V208 S723 S614 X604 F103 S501 RBr GR GyO WR RLg SbY GB 221 266 F604 180 182 162 X803 S801 K106 S731 S806 B506 RB GyL LgL LgG LgB GyB 331 019 325 S724 506 500 S619 D609 K101 N802 C308 C307 RG OR RO WL PL PB 70 64

H6 1

PB LgR LP S920 X802 S517 152 150 149 LY LG LO LR LB LBr S518 S502 S505 S613 S601 S604 141 142 143 146 147 148

F7 SECONDARY EMERGENCY STEERING STEERING RELAY RELAY (EU: STANDARD) (EU:STANDARD)

BY V Br S707 S709 D110 H724 H708 003 LgL BrR BrW S504 S826 G302 261 251 250

1A 2 4

(BLACK)

3 3

E/G DROOP SELECTION RELAY

BUZZER RELAY

1A 1 3

R R D108 D108 001 001 RB RB B914 301

FUSE

G L D102 D205 014 005-a RL SbP H761 S618 703 145

AIR TEMP. PROBE (MCU)

BrG YO S922 B001 255 176 BW LgY S813 A803 271 167 B LP S915 168

H742 306 H767 A102 F403 A107 B RBr RY RO 311 H756 329 308 B108 F604 F804 F404 RLg RB GW RW

BR Y C509 C611

WY V PB YB VW P H920 H919 H918 H917 H916 H914

1 168 T606 B LP 271 167 T706 T608 BW LgY 255 176 T708 T601 BrG YO

B J

LO GW BY BrY Y RL 12 H901 H902 H903 H904 C801 D701

4 GyY GyW BL H746 H732 H717 736 737 741 YV BLg BrW H719 H705 H733 734 735 733

DECLUTCH SENSOR 2

−

TORQUE SELECTION RELAY

SbY SbR H737 S608 209 208 B B

E/G IDLE SELECTION RELAY

RB BrB LgY F604 H912 H911 300

BR BL 10 WP LgR PL C5 H910 H913 H015 C802 H008 H011 WG OL BrW BG B H014 H013 H012 H007

THROTTLE PEDAL

16 RY RBr RO F403 A102 A107 307 326 324 LgY RGy F002 B101 167 B201 1

Sb GO WR 6 H907 H908 H909

DECLUTCH SET-UP

CAB (AIRCON) 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 H764 H765 D609 D608 D607 D606 500 506 019 018 017 016

GyB B S514 103 LgR GY WL S521 S520 S624 130 169 400 8

L C101 801 L C102 802

LLg

LIFT KICKOUT SET-UP/ LOWER KICKOUT SET-UP

DECLUTCH CUT-OFF S/W

S921

S2L S2H H759 H760 S720 S729

GND

L B402 802 L B401 801

RB A611 300

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

HORN S/W

6 L LgG D206 H753 005-b 162 GO SbW B S901 A712 164 163 1 3

R D602 023 R D601 024

S2S H758

COMBINATION S/W FOR LAMPS

F801

PARKING S/W

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 H749 H735 H763 S524 S734 S721 013 241 235 731 732 730 224 401 402 10

A0 SHIFT LEVER

−

EMP GND

1/4

1/2

B3 1

3/4

SS WTM TTM

257 T903 BrB

8 RO RO BP B911 A815 G803 321 K101 323 RBr RBr BP B910 A814 G803 322 K103 323

EG2 EG1 EG3

250 K206 BrW

8 GyG Gy LgY LgW S515 S519 S528 F903 753 749 173 102 Sb WG LgW GyL S513 H710 S527 S516 194 705 192 190 4 1

272 T003 BrR

3 4

GND

YSb S506 403

F/R S/W SELECTION (EU STANDARD)

COLD STARTER S/W

INSTRUMENT PANEL

S914

REAR WORKING LAMP

1 2

HAZARD

FRONT WORKING LAMP

EFFICIENT LOADING SYSTEM (ELS)

FUEL EFFICIENT MODE SELECTION

212 748 735 205 207 405 409 S525 T402 C002 F203 X603 S817 S821 GW YO BLg Sb SbW YR YG 140 160 734 738 741 406 015 S507 S716 C001 G004 C004 S828 D101 LLg Y YV BrG BL YB WR 732 159 733 737 740 407 751 A606 S708 C003 C005 G002 S820 F302 BrW Y BrW GyW PW YL GyR 731 184 722 736 739 408 161 A607 S815 A008 C006 G003 S829 S715 BrB Sb BrB GyY PG YBr W 730 183 703 T406 T405 T404 747 A605 S814 F704 C201 C202 C203 T403 BrR SbO RL S2H S2L S2S YL 63 57

C501 C510 BG BL

D803 D701 H722 C508 C504 C503 C502 C509 YR PL WG OL BrW BR RG RL

D804 D802 H709 H723 R RB RW Y

This page illustrates the transmission is in neutral and key switch is in OFF position. (FM) 115ZV2-09709-09370A EU 1/3

115V2E92028

115ZV-2 FS EU 92-14 92 Drawing & Diagrams Electrical Wiring Diagram (2/3) (S/N 9051~9100)

Electrical Wiring Diagram (2/3) (S/N 9051~9100) MCU A16.TT_L A17.D_SO A18.1_SO A19.EP_L A20.AB_L A21.A_L A22.1/2_L A23.E_L A24.SS_L A25.SC_SW A26.TF_L A27.AC_L A28.BP_L A29.N_L A30.SC_L

A 1.2S_SO A 2.2_SO A 3.ES_R A 4.DD_SO A 5.3_SO A 6.HM A 7.LU_SO A 8.4_SO A 9.EG_SW1 A10.R_L A11.F_L A12.ST_L A13.WL_L A14.CW_L A15.ET_L

OPT

A10

A11

A12

A13

A14

A15

A16

A17

A18

A19

A20

A21

A22

A23

A24

A25

A26

(WHITE)

A27

A28

A29

A30

A31

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.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

A33

A34

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

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

E10

E26

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

E33

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

C10

C11

C12

C13

C14

C15

C16

C17

C18

C19

C20

C21

C22

C23

C24

C25

C26

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

C27

C28

C29

C30

C31

C32

C33

D10

D11

D12

D13

D14

D15

D16

D17

D18

D19

D20

C34

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

D21

D22

D23

D24

D25

D26

(BLUE) B

JPN 3

PL P S803 S802 108 107 B

AUTO/FULL AUTO SELECTION

F23 CHANGE POINT SELECTION

F34 CHANGE POINT SELECTION

ODOMETER SELECTION

PW S831 111

VG S925 157

VY S913 158

PB S916 110

PG S902 109

A/M SELECTION

(BLUE)

(GREEN)

(BROWN)

SbO LgW LgY GR OSb YBr RL YB A612 A502 A507 A701 V204 A618 A608 A616 193 192 173 135 211 413 235 411 YG LgB GW LY Gy GY LgR YL A708 A506 A807 A808 A617 A619 A604 H707 H201 749 169 130 412 414 224 V212 YR Sb GyB GyG GyL LP 0 RL A615 A609 A504 A809 A505 A501 H208 330 410 241 194 103 753 190 149 GB LG YGy LgL LO YSb LLg LW SbP H736 H202 E804 K204 A710 A901 H721 A711 F202 267 V303 242 261 H203 403 140 V302 202

GR YB WL GyG YO T103 T303 A806 W301 T305 811 115 400 754 118 WR SbW GL YBr SbP RG H739 X601 T104 T301 F701 H770 170 203 810 119 145 331 L SbR LgBr BrB LgW LR F102 X501 T001 T901 F901 H204 208 104 273 258 101 146 LB GB LBr LgR LgL BL H205 V101 H206 X801 E502 E001 147 278 148 154 225 237 9

YG LgR S2H SbY GyL G YB C703 C201 H725 H755 C901 T302 A603 166 171 180 415 116 401 YL G S2L BrW SbY GyO WL E003 C202 A602 H711 H740 H766 T304 234 402 172 220 707 117 L L W Y G D203 D204 H743 H720 D107 005-C 005-D 161 160 010 B V BR LgB L L B BY Y E002 X804 D201 D202 H734 236 226 005-A 005-B 159 7

100 C702 E803 E004 K202 T101 H708 9

(BLACK)

C701 C902 E801 114

PB LLg BrG GW LB VG YW H210 B002 F004 V201 E006 W801 E012 152 165 255 210 230 157 233 YL LP PB YSb YV YO G101 F001 S301 G901 A407 E005 124 168 110 125 231 232 LR B LY LW VY B703 B709 B706 W901 121 126 120 158 GO PG LG LBr LO B503 S401 B702 B708 B701 164 109 122 128 123

PW Y GyW LgY BrR SbR YB YBr E603 E501 K205 E802 H716 H744 T202 W701 251 240 406 408 105 111 260 223 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 H750 S102 S103 H754 266 107 108 182 1

E007 W302 K203 T102 H724

S9 T3

FUSE BOX (CAB) R5

ACC C

W W

STARTER S/W

WRx2 WBx2

STARTER SWITCH

G D502 064

O WR

LW B

R B202 B207

R G702 004

BW A007 012

R H301 910

WR RL

O OL OR D608 D609 D610

OG D606 L V808

4 3 5 6 1 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 X602 005-a

BW W H712 E202 062 T407 WR G WR E107 E101 E106 065 064 063

R H302 911 R H401 912

1 V203 X502 X503 X703

RG OY B102 T501 B107 007 WR G F703 H715 014 015

013 A207 A307 A610 A706 E601

MCU SELECTION

7 C304 F802 F803 G501 G802 S717 010

W D506 060 W H601 901

WR WR D501 D503 063 065

001 8 R F406 F502 F503 F602 G F603

4 RL RG LR LW YR YW

003 G201 G301 G401 K201

R R D602 D601

RL 1

(EU:STANDARD)

5 V801 W

RG RB H018 H002

1 4

R H402 913

R H501 914 R H502 915

OUT

R Y S812 S830 106 105

SPARE

G G501

L V904

W D604 1

YO E405 232

8 YW E412 233

RL X704 330

Lg LgL S825 S606 222 225 B LgY S834 223

SECONDARY EMERGENCY STEERING STEERING (EU: (EU :STANDARD) STANDARD)

RIDE CONTROL S/W

REVERSAL FAN S/W

BACK LAMP

E/G WATER TEMP. SENSOR (FOR INSPECTION)

1 3 4 6

Y D607

1 B

OUT

FR SWITCH (EU : STANDARD) 2

BIN

RS232C

1 BY GyG S707 S625 114 754

C612 H915 H017

V902 V901 R R

DC-DC CONVERTOR (EC : STANDARD)

O 10 OG OW OL OR C312 C311 C310 C309 C301 016 017 018 H768 020 WBr R R C303 B301 B302 022 023 024

V GL S616 S709 810 100 GR BY S622 S707 811 114

V906 V804 V908 V909 V910 O 10 Y OL OR 6 OG

W3 1

R H001

1 YG YBr YB S623 S733 S617 115 116 119 YO YL B S725 S626 117 118

FUSE BOX (MAIN) R5

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

FR SWITCH (EU : STANDARD)

6 B

B 6

YO E306 232

PRESS. INTENSIFYING

YW E308 233 12

TRACTION CONTROL (EU : STANDARD) 1

BR G V YO LB BL S607 S701 S719 S709 S919 S924 237 236 234 100 232 230 YW B L BY S926 D205 S707 233 005-a 114 12

F/R SWITCH/ STICK STEERING

GB GB S603 S824 278 277 1

6 GW Lg OSb V602 V607 V604 210 013 211 GW BG B GR GY V502 V503 V501 212 744 742 743

OSb Lg GW S530 D103 S923 211 013 210 GY GR B BG GW H727 H741 H713 S525 743 742 744 212 12

Note: Refer to "Traction Control Switch Mount" page 92-58.

This page illustrates the transmission is in neutral and key switch is in OFF position. (FM) 115ZV2-09709-09370A EU 2/3

115V2E92029

115ZV-2 FS EU 92-15 92 Drawing & Diagrams Electrical Wiring Diagram (3/3) (S/N 9051~9100)

Electrical Wiring Diagram (3/3) (S/N 9051~9100)

329 K107 GW

LBr H206 148

HYD. OIL LEVEL S/W

+ −

1 RLg

311

K105

−

2 2

B W

−

K103

LO H203 143

−

303

K801

327

K802

V L301 BrR 100 L302 BY 251 L303 114

BrR K205 251

V K202 100 BY K203 114

1 B

WR H739 170

LgG H753 162

B LgL L401 261

LgL H754 182

LgL K204 261

LgL R801 R803

LgL L401 261 3

SECONDARY EMERGENCY STEERING STEERING OIL PRESS. SENSOR OIL PRESS. SENSOR

LgL L806 182 R

ELECT. FAN CONDENSER

ETHER INJECTION VALVE

T/M OIL FILTER

LOCK UP SOLENOID

W N303 900

AIR CLEANER WP P601 708

WL N901 H766 706 707

W H601 P50A P50B P50F 901 081 085

R H301 H302 H401 H402 H501 H502 910915 BW H712 062

O R

WATER LEVEL SENSOR

BLg H705 PG H745

GyW H732

BrW H733 GyY H746

W H743

RLg H738

31 30 19 BrW H735

BrB H749

Sb H704 PW H731

SbW H703

BrR H763

N3 BATTERY RELAY

2 B

W N102 900

BW P001 702 2

N002 H758 S2S

N004 H760 S2H N003 H759 S2L

RGy R102

312

REAR WORKING LAMP

312

REAR WORKING LAMP

RGy R102

COMPRESSOR CLUTCH (ECC)

13 14

R N304 701

RL N906 703

WG N905 705

1 703 N701 RL 705 N704 WG

2 015 708 N401 N402 WR WP B

YR 3

WG B H710 705 RL WL H761 M701 703 706

WR WP H715 M702 015 708

DIODE UNIT

YR H722 1

330 R103 RL

R501

RB R104 303

R502

BACK UP ALARM

LICENSE LAMP

LH BATTERY −

1 303 R501 RB B 330 R301 R401 R201 RL RGy RL RGy H714 H728 330 312 RB B H756 303

REAR COMBINATION LAMP (R.H)

REAR COMBINATION LAMP (L.H)

RH BATTERY 1

− +

24 25

This page illustrates the transmission is in neutral and key switch is in OFF position.

4 1

N4 700 N301 WV 015 708 P601 P602 WR WP

23 12

ECM

N7 MAGNETIC S/W

WV N403 700

22 11

15 SbY H737

10 3

1 6

21 9

29 BrG H718

BL H717

20 8

N601

BrR

H747 BrB

3/4 B

M7 ALTERNATOR

GyG BY H769 H724 754 114

YV H719

70A

−

BW N702 702

FUSIBLE LINK

FUSIBLE LINK 30A

B L802

E/G WATER TEMP. S/W (COLD STARTER)

E Y

R N703 701

T/M OIL TEMP. SENSOR

1/2 W

Sb H748 184

FUEL LEVEL SENSOR

P0 STARTER

F E

N6 1 BrR M002 721

+ −

RW Y L803 L804

SECONDARY EMERGENCY STEERING STEERING MOTOR RELAY MOTOR RELAY

SECONDARY EMERGENCY STEERING STEERING MOTOR PUMP MOTOR PUMP

T D

1/8 G

1/4 R

−

182 L002 LgL

−

L903 B

SECONDARY EMERGENCY STEERING STEERING MOTOR PUMP MOTOR PUMP

GW H707

CAN (RESISTOR)

+ − −

L902 L901 RW Y

LLg H721 140

R H804 243

3 1

B RW Y H709 H723

SECONDARY EMERGENCY STEERING STEERING MOTOR RELAY MOTOR RELAY

V BY H803 H801 100 114 SbR H802 240

6 B

BG H713

BRAKE OIL PRESS. (MAIN)

GyL BY H755 H724 180 114

YR B H702 405 YB YG H716 H701 406 409 YL YBr H730 H744 407 408

PARKING SOLENOID

AUTO BRAKE SOLENOID

P J701 153

RIDE CONTROL SOLENOID (OPT)

U C

GyR H729

S +

V J B

GY H727

BY V H708 H724 100 114 SbY H711 172

BY V H708 H724 100 114 SbY H725 171

PRESS. S/W

PB P H210 J902 152 153

LgB H751 221 1

PRESS. S/W

M9 1

70A

V L201 100 BrR L203 251 BY L202 114

BO 745

Y Y H720 H734 160 159

8 7

DATA LINK CONNECTOR

LgR H209 150

BOOM ANGLE SENSOR

GROUND SPEED SENSOR

L5 M1

SPPC 1

LP H208 149

Br K201 003 BrW B K206 250

K803

GB H736 267

D B

K106

BrY H726 181

GyO BY H740 H724 220 114

GR H741

GyB H750 266 BY V H724 H708 114 100

(BLUE)

K0 1

JPN:CONNECT EU :DISCONNECT RBr

−

RW RY K108 K102 308 306 B

LG H202 142

FAN SPEED CONTROL SOL. VALVE

PL H765 506

PB PL

YO H706

4 R

FRONT HEAD LAMP (OUTSIDE)

BUCKET LEVELER

WASHER MOTOR

OR PB H764 H768 500 019

COMBINATION LAMP

LY H201 141

−

EFFICIENT LOADING SYSTEM (ELS) SOLENOID VALVE

YL H757

5 1

HYD. OIL TEMP. SENSOR

W N101

S2L 2 S2H P902 S2S P901 P903

−

EFFICIENT LOADING SYSTEM (ELS) OIL PRESS. SENSOR

3 4

−

114 L601 M301 L702 M502 M201 M602

WORKING LAMP (INSIDE)

B GW K701 K703

W N101

GW K601 329

L602 M202 M302 100 H7

WR H715

−

LB H205 147

−

K7 HORN (H)

W N101

GW K601 329

+ 4

R103 R602 R702 330

70A

HORN (L)

−

W N101 901

V Br BY L103 L201 L202 003 100 114 BrW BrR LgL L102 L203 L401 250 251 261

311

K105

−

LR H204 146

R N201 915 R N201 914

3 RLg

R N201 913 R N201 912

WORKING LAMP (INSIDE)

R N201 911 R N201 910

325 330 H767 H714 RO RL 303 331 H756 H770 RB RG

H2 T/M SOLENOID VALVE 4

RW RY K108 K102 308 306 B

3 240 100 P403 P402 SbR V 114 X301 P401 P301 BY R

57 BrR SbO RL S2H S2L S2S YL P816 X101 N906 P901 P902 P903 N001 730 183 703 747 W BrB Sb BrB GyY PG YBr P817 X201 M001 P809 P823 J804 P831 731 184 722 736 739 408 161 BrW GyW PW YL GyR BrW Y P818 M901 P820 P810 P824 J803 P70A 732 159 733 737 740 407 751 YV BrG BL LLg YB WR Y N502 M902 P821 P801 P811 J802 P50H 140 160 734 738 741 406 P602 YG GW YO BLg Sb SbW YR P70O N008 P822 P812 P813 J801 J805 212 748 735 205 207 405 409 7 1

K503 2

327 330 H742 H714 RBr RL 303 331 H756 H770 RB RG

64 RG GyG OR RO WL PL PB R605 M601 M801 R603 M701 M803 M802 R705 754 019 325 707 506 500 RB GyL LgL LgG LgB GyB M501 L806 M101 P101 L603 221 266 180 182 162 RBr GR GyO WR RLg SbY GB R703 P70L L701 X401 P808 P814 L501 327 742 220 170 206 209 267 RGy GY BrY SbY BY Y YR R102 P70M M401 M203 L804 P201 312 743 181 171 V BG BW SbY WG RW RL P70N N201 M303 N905 L803 744 062 172 705 14 8

K502

70 303 R104 R604 R704

−

325

FRONT HEAD LAMP (OUTSIDE)

6 LG LY LO LR LB LBr J402 J502 J602 J102 J202 J302 141 142 143 146 147 148 PB LgR LP B J702 J001 R901 152 150 149

K101

K501

SbO H762

K106

303

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

(FM) 115ZV2-09709-09370 EU 3/3 115V2E92030

115ZV-2 FS EU 92-16 92 Drawing & Diagrams Electrical Wiring Diagram (1/3) (S/N 9101~9200)

Electrical Wiring Diagram (1/3) (S/N 9101~9200)

RO B911

8 BP G803

ES TF

SbO S526

012

013

173

705

192

1/4

YL YBr YG YR YB S511 S533 S522 S531 S523

193

410

013

241

235

731

732

411

412

413

730

224

401

P RBr RO RW G703 A103 A106 F401

RB RY F601 F501

320

322

321

304

LR LBr S911 S904

G 6 LgG H753

301

4 Sb GO WR 6 H907 H908 H909

520

300

010

022

521

020

500

506

019

018

017

016

736

(S/N ~9150)

YV S918

006

403

741

735

100

BW F005

BrG F004

LP F001

255

LgY F002

YO F003

733

O Y V

T606 LP

271

167

255

176

BrG YO S922 B001 255

E/G IDLE SELECTION RELAY

TORQUE SELECTION RELAY

167

LP S915

R H804

243

HI-BEAM RELAY (UL)

HEAD LAMP RELAY (LH)

WIDTH LAMP RELAY (LT)

NEUTRAL RELAY HORN RELAY

2 209

208

3 205

202

RLg H738

Sb SbP H704 S509

Gy GyR S816 H729 750

751

R D108

RY RW F504 B912

308

A813 W102

305

(BLACK)

(BLUE)

001

305

302

(BLACK)

C403 W106 H756 300 303

001

RB B914

014 703

010

329

328

(BLACK)

010

GW GL W107 B801

145

(BLACK)

G G D107 D107

005-a

RL SbP H761 S618 1

G L D102 D205

301

R R D108 D108

001

RY RY F402 B915

304

R R D108 D108

001

RW W108 307 306

(BLACK)

R RL D111 S619 004

245

RG H770

2 102

005-a

LgW S612

742

744

GY V707

SbR L X002 D205

LgSb LgBr G601 S609

RLg SbW H738 S534

RLg SbLg H738 S615

207

013

104

005-a

206

216

203

206

YO H706

2 211

S2S H758

S2H W H760 D506

060

AIR-SUS.

5 OY D114

007

739

740

BrG H718

738

114

BACK RELAY

1A 2 4

L S610

258

273

144

LG A709

WG WL H710 H766 705

707

H714 T801

132

142

(BLUE)

CAB ALARM BUZZER

PILOT VALVE MAGNETS LEVELER

YSb S917

Br D110

B Br

125

1 (BLUE) Br

003

LgB LgR H751 H209 221

150

LgB LgR S702 S605 226

330

154

(BLACK)

P R B909 D111

112

010

BrB

3 A101 A108

G D107

323

B 1

SbR X703

216

SbW H703

010

207

004

LgSb X504 G D107

320

Br BrW

G V805

2 BrR

003

HAZARD

Br D110

138

RESISTOR

TURN SIGNAL

SHIFT HOLD S/W (OPT)

003

013

KICKOUT

Br D110

Lg LB D103 S510

(BLUE)

204

LW LG S502 S508

(BLUE)

BrB S611

005-a

AIRCON UNIT

C607 C608 C609 C610 LO GW BY BrY

C404 C405 C406 C506 Sb GO WR WP

272

BrR L G202 D205

(BLACK)

005-a

(BLACK)

2 PG PW H745 H731

257

BrB L G402 D205

(BLACK)

DIAG INC/DEC S/W 3

S2L H759

210

747

748

013

GW V701

YL H757

005-a

(BLACK)

FLOAT

Lg V703 OSb V704

743

8 5

GR BG V708 V711

VOLTAGE RELAY

(BLUE)

FUSE

4 SPEED INDICATOR RELAY

(BLACK)

DOWNSHIFT BUTTON

SbW L H703 D205

112

Lg Lg D103 D103 013

101

LgW L A508 D205

331

LOWER KICKOUT RELAY

LIFT KICKOUT RELAY

(EU:STANDARD)

E/G DROOP SELECTION 1 RELAY

1 3

168

BR Y C509 C611

242

E/G OIL PRESS. S/W RELAY

E/G DROOP CONTROLLER SELECTION 2 FAULT RELAY BUZZER RELAY RELAY

BRAKE RELAY

176

271

SLIP CONTROL

415

L YGy E706 E704

005-a

BW LgY S813 A803

BY G S707 S732

167

166

AIR TEMP. PROBE (CONTROLLER)

310

(BLACK) B

T708 T601 BrG YO

LgR S727

AIR TEMP. PROBE (THAM)

002

231

C306 H728

R RGy D109 A801

206

168

114

C302 W105

520 312

R G B

002

310

8 R RGy D109

521 311

RG RGy D113 A801

YSb S506

B101 1 B201

8 RG RLg D113

T706 T608 BW LgY

BY V S709 S707

8 308

F804 F404 GW RW

329

303

141

S707 H724

S709 H708 BY

114

100

261

251

Br D110

003

LgL BrR BrW S504 S826 G302 4

152

150

149

142

143

146

147

1 910

148

D301 R D402 R

1 912

D401 R 913

D901 R

114

915

D001 R

E201 W

240

8 330

744

062

172

X904 V211 D504 S722 RL BG BW SbY

243

312

SbR V E702 E703

901

100

327

181

171

742

220

170

180

182

162

019

325

H003 WG RW

114

303

RB 331

S619

(S/N 9108~)

100

RG 70

S731 S806 B506 GyL LgL LgG

707

748

735

205

207

405

409

S525 T402 C002 F203 S817 S821 GW YO BLg Sb SbW YR YG S507 S716 C001 G004 C004 S828 D101 LLg Y YV BrG BL YB WR

140

160

734

738

741

406

015

209

267

732

159

733

737

740

407

751

221

266

731

184

722

736

739

408

161

506

500

X803 S801 LgB GyB

C308 C307 D609 W101 PB OR RO WL PL 64 S724 N802

1 212

X603 X001 7

H004 H016 Y YR

F103 S501 W103 V208 S723 S614 RBr GR GyO WR RLg SbY GB

206

F604 W106

(S/N~9107)

743

B208 V207 S811 S730 RGy GY BrY SbY

F204 X604 X704

705

Z504

250

4 BY R E701 V404

914

D002 R

N803 S707 S709 A503 W203 W202

H6 1

911

PB LgR LP S920 X802 S517

LY LG LO LR LB LBr S518 S502 S505 S613 S601 S604

H756 F604

311

B108 RLg

H742 A102

H8 7

12 B

C606 C605 C604 C603 C602 D701 C601 C507 C402 C401 P LgR BrB LgY WY V PB YB VW RL 11

1 325 306

F403 RBr RY

H767 A107

327

737

(EU:STANDARD)

006

310

4 GyY GyW BL H746 H732 H717

REMOTE THROTTLE

DECLUTCH SENSOR C6

RGy

167

DATA LINK CONNECTOR

PB YB VW P WY V H920 H919 H918 H917 H916 H914

LgY F002

802

THROTTLE PEDAL

BY S707 114

7 LO Y RL 12 GW BY BrY H901 H902 H903 H904 C801 D701

166

400

SbY SbR H737 S608

LgR S727

169

324

L C102

168

(S/N 9151~) DECLUTCH SENSOR

130

(S/N 9108~)

V 2 S709 100

LgR GY WL S521 S520 S624

326

YV BLg BrW H719 H705 H733

307

734

300

6 WP LgR PL BR BL 10 H910 H913 H015 C802 H008 H011 WG OL BrW BG B H014 H013 H012 H007

PB PL OR OL OW OG H764 H765 D609 D608 D607 D606 1

RY RBr RO F403 A102 A107

801

CAB

RB BrB LgY F604 H912 H911 3

RGy RB G WBr RLg O B208 A611 D107 D604 B108 D610

S2L S2H H759 H760 S720 S729

(EU:STANDARD)

176

S2S H758

CAB (AIRCON)

L C101

123

300

DECLUTCH CUT-OFF S/W (OPT)

165

163

122

LIFT KICKOUT SET-UP/ LOWER KICKOUT DECLUTCH SET-UP SET-UP

302

271

121

RB A611

SECONDARY STEERING RELAY

R D602

120

103

LG LO LY S910 S903 S905

162

135

LLg

005-b

GO SbW S901 A712

128

LW S912

GyB S514

GR S529

S921

L D206

126

176

GND

164

163

013

024

1 6

F003

144

Lg D103

402

HORN S/W

328

143

R D601

132

023

F801

PARKING S/W

801

141

12 LY LG LO LW SbW S518 V304 S505 S508 B502

COMBINATION S/W FOR LAMPS

802

414

SHIFT LEVER

L B401

265

L B402

EMP GND

Lg O RL BrB BrW BrR LgB YB BrW D103 S512 S532 H749 H735 H763 S524 S734 S721

190

722

WTM TTM

1/2

3/4

20 7 300

102

Sb WG LgW GyL S513 H710 S527 S516 194

257

GL S822

749

EG2 EG1 EG3

T903 BrB

753

GyG Gy LgY LgW S515 S519 S528 F903

8 BW BrB D105 H747

Lg D103

200

326 327

013

GyW S823

323

A814 W103

+ (+)

250

8 Lg D103

323

322

TT CE

W206 BrW

RBr RBr BP B910 G803 4

AC BP

272

321

C EP

WL WT

GND

A815 W101

T003 BrR

(EU STANDARD)

B601 C305

COLD STARTER S/W

4 5

324 325

F/R S/W SELECTION

INSTRUMENT PANEL

REAR WORKING LAMP

124

HAZARD

FRONT WORKING LAMP

EFFICIENT LOADING SYSTEM(ELS)

S914

FUEL EFFICIENT MODE SELECTION

C501 C510 BG BL

D803 D701 H722 C508 C504 C503 C502 C509 WG OL BrW BR YR PL RG RL 18

D804 D802 H709 H723 R RB RW Y

A606 S708 C003 C005 G002 S820 F302 BrW Y BrW GyW PW YL GyR A607 S815 A008 C006 G003 S829 S715 BrB Sb BrB GyY PG YBr W 730 183 703 T406 T405 T404 747 A605 S814 F704 C201 C202 C203 T403 BrR SbO RL S2H S2L S2S YL 63 57

115ZV2-09709-09970 EU 1/3

K115V2E92005

115ZV-2 FS EU 92-17 92 Drawing & Diagrams Electrical Wiring Diagram (2/3) (S/N 9101~9200)

Electrical Wiring Diagram (2/3) (S/N 9101~9200)

$ #

% " "

# ( # $ # $ # # ( # # # # #

2 $

$ $

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# (

# / #

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&! &

&! &!

, $

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# (

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# #

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( # # $) $ #

& #

/ #

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' $ $

! # ! # !

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' "

% % ' # &

+ 3

0 0

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& ' ! % 01

# / #

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( # ( # , #

# #

/ #

% " !

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Note: Refer to "Traction Control Switch Mount" page 92-58.

+& 0 ! !0 !! (

, & !

115ZV-2 FS EU 92-18 92 Drawing & Diagrams Electrical Wiring Diagram (3/3) (S/N 9101~9200)

Electrical Wiring Diagram (3/3) (S/N 9101~9200) 1

100

251

003

250

GB H736

SPPC

R9 2

SbY H711

114

406

409

407

408

1/4 R

1/8 G

1/2 W

E Y

3/4 B

L8 1

RIDE CONTROL SOLENOID (OPT)

V BY H803 H801

LgL H754

SbR H802

182

114

100

T/M OIL FILTER

B B

L903 B B

261

LgL L401

261

SECONDARY STEERING OIL PRESS. SENSOR

E/G WATER TEMP. S/W (COLD STARTER)

M7 ALTERNATOR

3 1

FUSIBLE LINK

900

AIR CLEANER WP P601

ELECT. FAN CONDENSER

WV N403

700

703

708

WL H766 707

901 081 085

WR H739

LgG H753

170

701

705

R H301 H302 H401 H402 H501 H502

015

N301 WV 015

703 705

AUTO BRAKE SOLENOID

P601 P602 WR WP

DATA LINK CONNECTOR

B 2

910915

YL H757

BW H712

705

WR WP H715 M702

062

015

DIODE UNIT

RL H761

708

703

23 12

13 14

24 25

REAR WORKING LAMP

RGy

748

R501 RB

3 3

N004 N002 H760 S2H H758 N003 S2S H759 S2L

330

R103 RL

REAR WORKING LAMP

BACK UP ALARM

RB R104 303

LICENSE LAMP

LH BATTERY +

312

R401 RL RGy RL RGy H714 H728 RB H756

P9 2

312

R102

303 330

YO H706

CAN (RESISTOR)

WG H710

5 15

22 11

312

R102

R501 R502

S2L 2 S2H P902 S2S P901 P903

330

209

1 4

SbY H737

10 3

730

PARKING BRAKE SOLENOID

708

207

RGy

N704 WG

708

N401 N402 WR WP

SbW H703

731

21 9

BrR H763

N701 RL

732

BrB H749

738

20 8

162

(BLUE)

MAGNETIC SWITCH N7

WG N905

30 BrW H735

BrG H718

741

Sb H704

161

206

736

740

R N304

W H743

RLg H738

737

PW H731

733

GyY H746

BL H717

205

747

W H601 P50A P50B P50F

RL N906

700

W N303

N601 721

H747

BrR

114

722

180

BrB

GyL BY H755 H724

2 E

702

70A

BW P001

30A

B L802

701

FUSIBLE LINK

RW Y L803 L804

T/M OIL TEMP. SENSOR

N3 BATTERY W RELAY N102 900

R N703

702

PG H745

BrW H733

ECM

735

B 4

PL H765

WASHER MOTOR

P0 BW STARTER N702

BLg H705

506

500

SECONDARY STEERING MOTOR PUMP

182

L002 LgL

L902 L901 RW Y

261

LgL K204

LgL

261

LgL L401

OR H768 PB H764

B +

019

GyW H732

70A

R801 R803

YV H719

S P

184

212

ETHER INJECTION LOCK UP VALVE WATER SOLENOID LEVEL SENSOR

2 S

F E

T D

721

243

240

RW Y H709 H723

1 BrR M002

734

R H804

243

FUEL LEVEL SENSOR

SECONDARY STEERING MOTOR RELAY X3

R H804

Sb H748

U G

744

GW H707

739

BG H713

M C

751

140

153

LLg H721

BRAKE OIL PRESS. (MAIN)

70A

114

GROUND SPEED SENSOR

743

GyR H729

M4 X1

YL YBr H730 H744

405

V J

GY H727

742

181

YG YB H716 H701

172

BY L202

251

114

100

YR H702

P J701

V K202 BrR K205 100 BY 251 K203

182

BrR L203

153

SbY H725

114

GR H741

BrY H726

221

V BY H708 H724

100

159

V BY H708 H724

171

PB P H210 J902

V L303 BrR 100 L302 BY 251 L301

1 L L H720 H734

LgB H751

100

152

114

YR H722

V BY H724 H708

PRESS. SW

267

L7 M9

160

745

R301 R201 2 2

312

303

REAR COMBINATION LAMP (RH)

100

266

143

LgL L806

V L201

114

LO H203

PRESS. SW BOOM ANGLE SENSOR

085

REAR COMBINATION LAMP (LH) R

250

W N101

250

220

150

085

COMPRESSOR CLUTCH (ECc)

251

GyO BY H740 H724

LgR H209

BrW K206

015

261

003

W N101

331

003

K801 K802

Br K201

L601 M201 M301 L702 M502

081

WR H715

100

BUCKET LEVELLER

W N101

409

303

114

K803

405

207

HYD. OIL LEVEL SWITCH

GyB H750

142

327

FAN SPEED CONTROL SOLENOID VALVE

LG H202

303

205

735

748

H756 H770 RB RG

149

K103

LP H208

K106

212

RB RBr

100

COMBINATION LAMP

P50H P602

114

ELS OIL PRESS. SESOR

LY H201

JPN,EXPO:CONNECT EU:DISCONNECT

ELS SOLENOID VALVE

WR 015

GW YO BLg Sb SbW YR YG P70O N008 P822 P812 P813 J801 J805

705

751

172

406

B 261

062

741

738

251

BG BW SbY WG RW P70N N201 M303 N905 L803

734

160

161

331

HYD. OIL TEMP. SENSOR

141

LgL BrR BrW W204 W205 W206

250

140

407

740

737

308 329

B 2

BrW BrR LgL L102 L203 L401

114

181

733

159

408

739

736

BY V Br W203 W202 W201

100

171

743 744

732

267

312

330

148

V Br BY L103 L201 L202 003

209

722

184

303

LLg Y YV BrG BL YB N502 M902 P821 P801 P811 J802

206

170

731

266

747

Y YR RGy GY BrY SbY BY L804 P201 R102 P70M M401 M203

220

742

221

162

H756 H770 RB RG

RW RY K108 K102 308 306 B

FRONT HEAD LAMP (OUTSIDE)

703

BrW Y BrW GyW PW YL GyR P818 M901 P820 P810 P824 J803 P70A

182

311

K105

R103 R602 R702

183

730

RBr GR GyO WR RLg SbY GB R703 P70L L701 X401 P808 P814 L501

180

L602 M202 M302

LBr H206

311

303

W105 W106 W107 W108 RLg RB GW RW

901

63 57 BrR SbO RL S2H S2L S2S YL P816 X101 N906 P901 P902 P903 N001

500

506

Sb BrB GyY PG YBr BrB W P817 X201 M001 P809 P823 J804 P831

GyL LgL LgG M501 L806 M101

327

914

707

LgB GyB P101 L603

W N101

915

912

303

325

LB H205

1 325 306

325

306 327

327

W103 W102 W101 RBr RY RO

RLg

R N201

913

910

WORKING LAMP (INSIDE)

R N201

911

8 308

RO K502 RY

303

K401 K901

329

GW K601 RB

RBr K802

K701 K703

K302 K002

329

K107 GW

311

B 329

K501 K801 1

K7 329

RLg

K303 K003

GW K601

R N201

147

329

HORN (H)

R N201

146

R N201

LR H204

HORN (L)

R104 R604 R704

019

330

X301 P301

T/M SOLENOID VALVE

BrW Br K201 K206

243

V BrR K202 K205

311

K105

261

114

P401 BY

331

325

RLg

114

149

64 OR RO WL PL PB M801 R603 M701 M803 M802

R605 R705

H767 H714 RO RL

WORKING LAMP (INSIDE)

BY LgL K203 K204

150

100

308

152

3 240

P403 P402 SbR V

306

RW RY K108 K102

327

306

RW GW RB RLg K108 K107 K106 K105 308 329 303 311

2 R

148

330

FRONT HEAD LAMP (OUTSIDE)

325

147

327

RO RY RBr K101 K102 K103

146

PB LgR LP J702 J001 R901

H742 H714 RBr RL

K503

143

325

142

K101

K106

141

183

6 LY LG LO LR LB LBr J401 J501 J601 J101 J201 J301

K501 K502

303

SbO H762

JPN,EXPO:CONNECT EU:DISCONNECT

COMBINATION LAMP

RH BATTERY +

115ZV2-09709-09970 EU 3/3

K115V2E92007

115ZV-2 FS EU 92-19 92 Drawing & Diagrams Electrical Wiring Diagram (1/3) (S/N 9201~)

Electrical Wiring Diagram (1/3) (S/N 9201~) ##'!' (" '( " ,- .

! ($

! (

! !

! "!$ (

$ $ $

! $

$' , - .

$ , - $.

% % $

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(

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115ZV-2 FS EU 92-20 92 Drawing & Diagrams Electrical Wiring Diagram (2/3) (S/N 9201~)

Electrical Wiring Diagram (2/3) (S/N 9201~) )

#" / 1

/ +" 1

2 # *

" " "+ *

* # +*" "+ *

% " " "

% ! !

% !

$ !

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$ % % % # &

/ 1

% # #

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3 " * 1

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3 " * 1

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3 " * 1

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$ " " & &

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# # $

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$ $ %

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' # ' "" ' * ' (# ' * '")() ' ( ' "( ' " ' & '" # '+* ( ' ' * ' (

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# ' +*" * + +*

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115ZV-2 FS EU 92-21 92 Drawing & Diagrams Electrical Wiring Diagram (3/3) (S/N 9201~)

Electrical Wiring Diagram (3/3) (S/N 9201~)

)

# * *

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115ZV-2 FS EU 92-22 92 Drawing & Diagrams Electrical Wiring Diagram

Electrical Wiring Diagram Way of looking at connectors Machine control unit (MCU)

White (Male connector)

MCU MCU A 1.2S_SO A 2.2_SO A 3.ES_R A 4.DD_SO A 5.3_SO A 6.HM A 7.LU_SO A 8.4_SO A 9.OTH_OUT A10.R_L A11.F_L A12.ST_L A13.WL_L A14.CW_L A15.ET_L

Female connector

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

SbO LgW LgY GR OSb YBr RL YB A612 A502 A507 A701 V204 A618 A608 A616 193 192 173 135 211 413 235 411 LY Gy GY LgR YL YG LgB GW A708 A506 A807 A808 A617 A619 A604 H707 H201 749 169 130 412 414 224 V212 0 RL YR Sb GyB GyG GyL LP H714 A615 A609 A504 A809 A505 A501 H208 T801 410 241 194 103 753 190 149 LO YSb LLg LW SbP GB LG YGy LgL H736 H202 E804 K204 A710 A901 H721 A711 F202 267 V303 242 261 H203 403 140 V302 202

B21

B22

B23

B24

B25

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

C12

C13

C14

C15

C16

C17

C18

C19

C20

C21

C22

C23

C24

C25

C28

C29

C30

C31

C32

C33

C11

C27

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

C10

C26

S2H SbY GyL G YG YB C201 H725 H755 C901 T302 A603 171 180 415 116 401 G S2L BrW SbY GyO WL YL E003 C202 A602 H711 H740 H766 T304 234 402 172 220 707 117 L L W Y G D203 D204 H743 H720 D107 005-C 005-D 161 160 010 V BR LgB L L B B BY Y E002 H751 D201 D202 H734 236 221 005-A 005-B 159 1

C 1.2S_SE C 2.DSUB2 C 3.DSUB4 C 4.BSLC 5.TT C 6.AC C 7.ET C 8.BL C 9.BD C10.DSUB1 C11.DSUB3 C12.DR C13.BSL+ C14.TF C15.WL

E12

Male connector S5

E11

LgR C703 166

E10

E26

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

115ZV-2 FS EU 92-23 92 Drawing & Diagrams Electrical Wiring Diagram

40 poles connector

6 poles connector

Female connector Male connector

Male connector

Female connector

Black (Female connector) Female connector

H7 10

6 C201 C202 C203 F704 T406 T405 T404 T403 RL S2H S2L S2S YL D101 A606 S534 T402 WR BrW SbLg RLg YO H808 A607 S811 S723 S716 WY BrB BrY GyO Y

A503 A605 A802 S708 WG BrR BG GyR Y 40 36

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

PARKING S/W

C401 C004 G001

Male connector

GyY PG W PL P701 P724 M803 P741

Y WY BrB BrY GyO P201 P744 M401 L701 M902

BrW GyW PW PB GyR P722 P711 P725 M802 P749

BL YO P734 P720

OR SbY YV BrG BL P709 P702 P734 M801 P713

WR P739

BLg Sb P723 P731

YL S2H S2L S2S P901 P902 P903 P710 10

Female connector

SbY SbY M303 M203 1

Y B

L D206

LgG H137

GyR Y P742 M901

BrR P743

Male connector

White (Male connector)

GO SbW S901 A712

B 1

White (Male connector)

Black (Female connector)

90V2U92009

115ZV-2 FS EU 92-24 92 Drawing & Diagrams Electrical wiring diagram abbreviation chart

Electrical wiring diagram abbreviation chart (S/N 9001~9200) INSTRUMENT PANEL

INSTRUMENT PANEL

MCU

Radiator coolant level alarm

AUTO lamp

A22

Fuel level lamp (1/2)

Charge lamp

Auto brake

A23

Fuel level lamp (E)

Air cleaner clogging alarm

Meter (Speed/Tacho) +

A24

S/S indicator lamp

T/M oil temperature alarm

Meter (Speed/Tacho) –

A25

Traction control selection

Engine water temperature alarm

Engine oil pressure alarm

Declutch lamp

—

MCU E/G coolant temperature sensor (S/N 9001~9050) B25 E/G water temperature sensor (For inspection) (S/N 9051~)

MCU C1

Efficient loading system oil pressure sensor

Parking switch

Auto/Manual selection

Specification change 1

Shift lever 2

Specification change 2

Shift lever R

A26

T/M oil filter warning lamp

B26

Communication TXD1

Spare digital input

Shift lever 3

A27

Air cleaner warning lamp

S/S solenoid valve R

T/M oil temperature switch (not used)

Shift up switch

Air cleaner clogging switch

Shift down switch

E/G coolant temperature switch (not used)

E/G speed sensor selection

Meter selection

Brake oil pressure alarm

Preheating lamp

A28

Brake pressure warning lamp

Fan speed control solenoid valve

MCU error (failure alarm)

Work lamp

A29

Neutral indicator lamp

Power supply +24 V

+24 V power supply

Central alarm lamp

A30

Traction control indicator lamp

Power supply +24 V

Secondary steering

GND

GND (–)

Reversal fan indication lamp

EG2

Engine warning lamp

EG1

Engine protection lamp

EG3 SS WTM

Engine water temperature gauge (sensor)

GND

Hour meter (–)

TTM

T/M oil temperature gauge (sensor)

Hour meter (+)

A31

Fuel level lamp (1/4)

Power supply GND

—

D10

Shift lever 1

—

A32

Reversal fan indicator lamp

Power supply GND

—

D11

Shift lever F

—

D12

Shift lever A

A33

Fuel level lamp (3/4)

Power supply GND

C10

Spare digital input

High-beam lamp

A34

E/G droop selection 2

Power supply GND

C11

Hydraulic oil level switch

Engine stop lamp

Turn signal (left) lamp

H solenoid valve

FR switch, S/S switch indication lamp

Turn signal (right) lamp

—

B3 B4 B5

SSPC solenoid valve

Reversal fan solenoid valve

S/S solenoid valve L

E15

—

— (+)

Instrument panel illumination

T/M oil filter alarm — —

MCU

+5 V output

E10

Tacho-graph E/G speed

Pressure intensifying solenoid valve

E11

Power supply +24 V

C13

Lower kickout set-up

D14

Downshift button

R solenoid valve

E12

Power supply +24 V

C14

T/M oil filter switch

D15

Declutch set up

E13

Communication CAN H1

C15

Radiator water level switch

D16

Odometer selection

E14

E/G speed sensor 2 (not used)

C16

E/G oil pressure switch

D17

Shift hold switch

E/G ECM

C17

Fuel level (F) switch

D18

S/S shift selection switch

Spare analog input

C12

Efficient loading system solenoid valve

E/G idle selection

E16

Machine speed sensor

C18

2nd speed solenoid valve

Buzzer

E17

Power supply

C19

Reset switch (S/N 9001~9050)

Spare digital input (S/N 9001~9050) D13

Spare (S/N 9051~)

—

F34 change point selection (S/N 9051~)

D19

S/S shift switch F

D20

T/M accumulator limit switch

Secondary steering motor relay

B10

Lower kickout relay

E18

Communication CAN L1

C20

Fuel level (1/2) switch

D21

Declutch switch

Fuel level lamp (F)

Ride control solenoid valve

B11

Lift kickout relay

E19

S/S potentiometer

C21

Fuel level (1/8) switch

D22

Kickout set up

3/4

Fuel level lamp (3/4)

3rd speed solenoid valve

B12

MCU fault relay

E20

Communication CAN L0

C22

Efficient loading system switch

D23

Traction control switch

1/2

Fuel level lamp (1/2)

Hour meter

B13

L solenoid valve

E21

T/M oil temperature gauge

C23

E/G mode selection switch

D24

Armrest switch

1/4

Fuel level lamp (1/4)

Lock-up solenoid valve

B14

Auto brake solenoid valve

E22

Brake oil pressure sensor 2

C24

Pressure intensifying switch

EMP

Fuel level lamp (E)

4th speed solenoid valve

B15

E/G droop selection 1

E23

Hydraulic oil temperature sensor

C25

Reversal fan (manual) switch

GND

GND (–)

E/G torque selection

B16

Communication RINI

E24

Alternator

C26

Boom angle sensor

+ 24 V power supply

A10

Back-up lamp

B17

—

E25

Communication RXD1

—

A11

Fuel level lamp (F)

B18

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

Neutral relay

—

A12

Steering oil pressure warning lamp

—

A13

Radiator coolant level warning lamp

—

A14

Central warning lamp

B20

—

E28

Spare analog input

A15

E/G coolant temperature warning lamp

B21

—

E29

Communication CAN H0

E30

Brake oil pressure sensor 1

E31

T/M oil temperature sensor

Neutral

B19

Brake lamp (S/N 9001~9107) Brake relay (S/N 9108~)

Communication DOUT1

C30

Recall switch (S/N 9001~9050) Spare (S/N 9051~)

GND (–)

A16

T/M oil temperature warning lamp

B22

1st speed indication

A17

D solenoid valve

B23

2nd speed indication

A18

1st speed solenoid valve

B24

E32

Air temperature probe

C32

Spare digital input

3rd speed indication

A19

E/G oil pressure warning lamp

E33

—

C33

Ride control switch

4th speed indication

A20

Auto brake indicator lamp

E34

C34

Auto fan reversal switch

Parking brake lamp

A21

Auto shift indicator lamp

— Meter output (Speed/Tacho)

E/G coolant temperature gauge

C31

Lower kickout switch (S/N 9001~9050) Auto/Full auto selection (S/N 9051~)

Tire diameter selection (S/N 9001~9050) D25 F23 change point selection (S/N 9051~) D26

S/S shift switch R

115ZV-2 FS EU 92-25 92 Drawing & Diagrams Electrical wiring diagram abbreviation chart (S/N 9201~) INSTRUMENT PANEL (A5) +

INSTRUMENT PANEL (A6)

MCU

+24V power supply

F/R switch

A19

E/G oil pressure warning lamp

BATT

Ride control

A20

Auto brake indicator lamp

GND

GND(-)

Reversal fan

A21

1st speed indication

EG4

A22

—

MCU

B25

E/G water temperature sensor (For inspection)

Efficient loading system oil pressure sensor

Parking switch

Auto/Manual selection

Auto shift indicator lamp

B26

Communication TXD1

Specification change 1

Shift lever 2

Fuel level lamp (1/2)

S/S solenoid valve R

Specification change 2

Shift lever R

2nd speed indication

EG1

Engine protection lamp

A23

Fuel level lamp (E)

Fan speed control solenoid valve

Spare digital input

Shift lever 3

3rd speed indication

EG2

Engine warning lamp

A24

S/S indicator lamp

Power supply +24 V

T/M oil temperature switch (not used)

Shift up switch

4th speed indication

EG3

Engine stop lamp

Air cleaner clogging switch

Shift down switch

E/G coolant temperature switch (not used)

E/G speed sensor selection

Meter selection

— —

SUB2

—

A25

Traction control selection

Power supply +24 V

—

A26

T/M oil filter warning lamp

Power supply GND

—

A27

Air cleaner warning lamp

Power supply GND

Brake alarm

—

A28

Brake pressure warning lamp

Power supply GND

—

D10

Shift lever 1

A29

Neutral indicator lamp

Power supply GND

—

D11

Shift lever F

Secondary steering

Engine oil pressure alarm

A30

Traction control indicator lamp

+5 V output

C10

Spare digital input

D12

Shift lever A

WTM

Engine water temperature gauge

Engine water temperature alarm

A31

Fuel level lamp (1/4)

E10

Tacho-graph E/G speed

C11

Hydraulic oil level switch

D13

F34 change point selection

1/4

Fuel level lamp (1/4)

T/C (T/M) oil temperature alarm

A32

Reversal fan indicator lamp

E11

Power supply +24 V

C12

Spare

D14

Downshift button

1/2

Fuel level lamp (1/2)

Air cleaner clogging alarm

A33

Fuel level lamp (3/4)

E12

Power supply +24 V

C13

Lower kickout set-up

D15

Declutch set up

Charge lamp

A34

E/G droop selection 2

E13

Communication CAN H1

C14

T/M oil filter switch

D16

Odometer selection

Radiator coolant level warning lamp

H solenoid valve

E14

E/G speed sensor 2 (not used)

C15

Radiator water level switch

D17

Shift hold switch

—

E15

E/G ECM

C16

E/G oil pressure switch

D18

S/S shift selection switch

Pressure intensifying solenoid valve

E16

Machine speed sensor

C17

Fuel level (F) switch

D19

S/S shift switch F

R solenoid valve

E17

Power supply

C18

Spare analog input

D20

T/M accumulator limit switch

SSPC solenoid valve

E18

Communication CAN L1

C19

—

D21

Declutch switch

Reversal fan solenoid valve

E19

S/S potentiometer

C20

Fuel level (1/2) switch

D22

Kickout set up

EMP

Fuel level lamp (E)

Hour meter

EWL —

SUB1

—

TTM

T/C (T/M) oil temperature gauge

— CANH

—

CANL

—

Parking brake lamp

Tachometer

— 3/4

MCU A1

INSTRUMENT PANEL (A6)

Fuel level lamp (3/4)

Efficient loading system solenoid valve

S/S solenoid valve L

E20

Communication CAN L0

C21

Fuel level (1/8) switch

D23

Traction control switch

E/G idle selection

E21

T/M oil temperature gauge

C22

Efficient loading system switch

D24

Armrest switch

2nd speed solenoid valve

Buzzer

E22

Brake oil pressure sensor 2

C23

E/G mode selection switch

D25

F23 change point selection

Secondary steering motor relay

B10

Lower kickout relay

E23

Hydraulic oil temperature sensor

C24

Pressure intensifying switch

D26

S/S shift switch R

Controller failure alarm

Ride control solenoid valve

B11

Lift kickout relay

E24

Alternator

C25

Reversal fan (manual) switch

Fuel level lamp (F)

3rd speed solenoid valve

B12

MCU fault relay

E25

Communication RXD1

C26

Boom angle sensor

E26

Tacho-graph machine speed

C27

Secondary steering oil pressure sensor

E27

Declutch sensor (brake oil pressure sensor)

C28

Fuel level (3/4) switch

Turn signal (Right) lamp

Hour meter

B13

L solenoid valve

Work lamp

Lock-up solenoid valve

B14

Auto brake solenoid valve

High-beam lamp

4th speed solenoid valve

B15

E/G droop selection 1

(+)

Instrument panel illumination

E/G torque selection

B16

Communication RINI

E28

Spare analog input

C29

Fuel level (1/4) switch

T/M oil filter clogging warning lamp

A10

Back-up lamp

B17

—

E29

Communication CAN H0

C30

Spare

AUTO lamp

A11

Fuel level lamp (F)

B18

Neutral relay

E30

Brake oil pressure sensor 1

C31

Auto/Full auto selection

Turn signal (Left) lamp

A12

Steering oil pressure warning lamp

B19

Brake relay

E31

T/M oil temperature sensor

C32

Spare digital input

Air temperature probe

Neutral indication

A13

Radiator coolant level warning lamp

B20

—

E32

Central alarm lamp

A14

Central warning lamp

B21

—

E33

Auto brake lamp

A15

E/G coolant temperature warning lamp

B22

Declutch lamp

A16

T/M oil temperature warning lamp

B23

—

A17

D solenoid valve

B24

—

A18

1st speed solenoid valve

Communication DOUT1 — Meter output (Speed/Tacho)

E34

— E/G coolant temperature gauge

C33

Ride control switch

C34

Auto fan reversal switch

115ZV-2 FS EU 92-26 92 Drawing & Diagrams Electrical Wiring Diagram (CAB)

Electrical Wiring Diagram (CAB)

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115ZV-2 FS EU 92-27 92 Drawing & Diagrams Electrical Wiring Diagram (CAB)

Cab Working lamp (front)

(S/N 0107~)

Rotary warning lamp (spare) (A3) GND Speaker (option) (A4) Rotary warning lamp (spare) (A3) Working lamp (rear) (A5) (A2)

(B3)

(A6)

Room lamp

Speaker (B2) Wiper motor (rear) Speaker

(S/N ~0106)

(B4) (A1)

Cigar socket Wiper S/W (rear)(A9) Wiper S/W (front)(A8) (A7)

(S/N 0107~)

(S/N ~0106)

(A9) (A8)

Car radio (C5) (B1)

Relay wiper intermittent

(B6)

Wiper motor (front)

Working lamp (front)

(B5)

MODM

Speaker (option) (C1~C3)

(B7)

(C4) To floor board

Rotary warning lamp (option)

(B9) CAN (Resistor) (B8) 115ZV2 EU ROPS

K115V2E92015

115ZV-2 FS EU 92-28 92 Drawing & Diagrams Electrical Wiring Diagram (Cabin Air Conditioner)

Electrical Wiring Diagram (Cabin Air Conditioner) Control panel

Illumination power supply

24V(BR')

Fuse box 26

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 LgY VW YB A403 A604 A605

BR B A501 A509

BrR Y BY P GW WP WG OL A102 A611 A609 A606 A608 A506 A502 A503 BL A510

BrB Sb GO PB V WY WR LO BrY A402 A404 A405 A603 A602 A601 A406 A607 A610 10

BG RL RB LgR PL BrW A612 A401 A507 A101 A504 A505 A508

F27 5A F28

10A

F29

Insolation sensor (SS)

BR Y A509 A611

20A

B LgW B410 D104 1

(Black)

A4 1

Sb GO WR B304 B303 B302

LgY BrB RB A220 A210 A305

RB BrB LgY A801 B312 B311

BL BR PL LgR WP A308 A211 A303 A304 A311

P VW YB WY PB V A313 A218 A219 A207 A206 A205

WY V PB YB VW P B320 B319 B318 B317 B316 B314 1

Y R RB RW A704 A703 B101 B102

LO GW BY BrY Y RL B310 B309 B308 B307 A901 B315

Sb GO WR WP A404 A405 A406 A506

GW LO BrY BY B503 C601 C501 C903 B603 LgY BrB LgR WY V P RL VW YB PB C107 C106 D103 D201 C901 C203 C202 C407 C406 B807

BG BL B A505 A510 B103

BR RG RL PL WG OL BrW YR B A702 A701 B202 A508 A502 A503 A504 A509 A501 9

WP WR GO Sb C201 B806 B907 B906

WY V YB PB VW RL P LgR BrB LgY A601 A602 A603 A604 A605 A612 A606 A507 A402 A403

Floor harness

RL Y BrY BY GW LO A306 A315 A202 A314 A312 A203

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

OL WG BG BrW B 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

RG B604

Def selection servo motor (MV3) 9

B501 B601 D102

B803 B903 C101 C204 C401

Air mixing servo motor (MAM)

Vent selection servo motor (MV1)

Front vent selection servo motor (MV2)

Inside/outside air selection servo motor (MRF) 7

WP VW YB C203 C202 C201

Connector between floor and rear

PL C204

BR C205

C3 3

Rear harness

C307 C306 C305 WP VW YB

Electric blower condenser

1 1 3

B B410

WY WR BrW B320 B302 B403

PL B406

RW B416

BR B402

GO Sb OL B303 B304 B404 1

PL B406

BR B402

LgY BrB WG B311 B312 B405

BR B402

PB V BG B318 B319 B412

VW YB WP B316 B317 B301

BR PL B402 B406

PL B406

C303 C301 PL BR

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 3

G B RY BL 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

115ZV-2 FS EU 92-29 92 Drawing & Diagrams Electrical Circuit Diagram (Cabin Air Conditioner)

Electrical Circuit Diagram (Cabin Air Conditioner) SW K 1

10A

13 FU B

FU A

20A

5A LIGHT SW SIGNAL

M RF

M V3

9 1.25RY

9 2RY

M CD

25 15 26 22

28 15 29 22

225W M V 3A

80W

1.25G

2 +B 6

2G 2G

3 1

1.25RY

FRE

9 2RY

M REC

RL BM

SP CD

RL CD

RL EC

DEF

GND

RL BM

FOOT

RL EC

RL CD

FU EC

FU CD

GND

39 5

M V 3B

25 35

SV 3

M RFA

S RF

M RFB

9 BLC B 3

RL CH BAT

BLC 01

BLC F

AC M

11 8

1 01

28 G

4 R CD

7 RL CH

0.5B

EC C

22 B P

17 TH AM

TH W

20 TH I

21 TH F

27 15

4 23

21 30

31 M AMB

33 M V 1B

S AM

M AMA

36 36

35 M V 1A

S V1

37 M V 2A

38 M V 2B

S V2

S SD

40W

GND

SHUT

37 15 38 22 Vz

34 22 35 15

GND

FACE

31 22 32 15

FOOT

FACE

GND

Mhot

Mcool

22 01

0.5B

SP HL

01 0.5B

0.5B

M AM

ACM

Air conditioner control amplifier

M AM

Air mixing servo motor

RL CH

Condenser HI relay

BAT

Battery

Blower motor

RL EC

Compressor clutch relay

BLC

BLC (blower linear controller)

M CD

Condenser motor

S SD

Solar insolation sensor

Diode 1

M RF

Inside/outside air servo motor

SPCD

Condenser speed change pressure switch

Diode 2

M V1

Vent servo motor

SPHL

Refrigerant high/low pressure switch

ECC

Compressor clutch

M V2

Front vent servo motor

SWK

Key switch

FU A

Air conditioner fuse

M V3

Defroster selection servo motor

TH AM

Outside air thermistor

FU B

Blower motor fuse

R CD

Condenser motor speed change resistor TH F

FU CD

Condenser motor fuse

RL BM

Blower main relay

TH I

Inside air thermistor

FU EC

Compressor clutch fuse

RL CD

Condenser relay

TH W

Water temperature thermistor

M V1

M V2

Dotted lines indicate the wiring on the machine side.

Frost prevention thermistor

95ZVE72019

115ZV-2 FS EU 92-30 92 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

115ZV-2 FS EU 92-31 92 Drawing & Diagrams Electrical Connection Diagram (1/2) (S/N 9001~9050)

Electrical Connection Diagram (1/2) (S/N 9001~9050) )

! 2

! /

! !

+ ! +

!. ( *

% # 0

!+ +

&0 &0

! #

# ! +

& # ! %$

/ !

!# !+ +! + 2

&0 & !* $

* ! & $

0 * + 0 # $ %$ ! !0 40 4 * + $ 0 # $ %$ ! 40 4 $

* &0

&0 * $

&0 $ $

&0 ! 0 $ % $

)

$0! ! %$

!"+

* ! &

2 !

$ 40 #

! 0 0 % *

!!"

# 0! $

* ! &

$ 40 # ! !"#

# * $ ! 0

!" , !

! ! +

% 0! ! +

!0 40 4 ! + ! 40 4 ! +

* * * * * *

* * * * * * *

&+* 0! ! !

0 ! ! ##0 #

!"!

! ,

! ! 0* ! & ! 0* !

!# !

! ! !

$ * ! 0* !

! ! !

& 0 *0 ! +

* ! 0* !

4 ! 0* !

!!"

! ! 0* ! $

!"!

0* ! ! 0* ! 0 0 ! *0 # + % ! 0 ! 0* ! $ 0 0 +0 # ! 0* ! $

!"!

! !"

! ! 0* ! $

$$ ! 0* !

! 0* ! ! $ !"

$ * ! ! 0* !

!" # #- !"+

#-# #-! !"

+! + , +#

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$ 0 % $

# ,

* ! & 4 0! $ 4 0! $

0 0 ! *0 # + % 0! $

* + 0 # $

2 #-#

# ! %$ % 0! %$ 0* 0 %$

#-!

&+* 0! %$

% &0 $ * # $ *

&0 0 *0 ! %$ ! 0 *0 ! %$ ! 0 # ! %$ 4 0! $ 0 # ! %$ # 0! $ 0 # ! %$ # ! %$ 0 # ! %$ % 0! %$ 0 # ! %$ 0 ! 0 # ! %$ 0 # 0! $ 0 # ! %$

! 0* ! $

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! 0* !

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% #!

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* $ * ! 0* !

* + 0 # % ! + 0!

+#-

% !0%0

% 0! 0! 0 # ! %$ *0 ! ! ! 0 # ! %$ 4 0 *0 ! %$

2 #+

0 ! 0 *0 ! %$

! 0 *0 ! %$ $

0 *0 ! %$ $

! ! ! ! ! ! ! ! ! ! ! ! ! ! !

+ ,

!" ,

# ! %$ # #

% 0! %$ # # % $ $ * % & %

2 1

−

* 0 0 0 & * 0 0 0 & % ! 0 *% ! 0 0 *0 ! 0 $ * ! 0 % ! 0

$! $#

2$ 2

& % * 0 # 0*! ! 0

# 5 ! 0

* * * * *

# * $ ! 0 0 ! ! 0

4 $ ! %$

4 ! %$

+ +# +! + + ,

1 .* .* %* # *

% $ # % 0

& !

% 0 %

# * $ ! 0

& # $& % &0 $ * $

& # $& # $ * $

+ 2 2

3 3 .* .* 3%*

! +

0 0 ! *0 # + %

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! $ ! $

!* 0 &

$ 0 0 +0 # $

! 40 4 & % 0 & & 40

' (

! ,

% &

% &0 ! 0 %

)

&0 !

% &0 ! 0 %

% &0

$ 40 #

This page illustrates the transmission is in neutral and key switch is in OFF position.

0* ! .

% 0!

!" !" 2

0 #

115ZV-2 FS EU 92-32 92 Drawing & Diagrams Electrical Connection Diagram (2/2) (S/N 9001~9050)

Electrical Connection Diagram (2/2) (S/N 9001~9050)

* () ( ) &

* .( .

()

* !() (+ ! *

$ $$

( *

()& * ) ) ( ! ()

# $

* () ( ) ! &

) .() ( ! &

) .() ( !

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( ! . *

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# $

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(

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& !

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& ! & &

) & ( ) & *

)

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( ! ) & ( ) & *

&(+ ( & )& ! *

* +

)+ )& *

+ (). ))

( $

(

& & &!

( &

( ! ) ) &( )

( ! ) &( )

) ) &( )

( ! ) &( )

* () ( ) # & #

&! )( ! +

()&(+ ( & )& !( #

* *

) &( )

+ + )

* & *

( *

()

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*( )

&! *

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(

( &

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& &# &! &012 &

. *

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( &&"

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.() ( ! %

.() ( ! .() ( !

() + & ()

.() ( !

% #

.() ( ! &

+( ) & ( &

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* *

.() ( !

) .() ( !

# * () ) ) % # % #

)! )

( ! ! + ( ! ! + ( !

(+ & (+

&(&

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& ! & & &

! + ( ! !

# %

( ! ! + ( ! !

* +*

)

!( ! *

! + # () ! )() ## & )&

( ( !

+( ( )

( & & * &&

( *

# ()

( )& *

* !() (+ ! *

# #

( ) )(

# # #

! )

! ) & ! ) +( * * )

This page illustrates the transmission is in neutral and key switch is in OFF position.

115ZV-2 FS EU 92-33 92 Drawing & Diagrams Electrical Connection Diagram (1/2) (S/N 9051~9100)

Electrical Connection Diagram (1/2) (S/N 9051~9100) ACC’

STARTER S/W B

BR ACC R1 R2

(L) (005-b) F5

OFF

(005) L2

(L) (005-a)

30A

START

30A

BATTERY WL (707)

WV (700)

(063) WR1.25

F N R

BATTERY RELAY

LR (126)

(013) (Lg)

STARTER

23A

LBr (128)

SHIFT LEVER

LW (120)

70A

LG (122)

B C

[R5] x 6 (910~ 915)

LY (121)

[R5] (701)

MAGNETIC (702) S/W 5 [BW ]

YO (232)

S/S SHIFT S/W F

VOLTAGE

WG(705) RELAY

RL1.25 (703)

(013) (Lg)

F13

(705) (WG)

YW (233)

S/S SHIFT S/W R

70A

S/S SHIFT SELECTION S/W (OPT)

(707) WL

CHARGE LAMP

YV (231) F5

LB (230)

ARMREST S/W (OPT)

(707) WL1.25 R

LG (122)

SHIFT UP S/W (OPT)

ALTERNATOR

LY (121)

SHIFT DOWN S/W (OPT) 20

(YL) (124)

DOWNSHIFT BUTTON (005-a) ES (L)

100

ACC’

(BrR)

20A

10A

15A

10A

15A

20A

15A

10A

15A

10A

15A

30A

10A

15A

10A

15A

20A

(GB) (277)

REVERSAL FAN S/W (OPT)

Lg (222)

AUTO FAN REVERSAL S/W (OPT)

LgY (223)

SPARE SPARE

(105)

(R)

(106)

GO (164) GyW (200)

(013) (Lg)

GL (265)

YO(176)

(GyW ) (260)

(LgY) (167)

DECLUTCH S/W ON

E/G OIL PRESS S/W

DECLUTCH

HYD. OIL LEVEL S/W

(163) (SbW)

OFF ON

PARKING SOL (162) LgG

(Y)

LLg (165)

CAB

BW (271)

F13

BrG (255)

PRESSURE INTENSIFYING S/W (OPT)

THERMO (722) SWITCH (721) ETHER KIT

TO PILOT LAMP

(GW) (210)

TRACTION SECONDARY STEERING PUMP CONTROL S/W LIFT KICKOUT SECONDARY SET-UP STEERING PUMP LOWER KICKOUT SET-UP

COLD STARTER SWITCH

LP (168)

DECLUTCH SET-UP

BrB

YSb (125)

SHIFT HOLD S/W (OPT) M1 M2

15A

E11

E12 B18

E24 D11

B11

D04

B10

D12 D05 D03 D10 D19 D26

(062) (012) BW F12 BW

E04

AIR CLEANER CLOGGING S/W (005-b) (L)

OFF

PARKING S/W

FUEL EFFICIENT MODE S/W

Gy (750) BrY (181) LgL (182)

D18 D24 D06 D07 D14 D17 D15

A03 B13 B01 B04 A18

LgW (101) BrB (258) L

(273)

NEUTRAL RELAY

MCU FAILURE RELAY

LIFT KICKOUT RELAY T/M ACC. LIMIT S/W

A05

A17 B14 A07

D22

A01 B03 B06

C24 B05 C25

C30 C12

L SOLENOID VALVE

(147) LB

H SOLENOID VALVE

(148) LBr (141) LY

E01 B07 E02

C23

A21

C22

A29

C33

A14

C16

A28 A19 A15 A16 A27

4TH INDICATOR RELAY

D SOLENOID VALVE

WR (170)

BRAKE SOLENOID VALVE

LLg (140)

RIDE CONTROL SOLENOID VALVE

GB (267)

EFFICIENT LOADING SYSTEM SELECTION SOLENOID VALVE

GB (278)

PRESSURE INTENSIFYING SOLENOID VALVE (OPT)

LgL (225)

REVERSAL FAN SOLENOID VALVE (OPT)

(150) LgR 1A

S/S SOLENOID VALVE L (OPT) (221) LgB

(GR) (135) (GyB) (103) (LgY) (173) (749)

(GyG) (753) (GyL) (190) (LgW) (192) (O)

V (100)

G (234) BrR (251)

DECLUTCH SENSOR

(LgR) (166)

BRAKE OIL PRESS. SENSOR 1 BRAKE OIL PRESS. SENSOR 2

(241)

C17 C28 C20 C29 C21

E09 (+5V)

E19 C26 E27

A26 A13 A20 A30 A32 A24 A11 A33 A22 A31 A23 B09

E34 E21

SbY (171) E30 B24

FAN SPEED CONTROL SOLENOID VALVE F13

E10

EFFICIENT LOADING SYSTEM OIL PRESS. SENSOR

GyB (266)

SECONDARY STEERING PRESS. SENSOR

SbR (240)

C01 E26

GyG (754)

E/G COOLANT TEMP. SENSOR

GyL (180)

T/M OIL TEMP. SENSOR

(G) (415) GyO (220)

HYD. OIL TEMP. SENSOR

BY (114) Y (160)

MACHINE SPEED SENSOR E/G SPEED SENSOR

ECM(31)

W (161) Y (159)

(013) (Lg)

(SbO) (193) (Sb)

T/M OIL FILTER WARNING LAMP RADIATOR COOLANT LEVEL WARNING LAMP AUTO BRAKE INDICATOR LAMP

(194)

(GY) (169) (OSb) (211)

TRACTION CONTROL INDICATOR LAMP

(RL) (235)

REVERSAL FAN INDICATOR LAMP (OPT)

(LgB) (224)

S/S INDICATOR LAMP (OPT)

(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) LgBr (104)

BUZZER RELAY

(YB) (401)

E/G COOLANT TEMP. GAUGE

(BrW) (402)

T/M OIL TEMP. GAUGE METER OUTPUT (SPEEDOMETER/TACHOMETER)

(WL)(400)

SbY (172) E22

S/S SOLENOID VALVE R (OPT)

(LgR) (130)

C15

OUTSIDE AIR TEMP. SENSOR SPPC SOLENOID VALVE

(Gy)

YG (409)

D20 C14

LU SOLENOID VALVE (OPT)

LgL (261)

(226) LgB

YBr (408)

S/S POTENTIOMETER (OPT)

(LW) LP (149)

YL (407)

BOOM ANGLE SENSOR

(144) LW

(237) BL

YB (406)

3RD SPEED SOLENOID VALVE

D01

C06

1ST SPEED SOLENOID VALVE

FUEL LEVEL 1/4

2ND SPEED SOLENOID VALVE

(143) LO

(236) BR

YR (405)

FUEL LEVEL 3/4 FUEL LEVEL 1/2

4S (132)(LG)

(154) LgR

Sb (184)

RADIATOR WATER LEVEL S/W FUEL LEVEL F

R SOLENOID VALVE

(152) PB SbO (183)

T/M OIL FILTER S/W

FUEL LEVEL 1/8

(142) LG

D21

C11

(LO) A08

A04

C34

SECONDARY STEERING MOTOR RELAY COIL

(146) LR

(LG)

D23

C13

YGy (242)

(153) P

LOWER KICKOUT RELAY

(LY) A02

A12 F5

E/G DROOP SELECTION 1 (SbP) (145)

OPT

LO (123)

E03

B12

(708) WP

(065) (015) WR1.25 F15 WR

F13

F14

LX4 (005-A~005-D)

ECM(H)

R1 BR B AC R2 C

(014) G1.25

12V

E05 E06 E17

(060) (901) W [W5]

(064) G1.25

12V

100

ACC’

MACHINE CONTROL UNIT (MCU)

(081) (085) W W

G (010)

F10

E (900) [W5]

MACHINE CONTROL UNIT (MCU)

MACHINE

TO PARKING S/W

(420) OSb (+)

()

(421) OB (+)

()

A06

B25 E31

B08

E32

A09

E23

B15

E07

A34

E16

A25

YSb (403) SbR

(208)

SbP

(202)

SbW (203)

HOUR METER DRIVE AI

E/G IDLE SELECTION

E/G TORQUE SELECTION

P (107)

A10

E08

PW(111) PG (109) VG (157) VY (158) PB (110)

C02 C03

E/G DROOP SELECTION 2 (GW) (212)

B19

(OUT_FEW)B23 (OUT_RES)E33 (RXD0)E25 (TXD0)B26 (OUT_MD2)B17

TO BACK-UP LAMP

(RG) (331)

TO BRAKE LAMP

YB YG YL YO YBr

(100) V

D25

(RIN1)B16

+5V FEW RESET RXD TXD MD2 GND

MCU PROGRAM REWRITE

D13

(DOUT1)B22

GL (810)

S2H S2L S2S

(CANH0)E29 (CANL0)E20

MAIN MCU

RS232C

GR (811)

D09 E

(115) (116) (117) (118) (119) E

D02

D08

TRACTION CONTROL SELECTION

ECM(O)

(RL) (330)

C31

D16

E/G DROOP SELECTION 1

E15

PL (108)

TACHOGRAPH MACHINE SPEED (OPT)

C27

(E09)

DESTINATION SWITCH 1 DESTINATION SWITCH 2 AUTO/FULL AUTO SELECTION A/M SELECTION F23 CHANGE POINT SELECTION F34 CHANGE POINT SELECTION ODOMETER SELECTION SPEED SENSOR SELECTION METER SELECTION

TACHOGRAPH E/G SPEED (OPT)

CAN

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)

WARNING BUZZER

(112)

115ZV2-09708-06170A EU 1/2

115V2E92031

115ZV-2 FS EU 92-34 92 Drawing & Diagrams Electrical Connection Diagram (2/2) (S/N 9051~9100)

Electrical Connection Diagram (2/2) (S/N 9051~9100)

$ $

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This page illustrates the transmission is in neutral and key switch is in OFF position.

115ZV-2 FS EU 92-35 92 Drawing & Diagrams Electrical Connection Diagram (1/2) (S/N 9101~9200)

Electrical Connection Diagram (1/2) (S/N 9101~9200) 1 1 '

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115ZV-2 FS EU 92-36 92 Drawing & Diagrams Electrical Connection Diagram (2/2) (S/N 9101~9200)

Electrical Connection Diagram (2/2) (S/N 9101~9200)

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115ZV-2 FS EU 92-37 92 Drawing & Diagrams Electrical Connection Diagram (1/2) (S/N 9201~)

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115ZV-2 FS EU 92-38 92 Drawing & Diagrams Electrical Connection Diagram (2/2) (S/N 9201~)

Electrical Connection Diagram (2/2) (S/N 9201~)

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115ZV-2 FS EU 92-39 92 Drawing & Diagrams Electrical Equipment Layout

Electrical Equipment Layout Front chassis

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115ZV-2 FS EU 92-40 92 Drawing & Diagrams Electrical Equipment Layout

Front chassis

Combination lamp (option) Not used Head lamp (K5) Working lamp

(K3)

(K1)

To floor board

(K4)

(K2) Ride control (option) (L4)

Bucket leveler (L1) (L2) Horn (R. H) S/N 9051~ (K6) Working lamp Head lamp Combination lamp (option)

S/N - 9003~ Horn (L. H)

(K9)

(K0)

(K8)

Boom angle sensor (L3)

K115V2E92016

115ZV-2 FS EU 92-41 92 Drawing & Diagrams Electrical Equipment Layout Rear chassis ## 2 % )

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115ZV-2 FS EU 92-42 92 Drawing & Diagrams Electrical Equipment Layout

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115ZV-2 FS EU 92-43 92 Drawing & Diagrams Electrical Equipment Layout

Rear chassis

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115ZV-2 FS EU 92-44 92 Drawing & Diagrams Electrical Equipment Layout

Rear chassis E/G water temperature switch (for cold starter) (M0)

Alternator

Working lamp

(S/N ~9050) E/G water temperature sensor (M6)

A/C condenser (L9)

(S/N ~9100) Working lamp (R2) Back-up alarm Combination lamp (R4)

(L0)

License lamp (option) (L8)

(R6)

(R3) (R5)

Air cleaner Water level sensor (X2)

Fusible link (N1/ N2) T/C oil temperature sensor (M5)

Combination lamp

+ Magnet switch (N7)

Fan control solenoid (P1) Battery (R1) (R7)

Battery relay (N3)

Battery Voltage relay (N8) (S/N ~9050)

Starter motor

K115V2E92018

115ZV-2 FS EU 92-45 92 Drawing & Diagrams Electrical Equipment Layout Floor board To rear ground

Air temperature probe (Floor ground) (MCU) (red tape) (C9) Air temperature probe (Aircon) (C8)

(Floor ~ rear ground)

To control box

D solenoid (R9) To rear

To floor

To floor Accumulator pressure switch (J7/J9) To T/M (Red tape)

Accelerator pedal (C0)

1 L

To front

F H

H 2

To operation stand

Declutch sensor (C7)

SPPC solenoid (J0)

T/M solenoid connection

(S/N 9004~)

Top view Shift lever (B7)

Horn switch (B8)

Combination switch (B9) Red tape Four-way flasher (option)

Instrument panel switch To instrument panel, switch

A Parking switch (B5) A

Front

Front working lamp

Fuel efficient mode change

Rear working lamp Blue tape

Efficient loading system

(option) Selection switch for shift lever or F/R switch K-Lever switch (option)

Cold start Yellow tape

Hydraulic oil hose

Green tape

Blue tape

Harness

Operation switch connection A-A detail K115V2E92013

115ZV-2 FS EU 92-46 92 Drawing & Diagrams Electrical Equipment Layout

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Floor board

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115ZV-2 FS EU 92-48 92 Drawing & Diagrams Outline of MODM (Machine Operation Diagnostic Module) Operation

Outline of MODM (Machine Operation Diagnostic Module) Operation [

[ ] button

] button

(Press)

Press and hold Engine fault log

Replacement monitor

(Press)

Machine fault log

Input/Output monitor Press and hold Press and hold

Press and hold

Input signal Display window

[

(step back)] button

[

(step forward)] button

Fault log monitor

(Press)

Unit conversion Information monitor

Current output

Press and hold Language select.

Output signal (Press)

(Press)

Outside air temperature

(Press)

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

115ZV-2 FS EU 92-49 92 Drawing & Diagrams Outline of MODM (Machine Operation Diagnostic Module) Operation

& &( '

) * + " +

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)

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115ZV-2 FS EU 92-50 92 Drawing & Diagrams Outline of MODM (Machine Operation Diagnostic Module) Operation

Information Monitor Hour Meter

Outside Temprature (Information Menu Initial Screen) 3 sec

Unit Conversion

Language Selection 2 sec Change No Change Active Error

Machine Speed / Engine Speed Unit Conversion

Active Error Odometer Press any button Replacing Time Comming

Cycle

Engine Coolant Temprature

Reset

Unit Conversion

Replace Pop Up

Reset Press any button Hydraulic System Oil Pressure

Transmission Oil Temprature

Unit Conversion (Pressure)

Unit Conversion

Specification Setting Monitor

Reset

Voltage

Hydraulic Oil Temprature Unit Conversion

Replace Monitor

Reset

Press any button:

Hour Meter

Odometer / Trip Meter Unit Conversion

(

Reset

Cycle

)

Reset

Outside Temperature

80V2U92008

115ZV-2 FS EU 92-51 92 Drawing & Diagrams Outline of MODM (Machine Operation Diagnostic Module) Operation

Replacement Monitor Hydraulic Oil

Enigin Oil Filter Cartrige (Replace Monitor Initial Screen)

Engine Oil

Transmission & Torque Converter Oil

2 sec

2 sec Timer Reset

Timer Reset 2 sec Change No Change Fuel Filter

2 sec

2 sec Change No Change

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

115ZV-2 FS EU 92-52 92 Drawing & Diagrams Outline of MODM (Machine Operation Diagnostic Module) Operation

Fault Log Monitor 2 sec Engine Fault Log

Machine Fault Log 2 sec

Active Fault Engine Fault Log Maximum

Machine Fault Log Maximum

Machine Fault Log 1 (Initial Screen for Machine Fault Log)

Engine Fault Log 1 (Initial Screen for Engine Fault Log)

2 sec

Replace Pop Up

2 seconds or more: Return after clear Return without clear 2 sec

Press any button Replacing Time Comming (Timer 0)

Clear Fault Log

Machine Fault Log 2

Active Fault

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 115ZV-2 S/N 9103 and thereafter.

2 seconds or more: Return after clear Return without clear

Machine Fault Log 1

Engine Fault Log 1

80V2U92010

115ZV-2 FS EU 92-53 92 Drawing & Diagrams Outline of MODM (Machine Operation Diagnostic Module) Operation

Input/Output Monitor 2 sec

2 sec Other Output

Input Signal 2 sec

Analogue Input 2 sec

Output Signal

2 sec Other Output

2 sec

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

115ZV-2 FS EU 92-54 92 Drawing & Diagrams Outline of MODM (Machine Operation Diagnostic Module) Operation

Parameter Setting Monitor Power Control (Vni) Setting 2

Calendar

Deceleration Pervention Setting 1 (Initial Screen for Parameter Setting)

2 sec

Lower Kick Out Input/Output Monitor

Parameter Setting 2 sec Change No Change Deceleration Prevention Setting 2

2 sec

Lift Kick Out Specification Selection Monitor

Parameter Setting 2 sec Change No Change Ride Control Setting 1

2 sec

Calendar Parameter Setting

Parameter Setting 2 sec Change No Change

2 sec Change No Change Ride Control Setting 2

2 sec Deceleration Prevention Setting 1

Parameter Setting 2 sec Change No Change Speed Meter Divide Setting 1

Parameter Setting

2 sec Parameter Setting 2 sec Change No Change

- SPEED METER DIV2 - TRACTION CONTROL F1 - TACHOGRAPH DIV1 - TRACTION CONTROL DSsc - TACHOGRAPH DIV2 - TRACTION CONTROL Isc - SECONDARY STEERING ON - TRACTION CONTROL ti - SECONDARY STEERING OFF - TRACTION CONTROL SCv - K-LEVER V1 - TRACTION CONTROL SCeg - K-LEVER V2 - TRACTION CONTROL SCi - K-LEVER Vmax - TRACTION CONTROL SCt - K-LEVER i1 - T/M CUT OFF IS - K-LEVER i2 - 2 STAGE DSon - K-LEVER imax - POWER CONTROL TWni

The cursor flashes in a 1-second cycle. (lights for 0.5 second and lights off for 0.5 second). The cursor moves rightward. (upper right

lower left

lower right

upper left)

The cursor skips (digits/column) which can not be changed. Adding 1 to the value where the cursor is (0

Subtraciting 1 to the value where the cursor is. (9

Power Control (Vni) Setting 2

80V2U92012a

115ZV-2 FS EU 92-55 92 Drawing & Diagrams Outline of MODM (Machine Operation Diagnostic Module) Operation

Specification Setting Monitor (1/2) Program No. (Initial Screen for Specification)

Password Input The cursor moves rightward. (upper right

lower left

lower right

upper left).

The cursor moves leftward. (upper left

Password

lower right

lower left

upper right).

Adding 1 to the value where the cursor is. (

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 - Secondary steering - K-Lever - Hydraulic press. increase - Traction control - Tachograph - Efficient loading sys. (ELS) - Lower kickout - Lift kickout

Brake oil level

Wheel type

All reset

Group 1

Group 2

Specification setting monitor screen

Group 2

Group 1

80V2U92013a

115ZV-2 FS EU 92-56 92 Drawing & Diagrams Outline of MODM (Machine Operation Diagnostic Module) Operation

Specification Setting Monitor (2/2) Program No. (Initial Screen for Specification)

Password Input The cursor moves rightward. (upper right

lower left

lower right

upper left).

The cursor moves leftward. (upper left

Password

lower right

lower left

upper right).

Adding 1 to the value where the cursor is. (

To confirm the change, press this button for 2 seconds or more.

Password OK 2 sec

All Setting Reset

All Setting Reset Press and hold

2 sec Change No Change Press and Press and hold hold Group 1 of Specification setting monitor screen

Press and hold

Parameter Setting Monitor

Group 2 of Specification setting monitor screen Specification Selection Press and hold

Specification item 24 2 sec

Specification Item 2

Specification item 23 2 sec

Specification Item 1 Specification Selection

2 sec Change No Change

2 sec

Specification Item 4

Specification Selection

2 sec Change No Change - Ride control - Secondary steering - K-Lever - Hyd. press. increase Specification Item 15

2 sec

- E/G coolant temp. switch - E/G coolant temp. sensor - E/G oil pressure switch - E/G oil pressure sensor

Specification Item 22 Specification Selection

Specification Item 24

2 sec Change No Change 2 sec

2 sec Specification Selection

Specification Item 23

Specification Selection

2 sec Change No Change 2 sec

All Setting Reset

Specification Selection

2 sec Change No Change Specification item 2

The cursor flashes in a 1 second cycle.

2 sec Change No Change - Engine speed - Engine curve - Cooling fan - T/C oil temp. switch

- Traction control - Tachograph - Efficient loading sys. (ELS) - Lower kickout

Not returning to password screen

2 sec Change No Change Press and hold

2 sec

Specification Item 3

Information Monitor

Specification Selection

2 sec Change No Change Specification item 1 80V2U92014a

115ZV-2 FS EU 92-57 92 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

115ZV-2 FS EU 92-58 92 Drawing & Diagrams Traction Control Switch Mount

Traction Control Switch Mount 2

Traction control switch 1

Alternate throttle for traction control

2, 3

211 OSb

013 Lg 210 GW

743 742 GY GR

766 768 GL BP 743 GY

744 BG

211 013 OSb Lg

210 GW

211 013 OSb Lg

210 GW

766 742 GL GR 768 742 BP BG

743 742 GY GR

744 BG

A 1

A-A

Floor harness

Resistor (S/N 9051~)

1. Traction control switch 2. E/G RPM adjustment resistor for traction control 3. Knob 4. Resistor

2 4

115ZV2 03126-07461

K115V2U92010