To11c5 e 00 PDF

93216-00460
June 2009
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 Technical
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 meth-
ods. 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
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
Measurement for Performance Check .................................................................................................................. 03-1

Cautions on Safety ............................................................................................................................................ 03-2
Standard Measurement Values for Performance Check ................................................................................... 03-3
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
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
Function & Structure Power Group ........................................................................................................................ 22-1

Power Line ........................................................................................................................................................ 22-2
Engine / Transmission ....................................................................................................................................... 22-3
Engine / transmission mount ....................................................................................................................... 22-3
Radiator ............................................................................................................................................................. 22-4
Radiator mount ............................................................................................................................................ 22-5
Propeller Shaft .................................................................................................................................................. 22-6
First propeller shaft assembly ..................................................................................................................... 22-7
Second propeller shaft assembly ................................................................................................................ 22-8
Third propeller shaft assembly .................................................................................................................... 22-9
Axle Assembly ................................................................................................................................................. 22-10
Axle Support .................................................................................................................................................... 22-12
Differential Gear .............................................................................................................................................. 22-14
Conventional type ..................................................................................................................................... 22-14
Function of differential gear ....................................................................................................................... 22-17
Operation of differential gear ..................................................................................................................... 22-17
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
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 (not exact representation) ............................................................................................ 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
Check & Adjustment Torque Converter and Transmission Group ........................................................................ 33-1
Clutch Oil Pressure and Time Lag .................................................................................................................... 33-2
Measuring clutch oil pressure ..................................................................................................................... 33-2
Function & Structure Hydraulic Group ................................................................................................................... 42-1

Flushing Hydraulic Circuit ................................................................................................................................. 42-2
Purpose of flushing ..................................................................................................................................... 42-2
Cautions on Hydraulic Parts Replacement ....................................................................................................... 42-3
Hydraulic Circuit Symbols ................................................................................................................................. 42-4
Hydraulic lines ............................................................................................................................................. 42-4
Pumps & motors .......................................................................................................................................... 42-4
Cylinders ..................................................................................................................................................... 42-4
Operation methods ...................................................................................................................................... 42-5
Pressure control valve ................................................................................................................................. 42-5
Flow control valve ....................................................................................................................................... 42-5
Directional control valve .............................................................................................................................. 42-6
Check valve ................................................................................................................................................. 42-6
Miscellaneous hydraulic symbols ................................................................................................................ 42-7
Hydraulic System Operation ............................................................................................................................. 42-8
Hydraulic system operation outline ............................................................................................................. 42-8
Layout of Hydraulic Units ................................................................................................................................ 42-10
Hydraulic Tank ................................................................................................................................................. 42-11
Hydraulic tank breather valve (tank cap) ................................................................................................... 42-12
Hydraulic tank specifications ..................................................................................................................... 42-13
Hydraulic oil level check ............................................................................................................................ 42-14
Hydraulic Pump ............................................................................................................................................... 42-15
Loading and pilot and brake pump ............................................................................................................ 42-15
Pump specifications .................................................................................................................................. 42-15
Steering pump ........................................................................................................................................... 42-16
Steering pump specifications .................................................................................................................... 42-16
Hydraulic pump principle ........................................................................................................................... 42-17
Hydraulic pump wear plate ........................................................................................................................ 42-18
Hydraulic pump bushing lubrication .......................................................................................................... 42-18
Hydraulic Cylinder ........................................................................................................................................... 42-19
Boom cylinder ........................................................................................................................................... 42-19
Bucket cylinder .......................................................................................................................................... 42-19
Steering cylinder ....................................................................................................................................... 42-20
Hydraulic cylinder specifications ............................................................................................................... 42-21
Loading System .............................................................................................................................................. 42-22
Reducing Valve (for Pilot Pressure) ................................................................................................................ 42-23
Pilot Valve ....................................................................................................................................................... 42-24
Pilot valve function .................................................................................................................................... 42-26
Pilot valve operation (modulated position) ................................................................................................ 42-26
Pre-detent and detent magnet solenoid .................................................................................................... 42-28
Multiple Control Valve (KML35A/2T103) ......................................................................................................... 42-29
Multiple control valve specifications .......................................................................................................... 42-30
Multiple control valve main relief valve ..................................................................................................... 42-31
Multiple control valve overload relief valve (with make-up function) ......................................................... 42-33
Multiple control valve make-up valve ........................................................................................................ 42-34
Multiple control valve bucket spool ........................................................................................................... 42-35
Multiple control valve boom spool ............................................................................................................. 42-37
Adapter (Orifice) .............................................................................................................................................. 42-40
Ride Control (OPT) ......................................................................................................................................... 42-41
Ride control hydraulic circuit ..................................................................................................................... 42-41
Ride control operation ............................................................................................................................... 42-42
Ride control valve assembly (Reducing valve circuit) ............................................................................... 42-44
Ride control valve assembly (Accumulator circuit) ................................................................................... 42-47
Accumulator (for ride control) .................................................................................................................... 42-50
Steering System .............................................................................................................................................. 42-51
Orbitrol .......................................................................................................................................................... 42-52
Orbitrol structure ..................................................................................................................................... 42-52
Orbitrol specifications .............................................................................................................................. 42-53
Orbitrol operation .................................................................................................................................... 42-54
Orbitrol feed-back mechanism operation ................................................................................................ 42-56

Steering speed and flow rate control ........................................................................................................ 42-57
Hydraulic pump oil amount and steering force .......................................................................................... 42-57
Orbit rotor operation principle ................................................................................................................... 42-58
Steering Valve (KVS32-A4.0/21) ..................................................................................................................... 42-59
Steering valve operation ........................................................................................................................... 42-61
Steering spool variable throttle .................................................................................................................. 42-63
Steering valve flow control spool ............................................................................................................... 42-64
Steering valve main relief valve ................................................................................................................ 42-65
Steering valve overload relief valve .......................................................................................................... 42-67
Steering pilot circuit and its operation ....................................................................................................... 42-69
Stop Valve ....................................................................................................................................................... 42-71
Stop valve function .................................................................................................................................... 42-72
Stop valve operation ................................................................................................................................. 42-72
Reducing Valve (for Orbitrol) ......................................................................................................................... 42-73

Steering Line Filter .......................................................................................................................................... 42-74
Efficient Loading System ................................................................................................................................. 42-75
Efficient loading system outline ................................................................................................................. 42-75
Mounting of the ELS valve ........................................................................................................................ 42-76
Mounting of the variable kickout sensor .................................................................................................... 42-77
Efficient loading system operation ............................................................................................................ 42-78
Fan Motor System ........................................................................................................................................... 42-79
Mounting of fan motor ............................................................................................................................... 42-79
Fan Motor Line ................................................................................................................................................ 42-80
Hydraulic circuit (fan motor normal rotation) ............................................................................................. 42-82
Proportional relief valve (S/N 9001~9050) ................................................................................................ 42-84
Proportional relief valve (S/N 9051~) ........................................................................................................ 42-86
Reversing Fan Motor Line (OPT) .................................................................................................................... 42-91
Reversing fan motor function .................................................................................................................... 42-91
Hydraulic circuit (Reverse rotation) ........................................................................................................... 42-95
Secondary Steering ......................................................................................................................................... 42-96
Secondary steering circuit ......................................................................................................................... 42-96
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 ............................................................................................ 43-10
Hydraulic Cylinder ........................................................................................................................................... 43-15
Cylinder natural drift .................................................................................................................................. 43-15
Stop Valve ....................................................................................................................................................... 43-17
Stop valve adjustment procedure ............................................................................................................. 43-17
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 stop lamp) ................................................................................................................ 52-36
Pressure sensor (for Declutch) ................................................................................................................. 52-37
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
Function & Structure Electrical Group ................................................................................................................... 62-1

How to Use Electrical Wiring Diagram .............................................................................................................. 62-2
Utilisation des schmas des cblages lectriques (FRANAIS) ...................................................................... 62-3
Verwendung des elektrischen Schaltplans (DEUTSCH) ................................................................................... 62-4
Modalit di utilizzo dello schema dei collegamenti elettrici (ITALIANO) ............................................................ 62-5
Cmo utilizar un Diagrama de Alambrado Elctrico (ESPAOL) ..................................................................... 62-6
Como Utilizar o Diagrama de Ligaes Elctricas (PORTUGUS) .................................................................. 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 ............................................................................................ 62-35
Machine control unit (MCU) ...................................................................................................................... 62-35
MCU connection diagram ......................................................................................................................... 62-37
Machine control unit (MCU) function ......................................................................................................... 62-39
Modulator valve operation ......................................................................................................................... 62-46
Adjustable declutch preset switch ............................................................................................................. 62-47
Monitoring system ..................................................................................................................................... 62-57
Operation monitor lamps ........................................................................................................................... 62-59
Instrument Panel and Switch .......................................................................................................................... 62-60
Instrument panel ....................................................................................................................................... 62-60
Instrument panel rear surface ................................................................................................................... 62-61
Gauge circuit ............................................................................................................................................. 62-62
Fuel gauge circuit ...................................................................................................................................... 62-64
MODM ............................................................................................................................................................. 62-65
MODM function ......................................................................................................................................... 62-65
Monitor Changeover ................................................................................................................................. 62-65
Information Monitor ................................................................................................................................... 62-68
Replacement Monitor ................................................................................................................................ 62-72
Fault Log Monitor ...................................................................................................................................... 62-78
Input/Output Monitor ................................................................................................................................. 62-85
Parameter Setting Monitor ........................................................................................................................ 62-89
Specification Setting Monitor ..................................................................................................................... 62-98
Electrical Detent Circuit ................................................................................................................................. 62-104
Bucket leveler .......................................................................................................................................... 62-104
Detent solenoid ....................................................................................................................................... 62-105
Lift kickout & lower kickout ...................................................................................................................... 62-106
Sensor assy ............................................................................................................................................ 62-107
Detent solenoid ....................................................................................................................................... 62-109
Preset height adjustment ........................................................................................................................ 62-109
Diode ............................................................................................................................................................. 62-110
Diode check method ................................................................................................................................62-111
Caution for diode check method ..............................................................................................................62-111
Surge voltage and surge suppression diodes ......................................................................................... 62-113
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
Check & Adjustment Operator Station Group ....................................................................................................... 73-1
Air Conditioner .................................................................................................................................................. 73-2
Adjustment of lubricating oil quantity when components of air conditioner are replaced ............................ 73-2
Adjustment of air gap (between hub and rotor) in compressor magnetic clutch ......................................... 73-5
Compressor V-belt adjustment .................................................................................................................... 73-6
Parts to be replaced periodically ................................................................................................................. 73-7
Function & Structure Supplement ...........................................................................................................................80-1

Foreword ............................................................................................................................................................80-2
Quick Coupler .....................................................................................................................................................80-3
Power Boost Circuit ............................................................................................................................................80-7
Short Boom (OPT) ...........................................................................................................................................80-15
Limited Slip Differential (LSD) ...........................................................................................................................80-17
03-6
Measurement for Performance Check
MEMO
00-1
115ZV-2 General Information
General Information
How to Use Manual ................................................. 00-2

Outline ..................................................................... 00-4
00-2
General Information
How to Use Manual
How to Use Manual
Safety precautions - Do not start to work in an enclosed area if adequate

ventilation is not provided.
The most important point in providing repair service is - To remove a heavy unit (20 kg (40 lbs) or more), be
safety. To ensure safety, observe the general cautions sure to use a crane or other lifting device.
described below.
- Just after stopping operation, be careful not to
- This manual is intended for properly trained and directly touch a hot component. You may get burned.
equipped service technicians.
- Contact tire manufacturer's local dealer for tire ser-
- Any work on the machine must be performed by the vicing and changing.
trained personnel only.
- Always store the tools in good condition, and use
- Carefully read this manual to thoroughly understand them properly.
the operation method before you operate or repair
the machine. - Keep the work area clean. Clean up spills immedi-
ately.
- Be sure to wear appropriate clothes and protectors,
such as safety boots, hard hat and goggles. - Avoid the use of flammable solvents and cleaners.
- Place the machine on level and solid ground, and - When working outdoors keep work areas, ladders,
place chocks against the wheels to prevent move- steps, decks and work platforms clear of snow, ice,
ment. and mud.
- Remove the cable from the battery before starting - Use safe work platforms to reach higher areas of the
the service work, and attach a "DO NOT OPERATE!" machine.
tag to the steering wheel.
- Any technician that operates a refrigerant recovery
IMPORTANT and recycling machine must first be certified through
an EPA approved testing program.
If a battery terminal is removed from a machine in More information is available at http://www.epa.gov/
less than 30 seconds after the key is put into the ozone/title6/608/technicians/608certs.html.
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 start-

ing 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 ade-
quate cribbing under the unit to prevent unexpected
dropping.
00-3
How to Use Manual
Symbols
For safe and effective service work, the following sym-
bols are used for notes and useful information in this
manual.
Symbol Item Description
Shows the condition or procedure that will be useful

Reference
or efficient in doing service work.
Shows the weight of a part or unit. The weight

should be considered in selecting wire rope or cable
Weight
for slinging work or determining the working pos-
ture.
Tightening Shows the tightening torque of a section that should

torque be carefully tightened during assembly work.
Shows the type of coating or adhesive and the coat-

Coating
ing section.
Oil or
Shows the oil or water supply port and the refill
water
amount.
supply
Shows the oil or water drain port and the drain

Drainage
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 per-
formance 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 follow-
ing abbreviation list. Additional abbreviations are listed on page 92-20.
E/G ........... Engine RH ............Right hand side 3rd ............3rd speed

T/C ........... Torque converter LH ............Left hand side 4th ............4th speed
T/M ........... Transmission H ............High M/C ............Machine
SOL ........... Solenoid valve L ............Low min-1 ............RPM
SW ........... Switch GND ............Ground ELS ............Efficient loading system
F ........... Front or Forward OPT ............Option MODM ........Machine operation diag-
A/M ........... Auto/Manual Assy ............Assembly nostic module
B ........... Battery 1st ............1st speed MCU ...........Machine control unit
R ........... Rear or Reverse 2nd ............2nd speed
00-4
General Information
Outline
Outline
Layout of main components
16
8 10
6 11
9 23
7 19 2
15
17 22 20 3 21 4 18 14 1 12 13
115V2E00001
1. Engine assembly 9. Air cleaner 16. Efficient loading system (ELS)

(Cummins QSK19) 10. Muffler valve
2. Torque converter assy 11. Radiator 17. Front axle assembly
3. Transmission 12. Hydraulic oil cooler 18. Rear axle assembly
4. Hydraulic pump (air-to-oil type) 19. 1st propeller shaft
5. Multiple (loader) control valve 13. T/C oil cooler 20. 2nd propeller shaft
6. Steering valve (lower tank of radiator) 21. 3rd propeller shaft
7. Pilot valve (for loading) 14. T/C oil cooler (installed on E/G) 22. Parking brake
(right side) 15. Charge air cooler 23. Fan motor
8. Transmission control valve
00-5
Outline
Inspection and maintenance table IMPORTANT

Severe application require more frequent mainte-
Refer to Operation & Maintenance Manual for maintenance.
nance procedures. Severe conditions include heavy dust, extremely
abrasive material, caustic chemicals, exremely wet
conditions or abnormally hot or cold ambient temper-
atures.
: First time replacement or cleaning only

Operating hours
When
Section Item for check
Required
10 50 250 500 1000 2000
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

*1
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 After six cleanings or once a year
Replace Coolant 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.
00-6
General Information
Outline

Operating hours
When
Required
10 50 250 500 1000 2000
Check Transmission Oil Level
Transmission & Replace Transmission Oil Filter

Torque
Converter 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 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

00-7
Outline

Operating hours
When
Required
10 50 250 500 1000 2000
Check Hydraulic Oil Level
Greasing
Replace Hydraulic Oil Return Filter
Loading system Replace Hydraulic Oil, Clean Filter
Replace Filter in the Hydraulic Tank Cap
Replace Bucket Teeth (option)
Replace Cutting Edge (option)
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
Check Monitor Panel Operation

Electrical
system 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 Every 3 years or 6000 hours
Others Walk-Around Inspection

00-8
General Information
Outline
Recommended lubricants
Refill capacity Ambient Temperature (C) Change Interval

Kind of Oil
(Approximate) -30 -20 -10 0 10 20 30 40 (Hours)
SAE10W-30
Engine oil 2
Engine 66 liter SAE15W-40 500
(CH4 or CI4)
SAE10W
Engine oil (CD) or
Transmission 90 liter ATF 1,000
ATF
1 3 ISO VG32
Hydraulic tank 225 liter Hydraulic oil ISO VG46 2,000
Differential & Front: 180 liter

Planetary Rear: 180 liter Engine oil SAE40 or SAE50
Engine oil (CD) 2,000
Parking brake 3 liter
ASTM D975 No.1
Fuel tank 660 liter Diesel fuel ASTM D975 No.2 daily
Note: 1 shows "Hydraulic tank oil capacity at level gauge center."
Engine Use oil that meets engine oil classification API CH4, CI4 or CG4.
2. Change engine oil every 250 hours if CG4 is used.
Engine oil drain intervals need to be reduced by 50 % when fuel sulfur content exceeds
0.5 %.
Transmission Use engine oil classification API CD or A.T.F. (Auto Transmission Fluid).
Never mix engine oil and A.T.F.
Hydraulic System Use industrial-type hydraulic oils which are certified by suppliers having anti-wear, anti-
foam, anti-rust and anti-oxidation additive properties for heavy duty use. Use of the wrong
viscosity of oil can cause improper operation of hydraulic functions or premature pump fail-
ure.
3. In a case that fire-resistant fluid is used in the hydraulic circuit, replace hydraulic pump
every 6,000 hrs operation.
Differential & Use class API CD engine oil with 5 % "Antichatter" additive or friction modifier.
Planetary
Lubricating Grease Use multipurpose-type EP/MOLY grease for most applications.

NLGI NO.2 grease is suitable for most temperatures.
NLGI NO.1 or NO.0 grease for extremely low temperature.
Use lithium base grease for universal joints and a propeller shaft spline.
00-9
Outline
Diesel Fuel Requirements for diesel fuel

Specifications
Grade No. 1-D Grade No. 2-D
Flash Point C. min. 38 52
Water and Sediment % vol. max. 0.05 0.05
Distillation Temperature C. 90% vol. recovered max. 288 338
min. 1.3 1.9
Kinematic Viscosity mm2/s at 40C
max. 2.4 4.1
Ash % mass max. 0.01 0.01
Sulfur % mass max. 0.50 0.50
Cetane Number min. 40 40
Carbon residue on 10% distillation residue % mass max. 0.15 0.35
Coolant Recommended mixture of antifreeze
Coolant specification
Expected Minimum -35C -30C -25C -20C -15C
Ambient Temperature (-31F) (-22F) (-13F) (-4F) (-5F)
The machine is originally filled with Long Life Coolant
liter 68.1 75.4 82.6 89.9 97.1
(non-Amin type ethylene glycol) which need not be Pure Water
(gal) (18.0) (19.9) (21.8) (23.7) (25.6)
replaced for the first two years or 3,000 hours.
liter 76.9 69.6 62.4 55.1 47.9
Antifreeze
Do not use Amin type Long Life Coolant in cooling sys- (gal) (20.3) (18.4) (16.5) (14.6) (12.7)
tem. It may cause a corrosion against radiator or heater Mixture Ratio (%) 53 48 43 38 33
core.
If standard antifreeze (not Long Life Coolant) is used for - Too much antifreeze in the coolant mixture may
the replacement, it should be replaced every six cause engine overheating.
months. Keep 33% antifreeze mixture (same as the mixture
for a minimum ambient temperature of -15C (5F)) if
the engine overheats in a high ambient temperature.
- Do not use hard water or water with high levels of

calcium and magnesium ions as the coolant water.
IMPORTANT
Do not mix different brands of antifreeze because
they each contain special additives.
Careless mixing often diminishes the effect of these
additives that causes the packing damage or water
leakage.
00-10
General Information
Outline
Lubrication chart
DIFF & DIFF & EVERY 12000Hr

GEAR BOX HYD. TANK GEAR BOX
GO HO GO EVERY 2000Hr
DIFF TRANSMISSION DIFF
G TO G EVERY 1000Hr
PILLOW ENGINE OIL PAN
GO
UNIT G GO EO EVERY 500Hr
BUCKET LINK SYSTEM CENTER
G G PIN G AXLE EVERY 250Hr
SUPPORT
TO HO G EVERY 50Hr
EO EVERY DAY
G G
CENTER PIN STEERING CYL.
G
PROPELLER SHAFT
G G
SPLINE
2ND PROPELLER 1ST & 3RD PROPELLER
SHAFT SHAFT
115ZV2-44794-23630EU
G HO
Grease point Multipurpose grease Hydraulic oil
GO TO
Check and add if necessary Gear oil Engine oil
EO
Oil replacement Engine oil
00-11
Outline
Weight of main components
Item Approx. Approx.

Remarks
Unit name Part name weight (kg) weight (lb)
Bucket 4,985 10,970 RVT bucket

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 70 155
Engine room
Radiator guard 115/pc 250
Access panel 35/pc 80/pc
Hydraulic tank 360 795 Excluding oil
Chassis Fuel tank 330 730 Excluding fuel
Floor board 285 630 Including ope. board, instrument panel and control box
Cab 270 600 Soft cab
Rops 950 2,090
Left side 105 230 With handrail
Deck Right side 80 175 With handrail
Center 35 80
Front chassis 3,800 8,360
Rear chassis 4,300 9,460
Counter weight 2,150 4,730
Engine 1,980 4,360 Excluding oil
With air cooler, hyd. cooler and duct. Excluding water
Radiator assembly 890 1,960
and oil
Torque converter 440 970 Excluding oil
Transmission 1,310 2,880 Excluding oil
First propeller shaft 20 45
Power line Second propeller shaft 130 290
Third propeller shaft 35 80
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)
Front 745 1,640 Including parking brake
Differential
Rear 560 1,235
Multiple control valve 100 220
Pilot valve 7 15
Steering valve 50 110
Orbitrol 6 13
40 90 Switch
Hydraulic system Gear pump
40 90 Main & pilot
Fan motor 25 55
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 )
Other
Battery 65/pc 145/pc
00-12
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 Bolt strength
Type Nominal Nominal
Pitch 8.8 (8T) 10.9 (11T)
dimension diameter
M8 8 (C) 1.25 26 38
(C) 1.5 53 76
M10 10
(F) 1.25 55 80
(C) 1.75 90 132
M12 12
(F) 1.25 96 142
(C) 2.0 142 206
M14 14
(F) 1.5 152 221
(C) 2.0 216 314
M16 16
(F) 1.5 226 330
(C) 2.5 299 436
M18 18
(F) 1.5 324 476
Metric thread (C) 2.5 417 608
M20 20
(F) 1.5 451 662
(C) 2.5 559 814
M22 22
(F) 1.5 598 878
(C) 3.0 721 1,030
M24 24
(F) 2.0 770 1,128
(C) 3.0 1,030 1,520
M27 27
(F) 2.0 1,128 1,618
(C) 3.5 1,422 2,109
M30 30
(F) 2.0 1,569 2,256
(C) 3.5 1,912 2,844
M33 33
(F) 2.0 2,059 3,040
5/16 05 18 UNC 25 35
3/8 06 16 UNC 44 65
7/16 07 14 UNC 71 103
1/2 08 13 UNC 103 147
Unified thread 9/16 09 12 UNC 147 216
5/8 10 11 UNC 201 294
3/4 12 10 UNC 358 525
7/8 14 9 UNC 554 809
1 16 8 UNC 868 1,275
Note: Tighten the bolts according to the above list, unless otherwise specified.
00-13
Outline
(kgf-m)
Pitch 8.8 (8T) 10.9 (11T)
dimension diameter
M8 8 (C) 1.25 2.7 3.9
(C) 1.5 5.4 7.8
M10 10
(F) 1.25 5.6 8.2
(C) 1.75 9.2 13.5
M12 12
(F) 1.25 9.8 14.5
(C) 2.0 14.5 21.0
M14 14
(F) 1.5 15.5 22.5
(C) 2.0 22.0 32.0
M16 16
(F) 1.5 23.0 33.7
(C) 2.5 30.5 44.5
M18 18
(F) 1.5 33.0 48.5
Metric thread (C) 2.5 42.5 62.0
M20 20
(F) 1.5 46.0 67.5
(C) 2.5 57.0 83.0
M22 22
(F) 1.5 61.0 89.5
(C) 3.0 73.5 105.0
M24 24
(F) 2.0 78.5 115.0
(C) 3.0 105.0 155.0
M27 27
(F) 2.0 115.0 165.0
(C) 3.5 145.0 215.0
M30 30
(F) 2.0 160.0 230.0
(C) 3.5 195.0 290.0
M33 33
(F) 2.0 210.0 310.0
5/16 05 18 UNC 2.5 3.6
3/8 06 16 UNC 4.5 6.6
7/16 07 14 UNC 7.2 10.5
1/2 08 13 UNC 10.5 15.0
Unified thread 9/16 09 12 UNC 15.0 22.0
5/8 10 11 UNC 20.5 30.0
3/4 12 10 UNC 36.5 53.5
7/8 14 9 UNC 56.5 82.5
1 16 8 UNC 88.5 130.0
00-14
General Information
Outline
(lb-ft)
Pitch 8.8 (8T) 10.9 (11T)
dimension diameter
M8 8 (C) 1.25 19.5 28
(C) 1.5 39 56
M10 10
(F) 1.25 40 59
(C) 1.75 66 97
M12 12
(F) 1.25 70 105
(C) 2.0 105 150
M14 14
(F) 1.5 110 160
(C) 2.0 160 230
M16 16
(F) 1.5 165 245
(C) 2.5 220 320
M18 18
(F) 1.5 235 350
Metric thread (C) 2.5 305 450
M20 20
(F) 1.5 330 490
(C) 2.5 410 600
M22 22
(F) 1.5 440 650
(C) 3.0 530 760
M24 24
(F) 2.0 565 830
(C) 3.0 760 1,120
M27 27
(F) 2.0 830 1,190
(C) 3.5 1,050 1,550
M30 30
(F) 2.0 1,160 1,660
(C) 3.5 1,410 2,100
M33 33
(F) 2.0 1,520 2,240
5/16 05 18 UNC 18.0 26
3/8 06 16 UNC 32 47
7/16 07 14 UNC 52 76
1/2 08 13 UNC 76 105
Unified thread 9/16 09 12 UNC 110 160
5/8 10 11 UNC 150 215
3/4 12 10 UNC 265 385
7/8 14 9 UNC 410 595
1 16 8 UNC 640 940
00-15
Outline
Flanged hexagon bolt
1. Bolt type: Metric thread
2. Bolt strength: 8.8 (8T)
3. Thread pitch: Coarse pitch thread (C)
(N-m)
Type Nominal
Pitch 8.8 (8T)
dimension
M5 0.8 7
M6 1 12
M8 1.25 28
M10 1.5 53
Metric thread
M12 1.75 94
M16 2 231
M20 2.5 441
M24 3 765
(kgf-m)
Type Nominal
Pitch 8.8 (8T)
dimension
M5 0.8 0.7
M6 1 1.2
M8 1.25 2.9
M10 1.5 5.4
Metric thread
M12 1.75 9.6
M16 2 23.5
M20 2.5 45.0
M24 3 78.0
(lb-ft)
Type Nominal
Pitch 8.8 (8T)
dimension
M5 0.8 5.0
M6 1 8.6
M8 1.25 20.9
M10 1.5 38.9
Metric thread
M12 1.75 69.1
M16 2 169.2
M20 2.5 324.0
M24 3 561.6
00-16
General Information
Outline
Hose band tightening torque
Low pressure hose

(heat resisting hose) Tightening torque Tightening torque Tightening torque
Hose band
(N-m) (kgf-cm) (lb-ft)
Inner dia. (mm) Outer dia. (mm)
6.3 16.5
7.9 18.5 69002-02200 1.6 16 1.2
9.5 20.5
12.7 24.5 69002-02700
15.9 29.9
69002-03100
19.0 30.0
25.4 38.0 69002-04400
31.8 45.8 69002-05200 4 40 2.9
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 Tightening torque Tightening torque Tightening torque

Hose band
Inner dia. (mm) Outer dia. (mm) (N-m) (kgf-cm) (lb-ft)
6 16.5
8 18.5 69002-02200 1.6 16 1.2
9 20.5
9 22.0 69002-02300
12 24.5
69002-02700
12 26.0
15 29.0
69002-03100
15 30.5
19 32.0
69002-03800
19 34.0
4 40 2.9
25 39.5
69002-04400
25 41.5
32 46.0
69002-05200
32 48.0
38 54.0 69002-05700
50 70.5
69002-07600
50 73.0
To connect the hose to the pipe, tighten the hose band Hose
at the following position: Pipe
Hose band
Center of pipe
protrusion
10~20 mm 70ZV00003
00-17
Outline
Liquid gasket and screw lock Cautions regarding reassembly

agent To reassemble a screw
To reassemble the disassembled parts, be sure to use Completely remove the hardened lock agent from the
the specified liquid gasket or screw lock agent or the screw and the threaded hole before reassembling the
equivalent according to the following lists: screw.
Code Manufacturer Product name

Note
A piece of hardened lock agent may be peeled off and
AA01 Loctite Plastic Gasket 568
remain in the component. The remaining piece may
Liquid
gasket
AA02 Loctite Hydraulic sealant cause malfunction during fastener installation.
AA03 Three Bond Three Bond 1215
AB01 Loctite Loctite 262 To bond a plane or to fit a shaft
Screw lock
AB02 Three Bond Three Bond 1327
agent Remove the hardened lock agent using a wire brush or
AB03 Three Bond Three Bond 1374 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.
Cautions regarding parts removal Antiseize Agent
Code Manufacturer Product name

If a screw or shaft to be removed has been locked by
Loctite 767
one of the above agents, remove the screw or shaft AC01 Loctite
using a general tool, such as a wrench or puller. (Paste or spray)
If it is difficult to remove the screw or shaft, heat the bolt

to soften the agent (200~250C) 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.
00-18
General Information
Outline
Screw lock agent application procedure How to wind a seal tape

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

threads.
Seal tape
Screw lock agent
Leave 1~2 screw
65ZV00004
To avoid a piece of seal tape left in the circuit, leave 1 or

65ZV00002 2 screws from the end of the thread and start threading
it clockwise.
00-19
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 pos-
sible 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 5. To ground the welder, check that the electric current
negative sides from the battery. will not flow through the cylinders.
Cylinder head covers for some models have a low
conductive metal that will cause spark if the welding
IMPORTANT current flows. The spark may damage the cylinder
If a battery terminal is removed from a machine in rod.
less than 30 seconds after the key is put into the
OFF position, it can corrupt the ECM program, 6. Calibrate throttle pedal to ECM.
which can disable the engine. Always wait 1 full
minute to be sure to be past this write to memory (a) Turn the starter switch to "ON".
function prior to removing battery terminals. (b) Fully depress and release the throttle pedal
three times.
(c) Turn the starter switch to "OFF".
3. Disconnect the connector for MCU (machine con-
troller), ECM (engine controller) and air conditioner.
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 Section to be welded Ground this section.
through the cylinders. (correct grounding)
35C00006
00-20
General Information
Outline
7. The weld spattered on the hydraulic cylinders and

on the plated sections of pins will damage the cylin-
ders and pins. There are other parts that may be
damaged by the spatter; hydraulic units, har- Heat-resistant
cloth
nesses, hydraulic hoses, and nylon tubes.
Be sure to mask these units and parts before weld- Section to
ing. Hydraulic hose be welded
Nylon tube Remove
Harness and if
necessary
Hydraulic cylinder wrap
Chassis
35A00005
Plated section (Mask this section.)

(c) Hydraulic hoses, nylon tubes, or harnesses are
easily damaged by the heat during welding. To pro-
tect them from the heat, remove them from the sec-
Pin section with pin tion to be welded to make enough clearance.
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 corro-
sion.
Scrap material, etc.

1m or more
Section to
be welded
1m or more
35C00004
(b) Cover the hydraulic units, electrical units, har-

nesses, hydraulic hoses, nylon tubes, etc. with
heat-resistant cloth (glass wool or canvas) or scrap
material to protect them from spatter.
03-1
115ZV-2 Measurement for Performance Check
Measurement for
Performance Check
Cautions on Safety .................................................. 03-2

Standard Measurement Values for Performance Check
............................................................................ 03-3
03-2
Cautions on Safety
Cautions on Safety
WARNING CAUTION
Unexpected movement of the machine may cause an Touching the fan or the V belt of the engine or the hot
accident resulting in injury or death. area while the engine is running may cause severe
Therefore, to provide repair service with the engine accidents.
running, be sure to observe the following items: Make sure to stop the engine before opening the
- Park the machine on level ground. engine room access panel.
- 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 acci-
dents.
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.
03-3

Measurement conditions
Temperature of torque converter oil: 50~80C (120~180F)
Temperature of hydraulic oil: 50~80C (120~180F)
Temperature of engine coolant: 50~80C (120~180F)
Standard measurement
Item
values for performance check
Remarks
Fuel efficient
System Measurement item Normal
mode
Minimum no-load speed, Low Idle (LI) 92550 775 in hibernate mode
Maximum no-load speed, High Idle (HI) 1,91050
Engine speed
(min-1) (rpm) Maximum speed in torque converter stall mode 1,780100 1,690100
Maximum speed in multiple control valve relief mode 1,855100 1,705100
(S/N 9001~9100)
Maximum speed in torque converter stall plus multiple
1,420 +150
- 100 1,375 +150
- 100
control valve relief mode
Engine
Minimum no-load speed, Low Idle (LI) 92550 775 in hibernate mode
Maximum no-load speed, High Idle (HI) 1,91050 1,70050
Engine speed
(min-1) (rpm) Maximum speed in torque converter stall mode 1,780100 1,690100
Maximum speed in multiple control valve relief mode 1,850100 1,850100
(S/N 9101~)
Maximum speed in torque converter stall plus multiple
1,420 +150
- 100 1,380 +150
- 100
control valve relief mode
Main pressure Idling (LI) 2.60.2 (272) (38428)

MPa (kgf/cm2) (psi) Maximum (HI) 2.60.2 (272) (38428)
Transmission
Engine speed
Clutch pressure Idling (LI) 2.50.2 (262) (37028)
MPa (kgf/cm2) (psi) Maximum (HI) 2.50.2 (262) (37028)
Clutch time lag NeutralForward 1st speed

0.30.1 Before wheels move
(sec) (engine speed: 1,500 min-1 (rpm))
03-4
Item Standard measurement

values for performance Remarks
System Measurement item check
Cylinder drift Boom cylinder 3 (1/8) or less

(when boom and
bucket are horizon-
tal and with no load)
(mm/min) (in/min) Bucket cylinder 4 (5/32) or less
Idling (LI) 253.0

Boom rising time
-1
(no load) Engine speed 1,500 min (rpm) 10.51.0
(sec)
Maximum (HI) 8.40.5
Idling (LI) 5.00.5
Full steering time -1
Engine speed 1,500 min (rpm) 3.90.3
(sec)
Full accelerated engine speed 3.90.5
20.60.5 (2105)
Loading line main relief pressure (HI)
(2,98671)
Hydraulic line
Run engine at lowest

23.50.5 (2405)
Loading line overload relief pressure (LI) possible speed while
(3,41371)
setting
Relief valve setting
20.60.5 (2105)
pressure Steering line main relief pressure (HI)
(2,98671)
MPa (kgf/cm2) (psi)
24.5 +1.0 +10
0 (250 0 )
Steering line overload relief pressure (LI) +142 possible speed while
(3,555 0 ) setting
3.5 (36)
Pilot line reducing pressure (LI) possible speed while
(512)
setting
Engine water temp. <80C (180F)
T/C oil temp. <110C (230F) 1,120 +75
- 200
Fan maximum Hydraulic oil temp. <90C (195F)
revolution (HI)
min-1 (rpm) Engine water temp. >95C (205F)
T/C oil temp. >115C (240F) 1,300 +100
- 50
Hydraulic oil temp. >95C (205F)
Fan minimum
Engine water temp. <60C (140F)
revolution (LI) 900 +50
Engine idle revolution - 200
min-1 (rpm)
03-5
Item Standard measure-

ment values for perfor- Remarks
System Measurement item mance check
Slowly increase the
Shift lever position 2nd speed reverse engine speed, and
Performance of check that the machine
service brake does not move at the
Engine speed Maximum (HI) maximum engine
speed.
Shift lever position 3rd speed reverse Before brake check, be

sure to disconnect the
Performance of
Same as above cable connector of
parking brake
parking brake solenoid
Engine speed Maximum (HI) valve.
11.80.5 (1205)
Off (Cut-out)
(1,70671)
Unloader valve
setting pressure
6.91.0 (7010)
On (Cut-in)
Brake
Brake line setting (995142)

pressure
MPa (kgf/cm2) (psi) Low-pressure alarm switch setting pressure 3.90.5 (405)
(For brake accumulator circuit) (56971)
1.3 (13)
Auto brake reducing pressure
(185)
The time from the low-pressure alarm is

Accumulator charge
Engine speed (LI) turned off till the unloading valve cuts off 16
time (sec)
pressure
Run engine 1 minute high idle, then stop the engine. Repeat stepping on the
Number of brake (Turn key switch "ON" with engine off.) brake pedal as follows:
at least 11 times
pedal applications Step on the brake pedal and release, and check the number On: 5 sec.
of times until the low-pressure alarm is turned on. Off: 5 sec.
Declutch 1/5 slope
Engine: Maximum speed/ Declutch pedal: Quick release
engagement 15 (6) or less (approx. 11), unladen,
(Distance the loader rolls back before moving forward.)
(cm) (in) 1st speed
Note
These are the standard measurement values for the
machines at the time when delivered from the factory.
03-6
MEMO
12-1
115ZV-2 Function & Structure Chassis Group
Function & Structure

Chassis Group
Front Chassis .......................................................... 12-2

Rear Chassis........................................................... 12-5
Center Pin ............................................................... 12-7
12-2
Function & Structure Chassis Group
Front Chassis
Front Chassis
Loading linkage
10 2 8 3 9 4 5
7 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)
12-3
Front Chassis
Even contact both sides
5040
Hinge pin height at

300 bucket on ground
Typical bucket dump stopper clearance

(Contact attachment supplier for details on
Typical bucket roll-back stopper adjustment non-standard attachments)
(Contact attachment supplier for details on non-standard To increase clearance increase height of #9
attachments) To reduce clearance decrease height of #9
115V2E12001
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 cylin-

ders so the piston does not hit the cylinder head.
12-4
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 - 9. Boom cylinder -

Front chassis Front chassis
10. Front chassis - 11. Steering cylinder -

Steering cylinder Rear chassis
2 7 3 8 4
5 10 11
1 6 9 115V2E12002
12-5
Rear Chassis
Rear Chassis
Fuel tank
10
A-Detail
A
9
2 4
10
8 5 6
115V2E12003
1. Fuel tank
2. Fuel level sensor
3. Fuel tank filler assembly
4. Filter
5. Drain plug
6. Inspection hole cover
7. Gasket (Rubber seal type)
8. Suction pipe
9. Pipe (for vacuum prevention)
10. Fuel return pipe
12-6
Rear Chassis
Floor board mount Viscous mount
Floor board
1 2
1
115ZV12008
5
1. Floor board 6
2. Rubber cushion
7
The floor board is installed on the rear chassis by the
rubber cushion. The instrument panel, control box, 8
operator's seat and the air conditioner unit are on the 9 10 11
floor board.
95ZV12008
1. Stud bolt
2. Stud
3. Cushion rubber
4. Case
5. Seal plate
6. Damping rubber
7. Damping plate
8. Silicone oil
9. Plain washer
10. Hexagon head bolt
11. Plug
The floor board is supported by a viscous mount in four

positions so that vibrations, impacts and sounds gener-
ated in the chassis are not transmitted to the inside of
cabin.
12-7
Center Pin
Center Pin
Upper center pin Upper
1. Center pin
1 2. Plate
4 9, 10 3
3. Bearing cover
4. Sleeve
5. Shim
5
6. Bearing assy
7. Dust seal
Front 8. Bolt
chassis 9. Bolt
6
10. Washer
7 11. Bushing
11 Rear
2 chassis
8, 10
Upper
115ZV12010
6
4
9, 10
7
3 7
11
Grease pipe
Split shim
2
5
8, 10
115V2E12004
12-8
Center Pin
Lower center pin Lower
1. Center pin
2. Bearing retainer
3. Bearing assy
1 6 4. Dust seal
7 5. Bushing
6. Bolt
7. Plate
2
3
Front
chassis
5 4 Rear
Lower chassis
115ZV12011
6, 7 Grease pipe
4
2
115V2E12005
12-9
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.
12-10
MEMO
13-1
115ZV-2 Check & Adjustment Chassis Group
Check & Adjustment

Chassis Group
Linkage Pin ............................................................. 13-2

Center Pin ............................................................... 13-6
13-2
Check & Adjustment Chassis Group
Linkage Pin
Linkage Pin
WARNING CAUTION
Unexpected movement of the machine may cause an Unexpectedly dropped parts may cause an accident
accident resulting in injury or death. resulting in injury.
Before starting adjustment work, be sure to observe - Before liner insertion, be sure to lift the cylinder
the following items: using a crane to prevent the cylinder from unex-
- Park the machine on level ground. pectedly dropping during liner insertion.
- Apply the parking brake. - Wear protective clothes like work gloves and steel
- Remove the starter key, and attach a "DO NOT toed shoes.
OPERATE!" tag on the cab.
moving.
Liner
5 6
2 8
1 3 7
115ZV12005
Adjustment
1 2 3 4 5 6 7 8
portion
Liner hole diameter Adjustment
110 91 91 121 101 121 71
(mm) unnecessary
13-3
Linkage Pin
Bucket hinge pin section (#1)
Boom Bucket
Bushing 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.
3. Place the shim between the bucket boss and the

seal retainer assy so that the clearance between
R142
the boom boss and the seal retainer (* marked) is

less than 1mm.
5
Tighten the bolt for the seal retainer assy.

R5
Shim : 417 N-m (42.5 kgf-m) (307 lb-ft)
115V2E13001 Shim thickness
1.0, 0.5 mm (0.039, 0.020 in)

1. Attach the seal retainer assy to the bushings.
(2 kinds of shim thickness)
(When installing the dust seal to the seal retainer
assy, be sure to check the direction of the dust
seal.)
13-4
Linkage Pin
Bucket link pin section (#2)
Bucket
Bushing Link
Bushing
Pin
Dust seal
Shim
Seal ring assy
115V2E13002
How to assemble
1. Insert the bushings into the link boss and attach the
91 +10 seal ring assy to the bushing.
(When installing the dust seal to the seal ring assy,

be sure to check the direction of the dust seal.)
80 -10
0
18 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)
3. Align the pin holes in the bucket and the link. Then,
Shim 115V2E13003 insert the pin.
13-5
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 chas-
sis side while checking that the cylinder is not inclined.
13-6
Center Pin
Center Pin
Adjusting shim The clearance between the front chassis and bearing
cover (3) is 0.750.5 mm (0.030.02 in) before shim
adjustment.
1
4 9, 10 3
Add shims (5) so that the clearance is 0.10.05 mm
(0.0040.002 in). After that, tighten bolt (9).
5
Torque for assembly:
:
Front Bolt (8): 662 N-m (67.5 kgf-m) (488 lb-ft)
chassis Bolt (9): 441 N-m (45.0 kgf-m) (326 lb-ft)
6
(with lubricating oil (Engine oil or gear oil))
7
Installing bearing cover

11 Rear
2 chassis
8, 10
Upper
115ZV12010
1 Front
Grease pipe
3
Upper
115V2E13004
6
4
Install the bearing cover (3) so that the grease nipple
9, 10 mounting hole is positioned at the specified angle as
7 shown in the figure.
3 7
11
Grease pipe
Split shim
2
5
8, 10
115V2E12004
13-7
Center Pin
Installing bearing outer ring
1 6
Front Rear
7
3
2 Center line Split of outer
bearing
3
Front
chassis 95ZV13003
5 4 Rear
Lower chassis
115ZV12011
6, 7 Grease pipe
4
2
115V2E12005
Install the bearing outer ring (3) so that the split is per-
pendicular to the frontrear line of the machine.
13-8
MEMO
22-1
115ZV-2 Function & Structure Power Group

Power Group
Power Line .............................................................. 22-2

Engine / Transmission............................................. 22-3
Radiator................................................................... 22-4
Propeller Shaft......................................................... 22-6
Axle Assembly......................................................... 22-10
Axle Support............................................................ 22-12
Differential Gear ...................................................... 22-14
22-2
Function & Structure Power Group
Power Line
Power Line
11 2 12 1 15 4
8 10 6 3 7 5 9 13 14
115V2E22001
1. Engine The power output from the engine is transmitted to the

2. Torque converter transmission through the torque converter and the first
3. Transmission propeller shaft. The speed and direction are changed
4. Radiator according to the engagement of the transmission
5. 1st propeller shaft clutches. The power is then transmitted through the
6. 2nd propeller shaft second and third propeller shafts to the differential
7. 3rd propeller shaft gears of front and rear axles.
8. Front axle differential gear
9. Rear axle differential gear Finally the power is transmitted through the axles to the
10. Parking brake planetary gears, and tires to move the machine.
11. Air cleaner
12. Muffler On the fan side of the engine, there is a radiator. The
13. Hydraulic oil cooler radiator incorporates engine coolant, torque converter
14. Torque converter oil cooler (bottom tank of radiator) oil cooler, charge air cooler and an external air type
15. Charge air cooler hydraulic oil cooler. A parking brake is installed on the
front differential gear.
22-3
Engine / Transmission
Engine / Transmission
Engine / transmission mount
E,F
A B C
T/C E/G
side side
1 Spacer
1
1 4
1
2
3
E/G flywheel
housing
A-Detail B-Detail C-Detail D-Detail E-Detail F-Detail
115V2E22002
1. Rubber cushion Bolts are used to connect the engine flywheel housing
2. Ring gear to the torque converter housing, and a spline ring cou-
3. O-ring pling is used to transmit the engine power to the torque
4. Plug 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.
22-4
Radiator
Radiator
Charge air Charge air

cooler OUT Coolant IN cooler IN
4
B
1
B
3
D D
A
C
A
C
5
Hydraulic oil Hydraulic oil
cooler IN cooler OUT
6
T/C oil T/C oil Coolant
cooler OUT cooler IN OUT
115V2E22003
1. Radiator assembly 4. Charge air cooler The torque converter oil cooler is in the radiator lower
2. Radiator duct 5. Hydraulic oil cooler tank.
3. Stay (Bracket) 6. T/C oil cooler
When the coolant is hot, the thermostat opens and the
The radiator incorporates the engine coolant, cooling coolant flows to the radiator.
fin, air charged cooler, and an external air type hydraulic
oil cooler. For the engine coolant, air charge cooler, When the coolant is cold enough, the thermostat is
hydraulic oil cooler, the air-cooling system is used. For completely closed and no coolant flows to the radiator.
the torque converter oil, the water-cooling system is
used. The air charge cooler is required to meet engine emis-
sion regulations.
22-5
Radiator
Radiator mount
A-Detail B-Detail C-Detail
D-Detail
115V2E22004
1.
2.
3.
4.
5.
6.
7.
8. Strip seal
Capacity in radiator:
Cooling water 86 L (23 gal)
Hydraulic oil 14 L (3.7 gal)
Torque converter oil 3 L (0.8 gal) x 2 pcs
Dry weight 890 kg (1,960 lbs)

22-6
Propeller Shaft
Propeller Shaft
4 2 1
5 6 3 115V2E22005
1. 1st propeller shaft The engine power is transmitted to the torque converter,
2. 2nd propeller shaft the first propeller shaft and the transmission, and is
3. 3rd propeller shaft (fixed type) then, transmitted to the second and the third propeller
4. Pillow block shafts to the front and the rear axle.
5. Parking brake
6. Slip joint 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 propel-
ler shaft length.
A parking brake is installed on the front differential gear.
The third propeller shaft is the fixed type with universal

joints.
22-7
Propeller Shaft
First propeller shaft assembly

Transmission Torque converter
1 2 1 Grease nipple installation

angle (a,b)
b a
View Z
1
b
Every 12000
hours greasing
115V2U22002
1. Journal spider assy

2. Propeller shaft
22-8
Propeller Shaft
Second propeller shaft assembly

Front differential Transmission
1 2 1 5 1 Grease nipple installation

angle (a,b,c,d)
d c b a
45
View Z
3 4
Every 12000 hours greasing

1 d
b
2
1
c
1
Every 12000 a
hours greasing
115V2U22003
1. Journal spider assembly

2. Propeller shaft assembly
3. Pillow block
4. Spline yoke
5. Sleeve yoke assembly
22-9
Propeller Shaft
Third propeller shaft assembly

Transmission Rear differential
Grease nipple installation

1 2 1 angle (a,b)
b a
View Z
1
1

115V2U22004
1. Journal spider assy

2. Propeller shaft
22-10
Axle Assembly
Axle Assembly
50
22 2
3
36 44 42
35 45
43 28
45 37
11 40
52
23 31
16 34 10
12 6
30 29
21
26 24
41 14 18
17 19 25 9
18 32 25
14
17 49
18 15 48
8 13 46
38 47
20
4
39 37 7
27 51
33
115V2E22009
22-11
Axle Assembly
1. Differential assembly 31. O-ring

2. Axle housing assembly 32. O-ring
3. Wheel hub 33. O-ring
4. Spider 34. Socket bolt
5. Cover 35. Spring
6. Axle shaft 36. U-nut
7. Sun gear 37. Magnet plug
8. Disc gear 38. Bolt
9. Planetary gear 39. Socket bolt
10. Internal gear 40. Air bleeder screw
11. Internal gear hub 41. Spring pin
12. Snap ring 42. Ring
13. Planetary pin 43. O-ring
14. Wear ring 44. Spring pin
15. Wear ring 45. Plug
16. Brake piston 46. Spring
17. Separation disc 47. Sleeve
18. Friction disc 48. Bushing
19. Brake backing plate 49. Socket bolt
20. Plate 50. Bolt
21. Axle nut 51. Bolt
22. Taper roller bearing (inner) 52. Flange bolt
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
22-12
Axle Support
Axle Support
Grease pipe
connection port
(PT1/8)
A
9
Grease pipe
connection port Pin
(PT1/8) (Axle housing)
9
Front Axle housing

5
16
9 4
15
2
10
A 1 16 11
A-A 3
7 13 8 11
Groove at
bushing end
12
14 10
#10 Details #11 Details
115V2U22001
1. Shaft 9. Breather
2. Rear axle support (front) 10. Bushing
3. Rear axle support (rear) 11. Bushing
4. Wear ring 12. Ring
5. Plate 13. Snap ring
6. Plate 14. Bolt
7. Lip seal 15. Bolt
22-13
Axle Support
Grease piping
7
9
10
7 9
12 6
Grease piping 11
15
14 16
16
3
8
13
1
115V2E22011
1. Shaft 9. Breather
2. Rear axle support (front) 10. Bushing
3. Rear axle support (rear) 11. Bushing
4. Wear ring 12. Ring
5. Plate 13. Snap ring
6. Plate 14. Bolt
22-14
Differential Gear
Differential Gear
Conventional type
Front differential gear (S/N 9001~9050)
2 1 23 24
3 28
29
26
33
35
32
4
31
30
27
5
6
34
7
22
8
9
15
10
21
25
11
12
13
14 17 16 18 19
20
115V2E22012
1. Nut 11. Taper roller bearing 21. Roller bearing 31. Friction disc
2. Flange yoke 12. Adjusting nut 22. O-ring 32. Separation disc
3. Oil seal 13. Plate 23. O-ring 33. Pin
4. Plug 14. Wear ring 24. O-ring 34. Spring pin
5. Housing 15. Side gear 25. Snap ring 35. Spring
6. Shim 16. Differential pinion 26. O-ring
7. Taper roller bearing 17. Pin 27. O-ring
8. Spacer 18. Wear ring 28. Gear
9. Spiral gear set 19. Spider 29. Piston assembly
10. Carrier assembly 20. Housing 30. Oil seal
22-15
Differential Gear
2 1
29
36
K115V2U22002
Front differential gear (S/N 9101~)
2 1
29
36
K115V2U22003
1. Nut
2. Flange yoke
3. Oil seal
29. Piston assembly
36. Oil seal (Double lip) (S/N 9051~)
22-16
Differential Gear
Rear differential gear
1 22 3
2 31
23
28 5
4 24
8
21
6
20
10
27
25
11
12
30 18
19
14
13
26 29
17 16 15 K115V2U22004
1. Nut 9. Spiral gear set 17. Side gear 25. O-ring

2. Flange yoke 10. Carrier assembly 18. Spider 26. Bolt
3. Oil seal 11. Adjusting nut 19. Housing assy 27. Snap ring
4. Trunnion 12. Lock plate 20. Roller bearing 28. Bolt
5. Housing 13. Straight pin 21. O-ring 29. Bolt
6. Taper roller bearing 14. Wear ring 22. O-ring 30. Bolt
7. Taper roller bearing 15. Wear ring 23. O-ring 31. Oil seal (Double lip)
8. Sleeve 16. Diff pinion 24. Shim (S/N 9051~)
22-17
Differential Gear
Function of differential gear Operation of differential gear

Power transmission Straight
3
4
4 3 2
5 115K22005 115ZV22013
1. The power output from the engine is transmitted to When moving in a straight direction, each wheel holds
the front and rear axle through the torque converter the same amount of torque.
and the transmission.
Therefore, pinion gears (4) in the differential assy do not
2. The power is transmitted from pinion gear (1) to turn.
axle shaft (2) through bevel gear (5) and differential
(4) in the axle housing. Torque from carrier (6) is transmitted to each wheel
equally through pinion gears (4), side gears (3) and axle
3. Finally the power is transmitted to the planetary shafts (2).
gears and tires to move the machine.
22-18
Differential Gear
Turn
4 3 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).
23-1
115ZV-2 Check & Adjustment Power Group
Check & Adjustment

Power Group
Engine ..................................................................... 23-2

Propeller Shaft......................................................... 23-3
Axle ......................................................................... 23-5
23-2
Check & Adjustment Power Group
Engine
Engine
Measuring engine oil pressure
WARNING
Unexpected movement of the machine may cause an Measurement instrument
accident resulting in injury or death.
Therefore, to provide repair service with the engine - Pressure gauge
running, be sure to observe the following items:
- Park the machine on level ground.
- Apply the parking brake. Install position
moving. 1. Location (A)
- Determine the signals between the service men.
- Prohibit any person from walking into dangerous 2. Measuring port: 9/16-18 UNF
areas.
- Near articulation area of the machine 3. Oil pressure gauge: 1.0 MPa (10 kgf/cm2) (150 psi)
- Under the machine
- Around the engine
- In front of or behind the machine Standard measurement value
Engine speed Service standard

CAUTION 92550 min-1 0.14 MPa (1.4 kgf/cm 2) (20 psi)
Do not touch the fan or V-belt of the engine or high- 1,91050 min-1 0.34~0.48 MPa (3.5~4.9 kgf/cm2) (50~70 psi)
temperature section if the engine is running. [Engine coolant temperature 50C (120F)]
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 revo- A
lution.
Measuring engine speed
Measurement instrument
- Tachometer 115V2E23001
Standard measurement value
Low idle (min-1): 92550
High idle (min-1): 1,91050

23-3
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 trans-
mission torque and the reaction force. As a result,
the propeller shaft extremely vibrates, and the ser-
vice life of the shaft will be shortened.
Second propeller shaft alignment
Top view
Differential side (C) (B) (A) Transmission side
Side view
95ZV22008
- As misalignment may produce an abnormal noise,

be sure to align points (A), (B), and (C) of the yokes
when reassembling the propeller shaft.
23-4
Propeller Shaft
Propeller shaft tightening torque
2nd propeller shaft 3rd propeller shaft 1st propeller shaft
Front differential 1 3 1 2 2 Rear differential
6
4 4
2nd propeller shaft 1st propeller shaft 3rd propeller shaft
115V2E23002
:
1. 221 N-m (22.5 kgf-m) (163 lb-ft) 1. Screw lock agent (Loctite 262)
5. 220 N-m (22.4 kgf-m) (162 lb-ft)
6. 155 N-m (15.8 kgf-m) (114 lb-ft)
23-5
Axle
Axle
Axle nut tightening procedure
9 8
PT3/8
5 (Brake oil inlet)
4
2
6 3 7 10
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). 1. 89.7 N-m (9.15 kgf-m) (66 lb-ft)
2. 721 N-m (73.5 kgf-m) (532 lb-ft)
2. Loosen axle nut (6). 3. 33.3 N-m (3.40 kgf-m) (25 lb-ft)
4. 53.0 N-m (5.40 kgf-m) (39 lb-ft)
3. Tighten axle nut (6) again with 3,923 N-m (400 kgf- 5. 86.3 N-m (8.80 kgf-m) (64 lb-ft)
m) (2,894 lb-ft) tightening torque.
4. Turn wheel hub (9) 2~3 turns back and forth, and #1, 2, 4, 10: Screw lock agent (Loctite 262)
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.
23-6
Axle
Differential gear adjustment procedure

(S/N 9001~9050)
9 1
10
5
3
115V2E23004
:
1. 1,030 N-m (105 kgf-m) (760 lb-ft) #2, 3, 4, 5, 7: Screw lock agent (Loctite 262)
2. 314 N-m (32.0 kgf-m) (232 lb-ft) #1: Liquid gasket
3. 1,130 N-m (115 kgf-m) (832 lb-ft) (Three Bond 1215 or a locally procured Room
4. 52.5 N-m (5.35 kgf-m) (39 lb-ft) Temperature Vulcanizer (RTV) that does not con-
5. 314 N-m (32.0 kgf-m) (232 lb-ft) tain Acetic Acid)
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
23-7
Axle
Front differential gear (S/N 9051~9100) Preload adjustment
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 moving-

Front differential gear (S/N 9101~) breakaway force.
Note
1 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
7 spacers increase preload.
9
11
K115V2U23002
10
K115V2U23003
23-8
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
9
Snap ring
Apply grease
when
assembling.
3 mm
Bearing (8) (0.118 in)
3.6 mm
(0.142 in)
11 (S/N 9051~) (double lip)

K85ZV23003 9 (S/N ~9050) (single lip)
K95V2U23003
Note
A snap ring is set to bearing (8) as shown above. Incor- After reassembling the differetial assembly, apply
rect installation of bearing (8) may cause the snap ring grease to the grease nipple until the grease comes out
to drop, resulting in a serious mechanical trouble. from the breather.
23-9
Axle
Adjusting tooth contact
Tooth contact Possible cause Adjusting method
A Correct
Loosen the bearing adjuster on the rear

side of ring gear, and tighten the adjuster of 2
Ring gear is too close to the tooth side at the same quantity as loosen-
B
drive pinion ing, so that the ring gear is far apart from
the drive pinion. Check again the backlash
and tooth contact.
2
Ring gear is too far from the
C Do the reverse adjusting as B.
drive pinion
Increase the thickness of shim at the part

of bearing cage being installed and makes 2
Drive pinion is too close to the
D drive pinion apart from the ring gear.
ring gear.
Check again the backlash and tooth con-
tact.
1
Decrease the thickness of shim reverse as

2
D, and makes drive pinion approach the
Drive pinion is too far from the
E ring gear.
ring gear.
Check again the backlash and tooth con-
tact.
1
After adjusting the backlash to the standard value,

check that manual rotation of the gear is possible. After
that, paint blue or red on the tooth surface of ring gear,
and check the tooth contact. To adjust the tooth contact,
adjust the thickness of the shim between the pinion and
cage, and turn the adjustment nut.
23-10
Axle
Three types of tooth contact shown below are accept-

able as the best tooth contact.
Tooth contact position and length (rate)
10
1 5 4
Pattern TOP HEEL
A
Pitch line 4~5 10
TOE
BOTTOM
10
2 4 4
Pattern TOP HEEL
B Pitch line 4~5 10
TOE
BOTTOM
10
3 4 3
Pattern TOP HEEL
C TOE 4~5 10
Pitch line
BOTTOM
Service parts
After adjusting the tooth contact and backlash in our

factory, we will wrap the bevel gear and drive pinion as
a unit. Therefore, replace the bevel gear and drive pin-
ion as a unit.
Note
Single sale of the bevel gear or the drive pinion is not
possible.
32-1
115ZV-2 Function & Structure Torque Converter and Transmission Group

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
32-2
Function & Structure Torque Converter and Transmission Group
Torque Converter
Torque Converter
9 1 2 6 7
11
5 10 8 3 4
115V2E32001
1. Pump impeller 7. Ring gear

2. Turbine impeller 8. P.T.O. drive gear
3. Stator 9. P.T.O. driven gear
4. Turbine shaft 10. P.T.O. driven gear
5. Stator shaft (Fixed) 11. Output flange
6. Drive cover
32-3
Torque Converter
Torque converter structure Torque multiplication
Torque ratio (t)

Output Input
2
P T
0.5 1.0
Speed ratio (e)
95ZV32002 115ZV32002
The torque converter is between the engine and trans- If the engine speed/pump impeller speed stays the
mission, and consists of three impellers as shown in the same but the turbine impeller speed is reduced due to
figure. The three impellers are pump (P), turbine (T), the transmission load-output torque is increased. This is
and stator (S) impellers. "torque multiplication". Heat is also generated.
Turbine impeller speed (min 1 ) (rpm)

Speed ratio(e)= ------------------------------------------------------------------------------------------------
-
Pump impeller speed (min 1 ) (rpm)
Power flow path
The pump is connected to the engine flywheel, and
rotates together with the engine.
The turbine is connected to the torque converter output

shaft to transmit the power to the transmission.
The stator is fixed to the torque converter case. The

area of the impellers is filled with oil. When the engine is
started, the pump impeller rotates, therefore the oil will
circulate to rotate the turbine impeller (circulation order:
pumpturbinestatorpump). Oil is redirected by the
fixed stator impeller back to the pump impeller. When
the turbine impeller rotates, the power will be transmit-
ted to the output shaft.
32-4
Torque Converter (Lock-up) (Option)
Oil from Lock-up P T

solenoid valve
S
1
2
3
115V2E32024
1. Lock-up piston
2. Friction plate
3. Steel plate
4. Turbine shaft
5. Drive cover
32-5
Lock-up clutch structure Lock-up clutch function (only for-

ward)
Lock-up clutch
Output
Input
Oil from
Lock-up P T
Solenoid
valve S
S
Lock-up clutch
P T
95V2E32030
5
The torque converter is equipped with the lock-up
device. 4
When the lock-up clutch is engaged, the power from the 1

engine is directly transmitted to the turbine. As a result, 2
3
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
115V2E32028
ground speed can be reached, and less heat is gener-
ated.
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 pro-
vided in the center of turbine shaft (4) and the oil hole
provided in drive cover (5), then presses the lock-up pis-
ton onto the pressure plate.
As a result, drive cover (5) is coupled with turbine shaft

(4) to complete the lock-up status.
32-6
Automatic shift (with lock-up solenoid)
Shift up
Speed Shift down
F4L
F4
F3L
3
12.0 10.0 10.0 11.0 13.5 15.5 20.5 21.5 26.5 28.5
(7.5) (6.3) (6.3) (6.9) (8.4) (9.7) (12.8)(13.4) (16.6) (17.8)
Reverse Speed km/h (mile/h) Forward
Automatic shift map (Normal mode) 115V2U62008
3rd 3rd lock-up 15.5 km/h (9.6 MPH)

Shift Up
4th 4th lock-up 28.5 km/h (17.7 MPH)
4th lock-up 4th 26.5 km/h (16.5 MPH)

Shift Down
3rd lock-up 3rd 13.5 km/h (8.4 MPH)
32-7
Torque Converter Gear Pump
Torque Converter Gear Pump
Torque converter Torque converter

pump
115V2E32002
Gear pump specifications

Theoretical
100.4 cm3/rev (6.13 in3/rev)
discharge
Maximum operation
20.6 MPa (210 kgf/cm2) (2,986 psi)
pressure
Maximum operation
2,500 min-1 (rpm)
speed
Approx. 70 L/min (18.5 gpm)
Conditions:
Pump speed 900 min-1 (rpm)
Oil temp. 80~100C (176~212F)
Actual discharge
Oil viscosity 10CST (SAE10W)
Discharge pressure 3.4 MPa
(35 kgf/cm2)
(498 psi)
32-8
Transmission
Transmission
14 13 12 1
2 3 L R
1
H
3
6
4
2
7
11 10
115V2E32003
8 9
1. Input flange 7. 3rd speed clutch 11. Output flange

2. Low range clutch 8. Output gear (2nd propeller shaft side)
3. High range clutch 9. Output shaft 12. Modulator valve unit
4. Reverse clutch 10. Output flange 13. Clutch solenoid valve assembly
5. 1st speed clutch (3rd propeller shaft side) 14. Clutch valve assembly
6. 2nd speed clutch
32-9
Transmission
Clutch combination Shift lever position

Clutch Position of shift
L H R 1 2 3 Function
Speed range lever
F1 Held in 1st speed range for both forward and
1
reverse.
F2
Held in 2nd speed range for both forward and
F3 2
reverse. Downshift button operation.
F4
(Either 1st or 2nd or Held in 3rd speed range for both forward and
N * * * 3
3rd) reverse.
R1 Automatic speed change according to shift map
R2 (computer) for 2nd through 4th speeds forward
A
and 2nd through 3rd speeds reverse.
R3 Downshift button operation.
The transmission is equipped with six clutches: Automatic or manual speed change is available
depending on the position of the shift lever, as shown in
Forward low range, forward high range, reverse, and the table.
1st, 2nd and 3rd speeds. Combining the clutches as
shown in the table here provides four forward speeds, Automatic speed change refers to one where the best
and three reverse speeds for a total of seven speeds. speed range is determined by a computer according to
Two clutches must be engaged at the same time to the engine speed and the machine speed detected.
move the machine.
Downshift button operation

Planetary gear
This feature permits quick up and down shifting when in
2nd and Automatic.
Ring gear It operates from 2nd to 1st, and 1st to 2nd.
Planetary
gear carrier
Planetary gear Sun gear
95V2E32021
Gear reduction is by the planetary gear method. As

shown, each reduction gear set consists of a sun gear
at the center, three (four) planetary gears located
around it, a ring gear around them, and a carrier (frame)
supporting the planetary gears. The speed is changed
by fixing or releasing the ring gear or the carrier.
32-10
Transmission
Gear train and number of teeth
2 3 L R
94 94
94 94
25 25 26
31
1 44 44 42 32 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 Steel plate

Piston stroke Outer Inner Outer Inner Number of
Name of clutch Number Thickness (mm) Number Thickness (mm) return spring
(mm) diameter diameter diameter diameter
of plate New/Wear limit of plate New/Wear limit
(mm) (mm) (mm) (mm)
Low range clutch 6.00.5 6 40.15 / 3.5 6 9
420 330 482 350 3.20.1 / 3.0
Reverse clutch 7.00.5 7 (Sintered) 7 12
High range clutch 3.00.5 3 40.15 / 3.8 3 12
260 171 276 187 3.20.1 / 3.0
1st speed clutch 5.00.5 7 (Paper) 7 12
2nd speed clutch 3.00.5 4 40.15 / 3.8 4 12
420 330 482 350 3.20.1 / 3.0
3rd speed clutch 4.00.5 4 (Paper) 4 12
32-11
Transmission
Friction plate: mm (in)
For low, reverse clutch
0.6 (0.02)
2 60
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
115V2E32004
1. Plate
2. Facing (paper)
32-12
Transmission
For high, 1st speed clutch
2.0 (0.08)
2
0.2 (0.008) above
115V2E32005
1. Plate
2. Facing (paper)
Steel plate: mm (in)
For low, reverse, 2nd, 3rd speed clutch
115V2E32006
32-13
Transmission
For high, 1st speed clutch
115V2E32007
32-14
Clutch Pack
Clutch Pack
Inlets for 2nd and 3rd Inlets for reverse and

speed clutch oil low range clutch oil
27 13 14 25 21 22 18 17 8 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
1 H 1
34
2 3 L R
4
32 2
30 5
26 29 28 24 23 35 19 20 15 16 12 11 115V2E32009
1. Clutch input shaft 19. Low range ring gear

2. High range clutch drum 20. Low range sun gear
3. High range clutch piston 21. 3rd speed clutch piston
4. High range clutch piston return spring 22. 3rd speed planetary gear
5. Spider 23. 3rd speed ring gear
6. Friction plate 24. 3rd speed sun gear
7. Steel plate 25. 2nd speed clutch piston
8. Reverse clutch piston 26. 2nd speed planetary gear carrier / 1st speed clutch
9. Reverse planetary gear carrier gear
10. Reverse planetary gear 27. 2nd speed planetary gear
11. Reverse ring gear 28. 2nd speed ring gear
12. Reverse sun gear 29. 2nd speed sun gear
13. Friction plate 30. 1st speed clutch drum
14. Steel plate 31. 1st speed clutch piston
15. Anchor pin 32. Drop gear
16. Piston return spring 33. 1st speed clutch piston return spring
17. Low range clutch piston 34. Clutch output shaft
18. Low range planetary gear 35. Low/3rd speed planetary gear carrier
32-15
Power Flow Path in the Transmission

Forward 1st speed power flow path
Low range
clutch
Inlet of low
range clutch oil
22 18
1st speed clutch 17
31
Input power
33
Inlet of 1st speed

clutch oil
1 H 1
34
32 2 3 L R
Output power
26 29 24 23 35 20 15 19 K115V2J32007
When first speed forward is selected by the operator or When the 1st speed clutch is engaged, drop gear (32),
the computer, oil is sent from the modulator valve to the 1st speed clutch gear (26), 3rd speed ring gear (23), 3rd
low range clutch and the 1st speed clutch. When the speed sun gear (24), 2nd speed sun gear (29) and
clutch plates are pressed by low range clutch piston clutch output shaft (34) form one unit.
(17), low range ring gear (19) is locked to the housing
by anchor pins (15). The torque converter rotates low As a result, the rotation of 3rd speed planetary gear (22)
range sun gear (20) via clutch input shaft (1). This around sun gear is output as the rotation of drop gear
causes low range planetary gears (18) to rotate around (32).
sun gear (20) while rotating on their own axis. This
forces the carrier to rotate. Since the low range plane-
tary carrier and 3rd speed planetary carrier (35) are one 3rd speed planetary gear (22)
piece, 3rd speed planetary gears (22) also rotate (does not rotate on its own axis)
around sun gear.
3rd speed ring gear (23) and clutch

Low range ring gear (19) output shaft (34) form one unit
95ZV32007
Sun gear (20)
Low range planetary gear (18) The low range planetary decreases the speed of the
input shaft but increases torque. The first speed clutch
95ZV32006
is used to directly transmit this high torque-low speed to
the output shaft.
32-16
Forward 2nd speed power flow path
2nd speed
clutch oil Low range Low range clutch oil
clutch
2nd speed clutch
Input power
1 H
2 3 L R
Output power
115V2E32011
Forward 3rd speed power flow path
3rd speed
clutch oil Low range Low range clutch oil
3rd speed clutch clutch
Input power
1 H
2 3 L R
Output power
115V2E32012
32-17
Forward 4th speed power flow path
2nd speed clutch oil High range clutch
2nd speed clutch

Input power
High range clutch oil
1 H
2 3 L R
Output power
115V2E32013
Reverse 1st speed power flow path
Reverse clutch oil Reverse clutch
1st speed clutch

Input power
1st speed clutch oil
1 H
2 3 L R
Output power
115V2E32014
32-18
Reverse 2nd speed power flow path
Reverse
2nd speed clutch oil clutch oil Reverse clutch
2nd speed clutch

Input power
1 H
2 3 L R
Output power
115V2E32015
Reverse 3rd speed power flow path
3rd speed Reverse

3rd speed clutch oil clutch clutch oil Reverse clutch
Input power
1 H
2 3 L R
Output power
115V2E32016
32-19
Hydraulic System Diagram
Hydraulic System Diagram

Note
Numbers below correspond to page 32-20. Shift lever
Option 35 MCU
LU
34 32
3
33
36
9 10 5
24 2 14 L 20 R
3 22 H 18 1 16
25 23 15 19 21 17
8 6
11 3 4
30 29
R L 3 2
1
H
13
26
27
28
31 2
1
115V2E32017
32-20
Hydraulic Circuit Diagram

Neutral position (T/M type: PS400D02-S/N 0101~
PS400D03-S/N 0101~)
Limit switch
PMa PMb
Dr (T/M side) T/C

11
P T
32 33 S
44cc 44cc
12
0.1 - 0.58 MPa 0.1 - 0.58 MPa
(1 - 5.9 kgf/cm2) (1 - 5.9 kgf/cm2)
29 P1
20
(14 - 84 psi) (14 - 84 psi)
21
36 Option
1st
175cc 13
35
PR
27 16
17 Dr (T/M side)
R ACC2 ACC1 P3 P2
220cc
PG
9 10
26 PH 6
14
15
0.007 MPa
H (0.07 kgf/cm2)
(0.1 psi)
75cc
5 0.39 ~ 2.65 MPa
(4 ~ 27 kgf/cm2)
28 PF
18 (56.8 ~ 384 psi)
Dr (T/M side)
19
PG P4
L
150cc
30 P2
PG
30L/min
8
22
23 4.0
0.88 MPa P5
2nd 7 (9 kgf/cm2)
(128 psi)
113cc
34
P3
31 24 P1 P
25 PG
Dr (T/M side)
PM PG
Dr (T/M side)
P
3rd
113cc
4
Clutch valve Clutch solenoid Modulator valve unit
assembly valve assembly
3
Modulator valve unit M 100.4
cc/rev
Direct charge Lock-up clutch 2

valve solenoid valve 1
Clutch solenoid
valve assembly
Clutch valve
assembly
K115V2U32002
32-21
1. Transmission oil pan 19. Low range clutch valve

2. Strainer 20. 1st speed clutch solenoid valve
3. Torque converter gear pump 21. 1st speed clutch valve
4. Line filter with bypass valve 22. 2nd speed clutch solenoid valve
5. Clutch pressure regulator valve 23. 2nd speed clutch valve
6. Proportional relief valve 24. 3rd speed clutch solenoid valve
7. Priority valve 25. 3rd speed clutch valve
8. T/C inlet relief valve 26. High range clutch
9. Check valve (1) 27. Reverse clutch
10. Check valve (2) 28. Low range clutch
11. Torque converter 29. 1st speed clutch
12. T/C outlet relief valve 30. 2nd speed clutch
13. Oil cooler 31. 3rd speed clutch
14. High range clutch solenoid valve 32. Accumulator (for Reverse, 1st clutch valve)
15. High range clutch valve 33. Accumulator (for High, Low, 2nd, 3rd clutch valve)
16. Reverse clutch solenoid valve 34. Direct charge valve
17. Reverse clutch valve 35. Lock-up clutch solenoid valve (option)
18. Low range clutch solenoid valve 36. Torque converter (lock-up clutch) (option)
Note
The orifice in the clutch valve 17, 19 and 23 is to reduce
shock at clutch engagement.
32-22
Oil Flow
Oil Flow
Oil flow in the torque converter Oil flow in the transmission line
line
From torque converter gear pump to clutch
From torque converter gear pump to torque solenoid valve assembly
converter
The clutch solenoid valve consists of the solenoid
The oil discharged from torque converter gear pump (3) valves for the forward and backward driving gears and
goes through line filter (4) into priority valve (7). Priority the shift gears. By the specific shift operation, the clutch
valve (7) will transfer the specified amount (30 L/min) of solenoid valve is activated to send the pressure oil to
the oil to the clutch circuit, and the rest amount of the oil the clutch valve as the pilot pressure.
will be supplied to torque converter (11).
When the input pressure at torque converter (11) inlet

exceeds 0.9 MPa (9 kgf/cm2) (128 psi), torque converter From clutch solenoid valve to clutch valve
inlet relief valve (8) automatically opens to release the assembly
excessive pressure to the cooler line.
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
From torque converter to cooling circuit valve (6) will go through the specified clutch valve, and
filled in the clutch piston chamber to complete the clutch
Return oil from the torque converter flows through outlet engagement.
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 lock-
up clutch (option)
From cooler to lubrication circuit The oil sent from torque converter gear pump (3) is
transferred through line filter (4) and priority valve (7) to
Oil cooled in the cooler flows to the lubrication paths in lock-up solenoid valve (35). When the machine speed
the transmission. This lubricates and cools each bear- reaches the preset level, the MCU sends the signal acti-
ing and the clutch plates, and then drops into the oil vating solenoid valve (35) to open the hydraulic line.
pan. 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.
32-23
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
Two accumulators (32)(33) are installed between pro- the selected shift gear, in order to keep the potential
portional relief valve (6) and the clutch valve assembly. time lag at clutch engagement.
One (32) is for the reverse clutch and the 1st speed The hydraulic pressure is supplied from the torque con-
clutch. The other (33) is for the high range clutch, low verter gear pump to direct charge valve (34) through P1
range clutch, 2nd speed clutch and 3rd clutch. port, and then, directly supplied to the clutch valve by
switching the solenoid valve without going through the
- Initial oil charging into clutch piston chamber modulator valve.
In order to make the initial oil charging into the clutch Direct charge valve solenoid valve (34) is closely con-
piston chamber quickly, the accumulated oil (0.58 trolled by the signals from the MCU.
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) con-
tinues to fill the oil into the accumulator and it also
increases the oil pressure in the clutch piston cham-
ber gradually.
Limit switch
The limit switch is built-in the accumulator, and is turned

ON when the accumulator is fully filled up with the pres-
sure oil.
When the limit switch is turned ON, the MCU deter-

mines the pressurization and starts gradually increasing
the pressurizing current to proportional relief valve (6).
32-24
T/C and T/M Oil Circulation
T/C and T/M Oil Circulation
Radiator
Torque converter
oil cooler
Engine
Modulator
valve unit
Torque converter
Transmission
oil filter
Clutch solenoid
valve assembly
Clutch valve
assembly
Transmission
115V2E32019
32-25
Modulator Valve Unit

T/M type:
PS400D01 - S/N 0101~0126
8
5
(P4)
10
(P2)
7
Orifice
9 1.0
9 10
6
(Acc2)
5 Orifice
3.0
(Acc1)
(P3)
(P)
(PM)
7 8
7
(P1)
8
(P5)
115V2E32020
Numbers below also correspond to page 32-20.

1. 6. Proportional relief valve
2. 7. Priority valve
3. 8. T/C inlet relief valve
4. 9. Check valve (1)
5. Clutch pressure regulator valve 10. Check valve (2)
32-26
T/M type:
PS400D01 - S/N 0127~
PS400D02 - S/N 0101~
PS400D03 - S/N 0101~
8
5
(P4)
10
(P2)
7
Orifice
9 1.0
9 10
5 6 (Acc2)
Orifice
(Acc1)
3.0
(P3)
(P)
(PM)
7 8
7
(P1)
8
(P5)
115V2E32035

1. 6. Proportional relief valve
2. 7. Priority valve
3. 8. T/C inlet relief valve
4. 9. Check valve (1)
5. Clutch pressure regulator valve 10. Check valve (2)
32-27
Interior schematic (not exact representation)
From direct To clutch To lock-up clutch Relief

charge valve valve solenoid valve 10 5 valve
(opt)
PG ACC2 ACC1 P3
9
Drain
P1 P P2 P5 P4
To clutch From To Drain To T/M To T/C Drain

solenoid pump T/C lubrication cooling 6
valve line line To T/C
To direct ACC2 ACC1 P3 P2
charge valve 9 10 PG
6
1. 0.007 MPa
(0.07 kgf/cm2)
2. (0.1 psi) 5 Drain
3. 0.39 - 2.65 MPa
(T/M side)
4. (4 - 27 kgf/cm2)
(56.8 - 384 psi)
5. Clutch pressure regulator valve From direct
6. Proportional relief valve charge valve PG To T/C
P4 return line
7. Priority valve
8. T/C inlet relief valve 8
PG
9. Check valve (1) 30L/min
10. Check valve (2) To T/M
lubrication
0.88 MPa P5
7 (9 kgf/cm2) line
(128 psi)
Drain (T/M side) PG PM P1 P PG

Drain (T/M side)
T/M solenoid From T/C
valve gear pump 115V2E32021
32-28
Modulation Mechanism Modulator valve function
From direct To clutch To lock-up clutch Clutch pressure

When changing direction or speed, the modulation charge valve valve solenoid valve regulator valve
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 oper-
ator's comfort.
Drain
The modulation mechanism controls the clutch oil pres-
sure 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

solenoid pump T/C lubrication cooling Proportional
valve line line relief valve
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 mag-
netic 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 con-
verter gear pump to the clutch is also controlled by the
proportional relief valve.
In other words, when the control pressure from the pro-

portional 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.
32-29
Modulator valve operation Initial oil charging (t1) into the clutch piston
chamber
When the shift lever is shifted from the neutral to the 1st
Modulation chart (Neutral1st forward) speed forward, the low range clutch solenoid valve is
energized and oil in the accumulator flows into the
empty clutch piston chamber first.
ON
Low range clutch OFF Then oil under pressure flows into the clutch piston
solenoid valve chamber. After a given time, the control current to the
1st speed clutch ON modulator valve is reduced. Accordingly the main clutch
solenoid valve oil pressure is reduced, concluding the initial oil charg-
Oil filling completed Engagement
(clutch) (Acc.) completed ing into the clutch chamber.
Modulator The time taken for this initial charging, which depends
valve Current on the capacity of the clutch piston chamber, is con-
(mA)
trolled by a MCU.
0
Clutch piston chamber filling (t2)
To reduce clutch engagement shock, it is necessary to

engage the clutch while allowing some slippage of it. To
Main do this, the current to the modulator valve is held low for
pressure Pressure P1
P2
a given time. The torque converter gear pump fills the
MPa
(kgf/cm2) oil both into the accumulator and into the clutch piston
(psi) chamber. During this time, the clutch piston moves
0
while compressing the piston return spring.
Low range
clutch The holding pressure in this time depends on the speed
Pressure
pressure MPa of the engine: lower pressure with lower engine speed,
(kgf/cm2) higher pressure with higher engine speed.
(psi)
0
t2 This time is also controlled by the MCU.
t4
t1 t3
Accumulator filling (t3)

When shifted Shift completed
The pump continues to fill the oil into the accumulator.

At the same time the clutch oil pressure is raised slowly.
115V2E32023
This prevents the clutch engagement shock caused by

t1 Initial charging Changes with combination of
0~0.12 sec
a rapid pressure rise.
time clutches
Low pressure Less than
t2 holding time
Changes with engine speed
0.5 sec
Pressure rise Changes with combination of
t3 time clutches
0.3~0.7 sec
Changes with combination of

t4 Restoration time
clutches
0.5~1.3 sec
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

32-30
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 sig-
nal, and gradually increases the driving current to the
modulator valve.
Then the hydraulic pressure for the clutch will conse-

quently increases to complete the clutch engagement.
32-31
Control Valve Assembly

T/M type:
PS400D01 - S/N 0101~
Valve location
4 3 5
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)
32-32
T/M type:
PS400D02 - S/N 0101~
PS400D03 - S/N 0101~
Valve location
4 3 5
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)
32-33
Clutch solenoid valve assembly

T/M type:
PS400D01 - S/N 0101~
PS400D02 - S/N 0101~
5 2 A 3
P3 P2 PH PL P1 PR
2nd R P3~PR
L
T
3rd H 1st
6 1 4 A A-A
P
P3
3rd
P2
2nd
PH
H
PL
L
P1
1st
PR
R
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
32-34
T/M type:
PS400D03 - S/N 0101~
5 2 A 3
P3 P2 PH PL P1 PR
2nd P3~PR
L R
T
3rd
1st P
H
P
6 1 4 A A-A
P
P3
3rd
P2
2nd
PH
H
PL
L
P1
1st
PR
R
Hydraulic Diagram
K115V2U32001
1. High range clutch solenoid valve

2. Low range clutch solenoid valve
3. Reverse clutch solenoid valve
4. 1st speed clutch solenoid valve
5. 2nd speed clutch solenoid valve
6. 3rd speed clutch solenoid valve
32-35
For high, low, reverse and speed clutches

After power-off (clutch disengaged status)
5 4
Modulator
1
valve 2
6
Transmission
oil pan C
Clutch valve
3
80ZVE32026
1. Coil 4. Spring Under such a condition, pressing manual control push

2. Plunger 5. Spool button (6) (for emergency) opens the line between port
3. Push rod 6. Manual control push button A and B, and engages the clutch.
Releasing the manual control push button returns spool
When the power of the coil is turned off, spool (5), push (5) fully to the right, and disengages the clutch.
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 dis-
engaged.
After power-on (Clutch engaged status)
Modulator
valve 2
Transmission
oil pan C
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.
32-36
Clutch valve assembly

From clutch From clutch
solenoid valve solenoid valve
A B A B A B (P3, PH, P1) (P2, PL, PR)
P3 P2 PH PL P1 PR
Orifice
PM PM PM PM PM PM
PM PM
PC PC PC PC PC PC
PC PC
T T1 T T1
T T T T T T P
A B A B A B A-A B-B
6 5 1 2 4 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
PC
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
32-37
Accumulator assembly
1st, reverse clutch, ACC1
High, low, 2nd,

3rd clutch
From ACC2
9
Drain
115V2E32029
Accumulator structure
3 8 6 7 2 5 1 4
PC
D4
5
60.5
45.5
Stroke
28.3
115V2E32030
1. Tube Operating pressure 0.1~0.58 MPa (1~5.9 kgf/cm2) (14~84 psi)

2. Piston
3. Rod cover
4. Spring
5. U-packing
6. O-ring
7. Wear ring
8. Socket bolt
9. Limit switch
32-38
Direct charge valve
To clutch valve
4.0 mm
2
PA
From torque PA
converter gear
pump Hydraulic Diagram
PA PA
From T/C
gear pump
P P
To clutch valve
Solenoid power OFF Solenoid power ON
115V2E32031
1. Direct charge solenoid valve

2. Plug (Orifice: 4.0 mm)
32-39
Lock-up clutch solenoid valve
Lock-up solenoid valve
From modulator valve
To lock-up clutch
P
P T
T Drain (T/M side)
Hydraulic Diagram
Lock-up clutch Lock-up clutch

A A
Transmission Transmission
T T
oil pan oil pan
P P
Modulator Modulator
valve unit valve unit
Solenoid power OFF Solenoid power ON
115V2E32032
32-40
MEMO
33-1
115ZV-2 Check & Adjustment Torque Converter and Transmission Group
Check & Adjustment

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

33-2
Check & Adjustment Torque Converter and Transmission Group
Clutch Oil Pressure and Time Lag
Measuring clutch oil pressure Gauge port
1. Location:
WARNING
T/M type: PS400D01 - S/N 0101~
Unexpected movement of the machine may cause an
Main clutch
Therefore, to provide repair service with the engine
moving.
- Prohibit any person from walking into dangerous 1 H 3
areas. R L 2
Reverse clutch
- Near articulation areas of the machine 1st clutch
Low range clutch
- Under the machine High range clutch
- Around the engine Transmission 2nd clutch
- In front of or behind the machine Torque converter 3rd clutch
Lock-up clutch
- Pressure gauge
- Tachometer (MODM)
- Stop watch
Transmission oil pressure test port location 115V2E33001

33-3
115ZV-2 Check & Adjustment Torque Converter and Transmission Group
T/M type: PS400D02 - S/N 0101~ Clutch oil pressure measurement proce-
PS400D03 - S/N 0101~ dure
Main clutch
2.60.2 MPa
Idling (LI)
Main pressure (272 kgf/cm2) (38428 psi)
(engine speed) 2.60.2 MPa
Maximum (HI)
(272 kgf/cm2) (38428 psi)
2.50.2 MPa
Idling (LI)
Clutch pressure (262 kgf/cm2) (37028 psi)
1 H 3
R L 2 (engine speed) 2.50.2 MPa
Reverse clutch Maximum (HI)
(262 kgf/cm2) (37028 psi)
1st clutch
Low range clutch
High range clutch
Transmission 2nd clutch
3rd clutch 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.
5. Attach the pressure gauge to the pressure mea-

surement port. Place the gauge inside the opera-
Transmission oil pressure test port location K115V2E33001
tor's area, and start the engine.
2. Measuring port: PF 1/4 6. As the clutch oil pressure rises just after the engine
is started, keep the engine at low-idling before the
3. Oil pressure gauge: 5 MPa (50 kgf/cm2) (1,000 psi) pressure measurement.
with 2~3 m (6~10 ft.) hose
7. Measure and record the pressure in each speed
Note range.
Warm-up the engine before measuring the clutch oil
pressure and time lag 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.
33-4
Check & Adjustment Torque Converter and Transmission Group
10. Measure and record the pressure in each speed Time lag measurement procedure
range.
Note WARNING
Change the transmission speed range while keeping Unexpected movement of the machine may cause an
the shift lever at the neutral position. Check that the accident resulting in injury or death.
pressure instantaneously lowers just after speed To crawl under the machine, be sure to stop the
change, and then rises to the original pressure again. 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 Solution Standard measurement value

Inspection &
Malfunctioning modulator valve operation Neutral1st forward speed
repair
Clutch time lag (sec) (engine speed: 1,500 min-1 0.30.1
Defective MCU Replacement (rpm))
Disassembly &
Oil leakage from clutch
repair
1. Press the brake pedal, and set and confirm the


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
Inspection &
Malfunctioning modulator valve operation
repair
Defective MCU Replacement
Disassembly &
Defective clutch
repair
42-1
115ZV-2 Function & Structure Hydraulic Group

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 ....................................................... 42-15
Hydraulic Cylinder ................................................... 42-19
Loading System ...................................................... 42-22
Reducing Valve (for Pilot Pressure) ........................ 42-23
Pilot Valve................................................................ 42-24
Multiple Control Valve (KML35A/2T103) ................. 42-29
Adapter (Orifice) ...................................................... 42-40
Ride Control (OPT).................................................. 42-41
Steering System ...................................................... 42-51
Orbitrol ................................................................... 42-52
Steering Valve (KVS32-A4.0/21) ............................. 42-59
Stop Valve ............................................................... 42-71
Reducing Valve (for Orbitrol) ................................. 42-73
Steering Line Filter .................................................. 42-74
Efficient Loading System......................................... 42-75
Fan Motor System ................................................... 42-79
Fan Motor Line ........................................................ 42-80
Reversing Fan Motor Line (OPT) ............................ 42-91
Secondary Steering ................................................. 42-96
42-2
Function & Structure Hydraulic Group
Flushing Hydraulic Circuit
Flushing Hydraulic Circuit
Purpose of flushing
Debris
To tank
95ZV42001
If the inside of a cylinder, pump, or a valve of the

hydraulic system is broken, the debris will be sent into
the hydraulic line together with the oil. Most of the
debris will flow into the return filter or hydraulic tank.
However, there are some debris that will remain in the

valves, cylinders, or pipes. Therefore, even if the dam-
aged cylinder or valve is replaced, the debris sticking in
other valves, cylinders, or pipes will break loose and
then is fed into the cylinders, where the debris may
damage the inside of the cylinders, or stick into the
valve spools, reducing valves, or relief valves, and
cause another malfunction. To prevent such problems,
be sure to remove all the debris from the system.
42-3
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 replace-
ment.
After replacing oil or a part, be sure to observe the fol-

lowing 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 min-

utes or more. Do not operate any hydraulic func-
tions during this period.
(c) While keeping the engine at low-idling speed, move

each cylinder 5 times or more respectively.
At this time,
- Move each cylinder to a place near the
stroke end so that hydraulic pressure does
not go over relief.
- Lower the boom slowly. Dump the bucket
slowly. Do not activate the make up valves
from rapid activation of circuits.
(d) Perform general operations, and confirm that

abnormal sound, heat generation and any other
abnormality is not detected.
(e) Observe the hydraulic oil level sight gauge and

confirm that there are no bubbles in the hydraulic
oil.
42-4
Hydraulic Circuit Symbols
Hydraulic lines Pumps & motors
(1)
Working hydraulic
line Fixed
displacement,
Hydraulic pump
(1) Unidirectional (2)
Pilot line
(2) Bidirectional
Drain line
(1)
Lines joining Variable
displacement,
Non-compensating
hydraulic pump (2)
(1) Unidirectional
Flexible line
(2) Bidirectional
(1)
Lines passing Fixed
displacement,
Rotary hydraulic
motor (2)
Line to tank (1) Unidirectional
(Above fluid level) (2) Bidirectional
(1)
Line to tank Variable
(Below fluid level) displacement,
Rotary hydraulic
motor (2)
Hydraulic tank (1) Unidirectional
(Pressurized type) (2) Bidirectional
Fixed restriction
Cylinders
(1)
Rotary joint (1) (2)
(1) one line Single acting
(Unidirectional) cylinder
(2) three line (2) (without spring)
(Bidirectional)
(1) (2)
Single acting
cylinder
(with spring)
(1) (2)
Double acting
cylinder
(single rod)
(1) (2)
Double acting
cylinder
(double rod)
(1) detail symbol

(2) mnemonic symbol
42-5
Operation methods Pressure control valve
Single flow path

Spring valve,
Normally closed
Single flow path

Adjustable spring valve,
Normally open
Control methods
Pressure relief
Lever
valve
Push button
Unloading valve
Pedal or treadle
Mechanical control
Sequence valve
Plunger
Pressure reducing
Spring
valve
Solenoid control
Single acting
solenoid Flow control valve
Double acting
solenoid Flow control valve,
Adjustable non-
compensated
Electric motor
control Pressure
compensated flow
control valve
Unidirectional M
fixed
Bidirectional M
variable
Detent
Flow dividing valve

42-6
Directional control valve Check valve
Two position
Check valve
Two ports
Three position Check valve

Four ports Pilot operated
Four ports with

Shuttle valve
restrictor
Two position
Two ports
Mechanical
control
Spring offset
Pressure
control
Two position
Three ports
Pressure control
Spring offset
Solenoid
control
Restrictor
Two ports
Three ports
Four ports
Servo valve
42-7
Miscellaneous hydraulic symbols
(1)
Hydraulic tank
(1) Vented
(2) Pressurized (2)
Manual shut off

valve
Pressure switch
Accumulator
Electric motor M
Internal
combustion M
Power source
Filter or strainer
Heater
Cooler
Pressure gauge
Temperature
gauge
Flow meter
42-8
Hydraulic System Operation
Hydraulic system operation out- Return oil from the cylinders flows through the valve to
the oil cooler, return filter (12) and into the hydraulic
line tank.
The hydraulic system consists of the following systems:
Even if no hydraulic pump supplies oil to the loading
- Loading system and pilot control circuits due to trouble, or if the engine
is shut off, the boom can be lowered to the ground by
- Steering system 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 compo-
nents.
Loading system - Hydraulic pump (1)

- Steering valve (4)
The loading system consists of the following compo- - Line filter (81)
nents. All numbers base on page 92-4. - Reducing valve (18)
- Orbitrol (14)
- Hydraulic pump (2) - Stop valve (15)
- Unloader valve (22) - Steering cylinder (8)
- Line filter (81)
- Check valve (32) Oil from pump (1) flows to Orbitrol (14) through steer-
- Reducing valve (38) ing valve (4), line filter (81) and reducing valve (18). Oil
- Pilot valve (16) to Orbitrol (14) is reduced to 3.5 MPa (36 kgf/cm2) (512
- Multiple control valve (3) psi) by reducing valve (18).
- Boom cylinders (5)
- Bucket cylinders (6) A small amount of pilot oil supplied from Orbitrol (14)
controls steering valve (4) to realize steering operations.
Oil from pump (2) flows to pilot valve (16) through
unloader valve (22), line filter (81), check valve (32) and When the steering wheel is turned, oil at a flow rate pro-
reducing valve (38). Oil to pilot valve (16) is reduced to portional to the turning speed is sent from Orbitrol (14)
3.5 MPa (36 kgf/cm2) (512 psi) by reducing valve (38). and supplied to the oil pack of steering valve (4).
When the pilot control lever is operated, the pilot valve At this time, the pilot pressure is generated. The pilot
line is opened, and the oil pressure is generated pressure strokes the spool of steering valve (4), and
depending on the position of the pilot control lever. supplies hydraulic oil at large flow rate proportional to
the flow rate of the supplied pilot oil to the cylinder line.
The pilot pressure entering the oil pack to multiple con-
trol valve (3) moves the spool against its return spring. The excessive pilot oil flows through steering valve (4)
to the other side of the pilot port.
The spool press-in distance (displacement) depends on
the pilot valve pressure. Stop valves (15) are used in the circuit to stop the flow
of oil from Orbitrol (14) to steering valve (4) when the
Oil from the loader pump is then directed through multi- machine reaches full turn.
ple control valve (3) to boom cylinders (5) and bucket
cylinders (6).
42-9
When the steering wheel is not turned, the flow control Fan motor system
spool built in steering valve (4) supplies almost all
amount of the hydraulic oil fed from steering pump (1) to The fan motor system consists of the following compo-
the loading circuit. nents.
Oil returns from steering cylinders (8) flows through - Hydraulic pump (2)
steering valve (4) and oil cooler or cooler bypass valve - Unloader valve (22)
(11). - Fan motor (71)
- Proportional relief valve (72)
Finally it returns to the tank through return filter (12).
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).
Efficient loading system
Three kinds of signals sent from the engine water tem-
The efficient loading system consists of the following perature sensor (S/N 9001~9050), ECM (S/N 9051~),
components. torque converter oil temperature sensor, and hydraulic
oil temperature sensor, are input into the machine con-
- Hydraulic pump (2) trol unit (MCU) as information to regulate the maximum
- Pressure sensor (49) fan revolution.
- Relief valve (62)
- Check valve (63) The fan revolution is regulated by proportional relief
- Solenoid valve (64) valve (72). The setting pressure of the proportional relief
valve is changed in proportion as the engine revolution
When the ELS switch is turned off, the oil discharged and electric current value from MCU.
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. Ride control system (OPT)
On the other hand, the oil discharged from the main Refer to "Ride Control (OPT)" page 42-41 for the infor-
pump (front pump of (2)) opens the check valve, mation.
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 opera-

tion 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.
42-10
Layout of Hydraulic Units
Layout of Hydraulic Units
1 15 16 11 18 8
9 17 12 3 16 4 2 5 13 7
10 14 6
115V2E42001
1. Multiple control valve 10. Boom cylinder

2. Pilot valve 11. Steering cylinder
3. Pilot valve (for stick steering) 12. Reducing valve (steering pilot)
4. Steering valve 13. Reducing valve (loading pilot)
5. Hydraulic pump (for steering) 14. T/C line filter
6. Hydraulic pump (for loading, for pilot and brake) 15. ELS valve
7. Fan motor 16. Secondary steering pump
8. Proportional relief valve (for fan) 17. Stop valve
9. Bucket cylinder 18. Torque converter pump
42-11
Hydraulic Tank
Hydraulic Tank
Viewed from top
13
A A 10
13 A-A
3
A A
Outside of As seen from
machine chassis out
To chassis
1 4
15,16
14 6
12
5
11 115V2E42002
1. Hydraulic tank 9. Spring

2. Oil level gauge 10. Cover
3. Breather valve (tank cap) 11. Drain plug
4. Filter 12. Inspection port
5. Suction strainer (loading, pilot & brake) 13. Vent pipe (to axle housing)
6. Suction strainer (steering) 14. Temperature sensor
7. Return filter element 15. Oil level sensor
8. Filter bypass valve 16. Flange bolt
: #16: 11.8 N-m (1.2 kgf-m) (8.7 lb-ft)

Dont use the air tool when fasten #16.
42-12
Hydraulic Tank
Hydraulic tank breather valve

(tank cap)
1 2 3 4 5 6
7 7
a
b
c
Viewed from section A
70ZV42005
1. Cover When the pressure inside the hydraulic tank drops

2. Filter element below the outside air pressure, the outside air flows
3. Spring (for exhaust valve) through filter element (2) and to valve assembly (4).
4. Valve assembly Suction valve (b) is then opened to let the air flow into
(a) Exhaust valve the tank.
(b) Suction valve
(c) Air bleeder valve When the air pressure inside the hydraulic tank rises to
5. Spring (for suction valve) a certain point 29 kPa (0.3 kgf/cm2) (4.3 psi), Exhaust
6. Key (same as starter key) valve (a) is lifted (opened) so that the air can flow out of
7. Attaching bolts (3 pcs) socket head 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 reduc-

ing 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.

42-13
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
Return filter Filtration particle size (m) 28
2
Relief valve opening pressure (filter bypass) (MPa) (kgf/cm ) (psi) 0.10.02 (1.00.2) (142.8)
2
Loading Filtration area (cm ) 2,550
Pilot & brake Filtration particle size (m) 105
Suction strainer
2
Filtration area (cm ) 2,550
Steering
Filtration particle size (m) 105
2
Suction valve setting pressure (kPa) (kgf/cm ) (psi) 1 (0.01) (0.14)
2
Discharge valve setting pressure (kPa) (kgf/cm ) (psi) 29 (0.3) (4.3)
Breather valve (oil filling port) Filtration area (cm2) 235

Filtration particle size (m) 10
Pushing load before turning cap required for venting pressure,
186.2~215.6 (19~22) (42~48)
removing or installing cap N (kgf) (lb)
42-14
Hydraulic Tank
Hydraulic oil level check
Bucket on ground
Hydraulic tank
Oil level sight gauge

(59 US gal)
225 L
115ZV42005
Before checking the hydraulic oil level, observe the fol-

lowing 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 60C ~ 90C (140F
~ 200F) the oil level may be at or near the top of the oil
level sight gauge.
42-15
Hydraulic Pump
Hydraulic Pump
Loading and pilot and brake pump
5 6 6 2
4 7
115V2E42003
1. Drive gear (front) 5. Oil seal

2. Drive gear (rear) 6. Bushing
3. Driven gear (front) 7. Wear plate (floating type)
4. Driven gear (rear)
Pump specifications
Front Rear
Applicable circuit Loading circuit Pilot & Brake circuit
Theoretical discharge cm3/rev 100.4 71.3
Maximum operation pressure MPa (kgf/cm2) (psi) 20.60.5 (2105) (2,98671) 11.8 (120) (1,711)
Maximum speed min-1 2,500
Measurement conditions:
Oil temperature 50~80C (120~180F)
Hydraulic oil ISO VG46
42-16
Hydraulic Pump
Steering pump
5 6 6 2
4 7
115V2E42004
1. Drive gear (front) 5. Oil seal

2. Drive gear (rear) 6. Bushing
3. Driven gear (front) 7. Wear plate (floating type)
4. Driven gear (rear)
Steering pump specifications
Front Rear
Applicable circuit Steering circuit
Theoretical discharge cm3/rev 90.7
Maximum operation pressure MPa (kgf/cm2) (psi) 20.60.5 (2105) (2,98671)
Maximum speed min-1 2,500
Measurement conditions:
Oil temperature 50~80C (120~180F)
Hydraulic oil ISO VG46
42-17
Hydraulic Pump
Hydraulic pump principle
Inlet Outlet
Inlet Outlet
Inlet Outlet
95ZV42040
The oil at the inlet area is taken in the cavities between

the gear teeth right after disengagement and transferred
towards the outlet area enclosed in between the teeth
and the gear casing.
When the gear teeth mesh again, the oil is extruded out
of the tooth cavities and forwarded to the outlet.
42-18
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 volu-
metric efficiency is ensured.
General structure of pressure plate
Rotating gears feed the pressurized oil along the cir-

Suction cumference of the case to the outlet port. The pressur-
ized 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 pres-
sure 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.
Discharge
The high-pressure area in the rear of the pressure plate

is enclosed by the plate seal, backup seal, and isolation
plate.
Discharge
To prevent the gear-sealing area from extremely high
High pressure area pressure due to confined oil, there is a confined oil
bypass groove at the gear-sealing area of the pressure
Backup ring plate.
Hydraulic pump bushing lubrica-

O-ring
tion
The lubrication system uses the oil fed from the pressur-
Suction ized tank.
Part of the oil fed from the inlet port is sent to the bush-
ings to lubricate them. After that, the oil is returned to
Oil groove for
lubricating bearing 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
Suction
oil by:
Starting up a new pump with oil supplied to it.
- Allow new pump to idle (low rpm/no load) for 5 min-

utes.
Confinement
prevention groove - Use the proper viscosity for the coldest possible start
up temperature. Change viscosity if seasonal tem-
perature changes are great (always more than 20C
Discharge (68F)).
115ZV42006
42-19
Hydraulic Cylinder
Hydraulic Cylinder
1. Piston 11. O-ring 21. Wear ring

2. Piston rod 12. Slipper ring 22. Stop ring
3. Cylinder tube 13. Back ring 23. Bushing
4. Rod cover 14. O-ring 24.
5. Dust seal 15. Wear ring 25. Bolt
6. Backup ring 16. Piston nut 26. Washer
7. U-packing 17. Stop ring 27. Plug
8. Buffer ring 18. Flange bolt 28. O-ring
9. Bushing 19.
10. Backup ring 20. Dust seal
Boom cylinder
20,23 16 21 14 12,13 15 1 2 9 10,11 8 6,7 5,17
22 3 4 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 2 8 7 6 11 9 17 5 20,23 (Gauge port PF1/4)

27,28
25,26
A
27,28 (Gauge port PF1/4) 3 4
115V2E42012
: 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)
42-20
Hydraulic Cylinder
Steering cylinder
20,23 16,22 21 14 13 12 1 2 8 6,7 10,11 9 11 17 5 20,23
3 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)
42-21
Hydraulic Cylinder
Hydraulic cylinder specifications

mm (in)
225 x 120 x 1,132
Inner diameter x rod diameter x stroke
(8.85 x 4.72 x 44.56)
120 x 272
Boom cylinder Piston rod
Pin hole (4.72 x 10.70)
(inner diameter x width) 120 x 208.5
Cylinder
(4.72 x 8.21)
190 x 100 x 767
(7.48 x 3.93 x 30.19)
100 x 120
Bucket cylinder Piston rod
Pin hole (3.93 x 4.72)
(inner diameter x width) 100 x 120
Cylinder
(3.93 x 4.72)
110 x 60 x 720
(4.33 x 2.36 x 28.34)
70 x 80
Steering cylinder Piston rod
Pin hole (2.75 x 3.14)
(inner diameter x width) 70 x 80
Cylinder
(2.75 x 3.14)
42-22
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 Even if no hydraulic pump supplies oil to the loading
lock) and pilot control circuits due to trouble, or if the engine
is shut off, the boom can be lowered to the ground by
Reducing Multiple
valve control
the pressure in the accumulator in the brake circuit in
Oil packs Oil packs
valve case of an emergency.
From
From brake steering
line valve Cooler
P
Return filter
85V2E42004
42-23
Reducing Valve (for Pilot Pressure)
Reducing Valve (for Pilot Pressure)

Pressure
adjustment stud
Locknut
PPDB-LAN
CXCD-XAN CXCD-XAN
Ball
Passage Y
(P) (T)
(TA)
(PARKING)
(ACCR) (ACCF)
(PA)
(Z1) (Z2)
(Z) (PPI)
T Tank
Valve assembly
Note: Valve is shown rotated 180 from normal.

Orifice 2 C
From front brake A

accumulator circuit
A B
Orifice 1
Passage Z
B Plunger T
Hydraulic circuit diagram
Pilot oil circuit 85V2E42005
This valve provides pilot oil pressure to operate the park When the oil pressure on the pilot oil circuit side
brake and loader pilot valve functions. becomes less than the set pressure, the ball moves
down and the pressure at chamber C becomes equiva-
The oil fed from the brake accumulator circuit flows into lent to the pressure on the pilot oil circuit side (B). As a
the pilot oil circuit by way of passage Z. The oil pressure result, the plunger moves down by a spring, opens the
in the pilot oil circuit is applied also on chamber C by passage Z, then introduces the accumulator pressure to
way of orifice 1. the pilot oil circuit side so that the pressure is main-
tained at the specified value.
When the oil pressure in the pilot oil circuit is at or
above the set pressure, the oil in chamber C unseats This pressurized oil is supplied to the multiple control
the ball by way of orifice 2, and escapes to the tank by valve oil pack through the pilot valve and moves the
way of passage Y. As a result, the pressure in chamber multiple control valve spool.
C decreases, then the plunger moves up and closes
passage Z so that the pressure on the pilot oil circuit Set pressure
side does not exceed the set pressure. 3.5 MPa (36 kgf/cm2) (512 psi)
42-24
Pilot Valve
Pilot Valve
Float/Down
Raise (Detent)
White (Female)
(for port 4 solenoid)
Roll back (Detent)
White (Male)
Dump
18.20 16.20
Blue (Female) A B
For For
bucket control boom control
A B
(Port 1, 2) (Port 3, 4)
1 2
3 4
K115V2U42003
42-25
Pilot Valve
Roll back Raise

Dump Float
(Detent) (Detent)
(Detent) Down
21 21
20 20
19 19
18 18
2 2
3 4
5
7 9 6
Identifying
Identifying mark
8 mark 8
10 9
10 10 10
11
25 12
13 13 23
22 23 22
To tank port
14
15 16 15 16
14
24 From pump
port
17
Port1 Port2 Port3 Port4

To/from MCV oil packs To/from MCV oil packs
For bucket control For boom control
(Section A-A) (Section B-B) 115V2U42021
1. Lever 14. Spring

2. Push rod 15. Spring
3. Push rod 16. Spring
4. Push rod 17. Spool
5. Detent solenoid coil (boom down / float) 18. Detent bushing
6. Detent solenoid coil (boom raise) 19. Spring
7. Detent solenoid coil (bucket level) 20. Detent ring
8. Fixing disc 21. Steel ball (4 pieces per spool)
9. Fixing disc (identifying mark) 22. Spring seat
10. Push rod 23. Spring seat
11. Spring 24. Casing
12. Plug 25. Spring
13. Spring seat
42-26
Pilot Valve
Pilot valve function

1
The pilot valve applies oil pressure in proportion to the
operating angle of the lever, there-by carrying out 21
19
remote control of the spool in the multiple control valve. 20
Pilot valve operation

(modulated position)
3
Predetent section
10
10
12 12
22 23
14 14
15 16
24
17
Lever is in the neutral position
85V2E42009
T The pilot valve has holes of lengthwise direction in

which the reducing valve is built. The reducing valve
section consists of spool (17), spring for secondary
P
pressure (15)(16), return spring (14) and spring seat
(22)(23). Being inserted in plug (12), push rod (10) can
Reducing
valve
be moved smoothly to change the bending quantity of
secondary pressure spring (15)(16).
Multiple
control valve From front brake Return spring (14) contacts casing (24) and spring seat
accumulator
(22)(23). This spring works on returning push rod (10) to
Oil pack 85V2E42008
its original position without relation to secondary pres-
sure, 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) closes 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 center-
ing springs. There is no oil flow to the cylinder.
42-27
Pilot Valve
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
21
1 19 tank port. The pump port is opened. It raises the oil
20 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
18
3 maintains a constant pressure to the multiple control
valve.
Predetent section
The oil pressure to the multiple control valve is propor-
10 10 tional 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 load-
25
ing pump to the cylinder is also proportional. Cylinder
13 speed is easily controlled.
22 23
16
When lever (1) is moved fully forward or back the multi-
15
ple control valve spool should also be moved full stroke.
17 17 This allows maximum oil flow to the cylinders for the

fastest cylinder movement.
Lever is shifted from the neutral
In addition, spring seat (13) and spring (25) are installed
85V2E42010 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
When lever (1) is shifted from the neutral, push rod (10)
push rod (10) inside diameter. The inclination of second
and spring seat (23) are pushed down at the same time,
pressure changed by this spring force. Then, to be sure
the value of secondary pressure spring is changed.
the multiple control valve spool is fully stroked, spring
Spool (17) is forced down by secondary pressure spring
(25) and spring seat (13) are used. This allows spool
(16), and then, the tank port is closed and the pump port
(17) to be fully stroked and full pilot pressure will be
is opened.
directed into the oil pack, thus fully stroking the multiple
control valve spool.
As a result, the pressurized oil from the pump flows into
the multiple control valve oil pack. The spool of the mul-
tiple 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 feel-
ing of modulation.
- Spool diameter at tank side is greater than spool

diameter at pump side.
42-28
Pilot Valve
Pre-detent and detent magnet

solenoid 1
21
19 20
21 3
19
20 2
18 3
7
The figure that fixing
8
disc (8) is absorbed
18 by the detent
3 9
solenoid coil (7).
10
Actuation of electromagnetic detent

P
85V2E42012
Actuation of pre-detent In addition, the detent magnet works to hold the lever at
its position, when the lever is shifted to "Bucket Roll
85V2E42011
Back" or "Boom Raise" or "Boom Float" position.
The pre-detent function is installed in the "Bucket Roll Detent magnet section consists of detent solenoid coil
Back" or "Boom Float" position that extends the change (7), fixing disc (8)(9) and push rod (2)(3).
of feeling to operator just before electromagnetic detent.
When the circuit for the bucket leveler or the boom kick-
The pre-detent section consists of detent bushing (18), out (option) is turned on, detent solenoid coil (7) is ener-
spring (19), detent ring (20) and steel ball (21). gized and magnetized so that fixing disc (8) of forced up
side (opposite side) is held by magnetic force of detent
Push rod (3) installed in the "Bucket Roll Back" or solenoid coil (7).
"Boom Float" position has the notch that steel ball is fit-
ted in. For this reason, lever (1) is held at that position if you
keep the hand away from lever (1).
When push rod (3) is shifted and steel ball run upon the
step, operation load increases by reactive force of Therefore displacement of push rod (10) is maintained,
spring, because the spring is shortened. and it is the structure that continues generating the sec-
ond pressure constantly.
This extends the change of feeling to operator just
before electromagnetic detent. When the circuit is turned off, detent solenoid coil (7) is
de-energized and de-magnetized and lever (1) is
returned to the neutral position.
In addition, the detent magnet can be cancelled if the

lever is operated toward the neutral direction with
enough force to overcome the power of detents.
42-29
Multiple Control Valve (KML35A/2T103)
3 8
B2 A2
b2
C C
B1 A1
b1
B B
P T
2
P T
A A
1
10 9 A-A
Bucket Spool Boom Spool

6 6
B1 A1 B2 A2
4 4 5
a1 a2
B-B C-C
95ZV42074
1. Main relief valve

2. Spool (Bucket)
3. Spool (Boom)
4. Overload relief valve (Bucket circuit)
(with make-up valve)
5. Make-up valve (Boom circuit)
6. Load check valve
7. Casing
8. Spring cover
9. Cover
10. Gauge port
42-30
Boom Bucket Multiple control valve specifica-

B2 A2 a2 B1 A1 a1 T tions
Model KML35A/2T103
20.6 MPa
Main relief valve setting pressure (210 kgf/cm2)
(2,986 psi)
P1
23.5 MPa
Overload relief valve setting pressure (240 kgf/cm2)
(3,413 psi)
Rod side Installed
b2 b1 P Overload Bucket
relief valve Bottom side Installed
Hydraulic line diagram 95ZV42023
installation Rod side Non-installed
point Boom
Bottom side Non-installed
The bucket priority line is used for the multiple control Rod side Installed
valve, and consists of the following units: Make-up Bucket
valve Bottom side Installed
installation Rod side Installed
1. Main relief valve point Boom
Bottom side Non-installed
Relieves the pressure when the working pressure

Note
exceeds the relief setting pressure.
A third spool for an auxiliary function (Log clamps, Side
dump bucket, etc.) is available. If required, the inlet
2. Bucket spool
cover is removed and the third spool is installed. The
inlet cover is reinstalled.
Used for bucket operation, such as roll back, hold-
Priority oil then goes to the third spool function.
ing a tilt angle, and dumping.
3. Boom spool
Used for the boom operation, such as raising, hold-

ing 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".
42-31
Multiple control valve main relief Main relief valve operation

valve
Relief poppet Plunger Orifice 1
Passage B
The main relief valve is installed between the pump and
the control spool. When the cylinder comes to the stroke Tank
end, or if the pressure is above the set pressure, the oil port
fed from the pump will be discharged into the tank
through this valve (main relief valve) to prevent pump
Pump
and pipe damage. A port
Spring
Body
Spring seat
Seat Filter Passage A
95V2E42005
Passage C Passage D
Adjusting screw Tank

port
Pump
A 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 pres-
surized oil in the pump port escapes to the tank port.
42-32
Note Adjusting set pressure

Clogging of the orifice in plunger will cause low pres-
sure. Remove the cap nut. Loosen the lock nut and adjust the
Another possible cause of low pressure is contamina- pressure by the adjusting screw. Turn clockwise the
tion in, or damage to, the seat of relief poppet or adjusting screw to raise the set pressure, or turn coun-
plunger. terclockwise the adjusting screw to lower the set pres-
sure.
After adjustment, be sure to tighten the lock nut.
Set pressure
20.60.5 MPa (2105 kgf/cm2) (2,98671 psi)
IMPORTANT
Always be certain to tighten locknuts when finished
with adjustment.
Only set pressures in accordance with setting specifi-
cations.
42-33
Multiple control valve overload Overload relief valve operation

relief valve (with make-up func-
When the oil pressure is at the preset valve or less
tion)
(Installed on both the rod and bottom sides of the bucket
Orifice 1 Plunger
circuit) Relief poppet Passage A
Plunger seat
Each overload relief valve (with make-up function) is
installed in the circuit between the cylinder and the con-
trol valve spool. When the spool is in the NEUTRAL
position, if external force on the cylinder becomes too A
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 Cylinder
Spring port port
Passage B
Seat
95V2E42007
The pressurized oil from the cylinder flows to the cham-

ber 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 Tank Cylinder

Body port 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 low-

ers and the plunger is moved to the left. Then the
plunger opens the port to the tank port and the pressur-
ized oil in the cylinder port escapes to the tank port.
42-34
Make-up valve operation Adjusting set pressure
Plunger
Plunger seat
Adjusting screw
Spring
Lock nut Tank Cylinder

Tank Cylinder port
port
port port
Passage E 95V2E42010
95V2E42009
When the overload relief valve on one side of the cylin- Loosen the lock nut and adjust the pressure by the
der port is actuated, the plunger in the control valve is in adjusting screw. Turn clockwise the adjusting screw to
neutral. The port opposite to the one in which high pres- raise the set pressure, or turn counterclockwise the
sure was produced has a greatly reduced pressure. adjusting screw to lower the set pressure.
When the pressure is reduced below the tank pressure,
the make-up valve is opened. After adjustment, be sure to tighten the lock nut.
When the pressure at the cylinder port becomes less Set pressure
than tank pressure, the plunger seat is moved to the 23.50.5 MPa (2405 kgf/cm2) (3,41371 psi)
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 pas-
sage E. It prevents a vacuum (negative pressure) in the Multiple control valve make-up
cylinder.
valve
Note (Installed on the rod side of the boom circuit)
The make-up valve function is non-adjustable.
The make-up valve is installed in the circuit between the
control spool and boom cylinder.
Extremely quick boom lowering may generate low pres-

sure 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 genera-

tion 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 over-

load relief valve with make-up valve does. Refer to the
description on "overload relief valve" for the makeup
valve operation.
42-35
Multiple control valve bucket spool

Bucket spool operation
1. "Bucket Roll Back" position
D
B1 A1
From pilot valve

Pa1
To pilot valve Spool

Pb1
C
From pump
95ZV42024
- When the control lever is set to the "Bucket Roll - On the other hand, the oil on the rod side of the
Back" position, the pilot pressure is applied on the bucket cylinder returns from the B1 port to the tank.
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 bot-
tom side of the bucket cylinder, and finally rolls back
the bucket.
42-36
2. "Bucket Dump" position
E D
B1 A1
To pilot valve
Pa1
From pilot valve Spool

Pb1
From pump
95ZV42025
- When the control lever is set to the "Bucket Dump" - Extremely quick dumping generates negative pres-
position, the pilot pressure is applied on the left oil sure (or a void) on the rod side. To prevent genera-
pack (Pb1), the spool moves to the right, and the tion of negative pressure (or a void), the make-up
spool shoulder (C) closes the center bypass line. valve (E) opens so that the oil in the tank port flows
As a result, the oil from the pump opens the load into the rod side of the cylinder.
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.
42-37
Multiple control valve boom spool

Boom spool operation
1. "Boom Raise" position
D
B2 A2
From pilot valve

Pa2
To pilot valve Spool

Pb2
From pump 95ZV42026
- 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.
check valve (D), flows from the A2 port into the bot-
tom 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.
42-38
2. "Boom Down" position
E D
B2 A2
To pilot valve
Pa2

Pb2
C
From pump 95ZV42027
- 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.
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.
42-39
3. "Boom Float" position
B2 A2
To pilot valve
Pa2

Pb2
From pump 95ZV42028
- When the control lever is pushed downward beyond

the "Boom Down" position to the "Boom Float" posi-
tion, 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.
42-40
Adapter (Orifice)
Adapter (Orifice)
O-ring 1.3 mm
Orifice
Adapter
Installation position Port b2

Multiple
control
valve
80ZV42018
The adapter is installed in the boom lowering line Note

between the pilot valve and the multiple control valve. When the oil is very cold it will pass very slowly through
the orifice. As a result it will take longer than normal for
When the lever is shifted back to the holding position the spool to shift to neutral or holding position.
just after lowering the boom, the boom spool of the mul- Always warm up the oil before beginning normal opera-
tiple control valve is quickly returned to the holding position.
tion 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 return-
ing the pilot oil which was pushing the spool.
42-41
Ride Control (OPT)
Ride Control (OPT)
Ride control hydraulic circuit

4
(16) (18) (15)
(H)
(X)
(Ac) 3
Capacity: 9.5 L
(T) (Ac2) (Ac1) Gas pressure:
(14)
1.96 MPa
(20 kgf/cm2) From multiple
(Ac1) (284.2 psi)
(5) control valve
1
(13) (br)
(R)
Multiple control (P)
valve P line 8.34MPa
(85 kgf/cm2)(1,209 psi)
(11)
Multiple control (T)

valve T line 95V2E42011
1. Valve assy Ride control function

(11) Solenoid valve
(13) Reducing valve Ride control reduces fore and aft pitching motion to the
(14) Check valve machine in roading by using the boom cylinder and
2. Valve assy hydraulic circuit with the accumulator. Ride control can
(15) Selector valve be operated or released by turning the ride control
(16) Solenoid valve switch ON/OFF.
(18) Shuttle valve
3. Accumulator Turn the ride control switch ON, and when the machine
4. Boom cylinder travelling speed reaches more than 7 km/h (4.3 mile/h),
5. Bleeder valve solenoid valves (11)(16) come to ON by a signal from
the machine control unit (MCU), then the ride control
works.
When the machine travelling speed goes down to 5 km/

h (3.1 mile/h) or slower, no signal transferred from the
MCU, as a result, the ride control does not work.
42-42
Ride Control (OPT)
Ride control operation

Preparation mode (ride control switch is
OFF)
(16) (18) (15)
(H)
(X)
(Ac) 3
Capacity: 9.5 L
(14)
1.96 MPa
(Ac1) (284.2 psi) control valve
(5)
1
(13) (br)
(R)
(85 kgf/cm2)(1,209 psi)
(11)
Multiple control (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 sole-
noid 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.
42-43
Ride Control (OPT)
Running mode (ride control switch is ON)
(16) (18) (15)
(H)
(X)
(Ac) 3
Capacity: 9.5 L
(14)
1.96 MPa
(Ac1) (284.2 psi) control valve
(5)
1
(13) (br)
(R)

(85 kgf/cm2)(1,209 psi) (11)
Multiple control
(T)
The ride control switch is ON, and when the machine Therefore, when the pressure develops at the boom cyl-
travelling speed reaches more than 7 km/h, solenoid inder rod side by pitching motion in roading, oil is
valves (11)(16) come to ON by a signal from the MCU. drained to the tank. When the negative pressure devel-
ops at the boom cylinder rod side, oil from the tank fills
Pressurized oil in the upper part of selector valve (15) is the boom cylinder rod side.
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 cylin-

der 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.
42-44
Ride Control (OPT)
Ride control valve assembly (Reducing valve circuit)

Outline drawing
Pump Tank
2
(T)
(P)
(R)
Boom cylinder
rod side
(Ac1)
Accumulator
4
6
5
1. Block
2. Reducing valve (T)
3. Solenoid
4. Valve #2 #3,#4
5. Check valve (P)
6. Bleeder valve (R)
#5
(Ac1)
#6 (br)
Hydraulic circuit
95V2E42012
42-45
Ride Control (OPT)
Reducing valve Check valve
Passage A
Accumulator A Bleeder valve

Passage B
Passage B
B Poppet
Tank Tank
Orifice 2 Sleeve
Ball
A Reducing valve 95V2E42014
Orifice 1
Pump Oil from the reducing valve pushes the poppet up and
flows to the accumulator circuit.
Passage A
Plunger 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,
Check valve
95V2E42013
and pushes the poppet down with the spring force. As a
result, the oil never flows back.
Oil from the pump flows to the check valve through the
passage A. Also the oil pressure in the check valve cir-
cuit 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)
42-46
Ride Control (OPT)
Solenoid valve
Solenoid
Chamber A
Spring
Orifice
Boom cylinder
Sleeve
rod side
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 con-
nected 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
42-47
Ride Control (OPT)
Ride control valve assembly (Accumulator circuit)

Outline drawing
6 2
X 1
3
4
Tank
Boom cylinder
H bottom side
AC1 Reducing valve
AC2 AC
6
Accumulator 95V2E42016
1. Block
2. Selector valve
3. Solenoid
4. Valve #3,#4
5. Shuttle valve #2
6. Plug (H)
#5
(X)
(Ac1)
(T) (Ac2) (Ac)

Hydraulic circuit
95V2E42017
42-48
Ride Control (OPT)
Shuttle valve Solenoid valve
Movable iron core
Passage A Solenoid
valve
Solenoid
Passage B
Accumulator
Rod
Passage C
Ball Spool
Boom cylinder Passage B
bottom side 95V2E42018
Tank
When the pressure at the accumulator side is higher
than the one at the boom cylinder bottom side, oil flows, Shuttle valve B
pushing the ball down, to the solenoid valve through the
passage A and B.
Passage A
When the boom cylinder bottom pressure is higher, oil Sleeve
A Selector
pushes the ball up, and it flows to the solenoid valve valve 95V2E42019
through the passage C and B. The shuttle valve
switches the oil flow direction by selecting higher oil
pressure side. 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.
Voltage DC 24 V
Current 0.92 A
Resistance 26.2
42-49
Ride Control (OPT)
Selector valve
Passage B
Pressure receive
face E
A
Reducing valve
(solenoid valve) Poppet
Passage A
Passage C
Shuttle valve Boom cylinder

bottom side
Pressure receive Passage D

face F
Seat face Sleeve
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 accumu-
lator pressure applies to the bottom side of the poppet.
However the poppet is pushed down because the pres-
sure 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 pop-
pet 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 fluctua-
tions in the boom cylinder bottom side.
42-50
Ride Control (OPT)
Accumulator (for ride control)
7
2 4 1 3
13
10
12
11
9
6
95ZV52058
1. Body 6. Back up ring 11. Gas valve O ring

2. Hydraulic cap 7. Wear ring 12. Gas valve guard
3. Gas cap 8. O-ring 13. Bolt
4. Piston 9. Back up ring
5. V-O ring 10. Gas valve
Accumulator function Accumulator specification
Maximum operation pressure MPa (kgf/cm2)(psi) 20.6 (210)(2,986)

While the ride control operates, the accumulator
absorbs fluctuation of the boom cylinder bottom pres- Nitrogen gas pressure MPa (kgf/cm2) (psi) 1.96 (20) (284)
sure by air cushion function of the nitrogen gas charged Capacity (l) 9.5
in the cylinder.
The cylinder contains N2 (Nitrogen) gas at 1.96 MPa (20

kgf/cm2) (284 psi).
42-51
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 pro-

portional to the turning speed is sent from the Orbitrol
From and supplied to the oil pack of the steering valve.
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.
Shortly before the full turn, the stop valve activates, the
Stop valve Stop valve pilot circuit is closed.
RH While the steering wheel is not turned, almost all

LH
amount of hydraulic oil from the steering pump is sent to
the loading line by the action of the flow control spool.
Steering valve The pilot oil pressure from the steering pump is limited
by the reducing valve, then supplied to the Orbitrol.
To loading line
To Orbitrol
Oil returns from the steering cylinders flows through the
Cooler bypass valve
steering valve and oil cooler or cooler bypass valve.
P Oil cooler Finally it returns to the tank through the return filter.
Reducing
valve
Return filter
Note
When the oil is very cold it will pass very slowly through
the orifice. As a result it will take longer than normal for
the spool to shift to neutral or holding position.
Always warm up the oil before beginning normal opera-
tion.
80ZV42006
42-52
Orbitrol
Orbitrol
Orbitrol is used as a pilot valve, and it operates the Orbitrol structure
spool of the steering valve by discharging oil, that is in
proportion to rotation amount of the steering wheel, to
1. Spool 5. Drive shaft
the steering valve.
2. Sleeve 6. Centering spring
3. Stator 7. Cross pin
This Orbitrol is the closed center and non-load reaction
4. Rotor 8. Check valve
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 Valve part
works on P port.
T
6
7 L
Valve
1
R P
2
3
4
Rotor
85V2E42018
42-53
Orbitrol
- Spool (1) and sleeve (2) as a set form a rotary-type Orbitrol specifications
directional change-over valve. Spool (1) in this valve
is linked to the steering wheel by means of a spline.
Model ND-K5-D
- When the steering wheel is not being turned, spool Theoretical discharge (cm3/rev) 120
(1) and sleeve (2) are held in the neutral position by Operation pressure MPa (kgf/cm2) (psi) 3.5 (36) (512)
centering spring (6); the oil groove of the spool does
not match the oil hole of the sleeve, so the flow route
of oil is totally closed.
- When the steering wheel is turned, the oil groove of

the spool matches the oil hole of the sleeve, opening
the oil passage, permitting oil to flow.
Rotor part
1 2
Oil groove
To tank
To steering valve
To steering valve
Oil hole
From reducing
valve (pump)
70ZV42023
- A kind of internal gear, when the valve opens, it func-

tions 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.
42-54
Orbitrol
Orbitrol operation
Neutral
(When the steering wheel is not being turned)
6
T
2
8
L
Oil hole
T R
6 Oil groove
7 L
1
R P
2
70ZV42025
3
4
2. Sleeve 6. Centering spring
85V2E42019
- Spool (1) and sleeve (2) of the valve part each have
a slit into which centering spring (6) consisting of
plate springs is set.
- When the steering wheel is not being turned, spool

(1) and sleeve (2) are kept in the neutral position by
means of center spring (6).
- This Orbitrol is the closed center and non-load

reaction type.
When in the neutral position, the oil groove of the
spool does not match the oil hole of the sleeve, so
the flow route of oil from the pump to the steering
valve is totally closed.
42-55
Orbitrol
Turn
(When the steering wheel is being turned)
1
T
6
7 L
T To steering
2 valve Pa port
From steering
R P valve Pb port
L 2
Oil hole 5
1
From reducing valve
R (pump)
Oil groove 3
4
85V2E42020

65ZV42036 2. Sleeve 6. Centering spring
- When in the neutral position, the valve part is totally

closed and oil remains sealed inside the rotor, and
the rotor cannot move. Sleeve (2) is directly linked to
the rotor by means of a cross pin (7) and drive shaft
(5); it is also fixed.
- When the steering wheel begins to be turned, rotary

force is applied to spool (1), which then pushes and
compresses centering spring (6) set in the slit; the oil
groove of the spool matches the oil hole of the
sleeve, and opens the hydraulic circuit.
- As a result, all four ports (pump, tank and oil pack on

right and left side of steering valve) are opened,
allowing the oil to flow and rotating the rotor.
42-56
Orbitrol
Orbitrol feed-back mechanism

operation
To Steering valve
Pa port
From Steering valve

Pb port
70ZV42027
- When an angle of displacement (deviation in circum- - If the turning of the steering wheel stops, the spool
ferential direction) is generated between the spool immediately stops rotating; but, as long as there
and the sleeve through operation of the steering exists an angle of displacement between the spool
wheel, oil from the pump enters the steering valve and the sleeve, oil continues flowing into the
(pilot) and turns the rotor; this oil flows into the steer- Orbitrol, and the rotor can continue rotating. Due to
ing valve. At this time, the rotor rotation is transmit- this rotation, the sleeve catches up with the spool,
ted to the sleeve by the drive shaft and the cross pin. and closes the hydraulic circuit. Finally, the centering
spring returns the spool and the sleeve to the neutral
- As a result, the sleeve starts rotating slightly behind position and flow of oil is completely stopped.
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.
42-57
Orbitrol
Steering speed and flow rate con- Hydraulic pump oil amount and
trol steering force
- When there is plenty of oil flowing from the pump,
Low steering speed High steering speed 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.
1
- When the amount of oil from the pump is small, the
3
Small Large
displacement angle of the spool and sleeve reaches
displacement
angle
displacement
angle 2 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 maxi-
mum 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
70ZV42028 harder to turn.
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 regu-

lated 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.
42-58
Orbitrol
Orbit rotor operation principle
Drive shaft (0 rotation) Drive shaft (1/14 rotation) Drive shaft (1/7 rotation)
Rotor center Rotor (rotation)
Locus of rotor center Stator (fixed)

1 1 1
7 2 7 2 7 2
6 3
6 3 6 3
5 4 5 4 5 4
7 2
6 3
5 4
:Flow of high-pressure oil
:Flow of low-pressure oil 70ZV42029
- Inside the rotor there is a stator with 7 internal gears - The rotor makes a 1/6 turn per rotation of the rotor,
that is fixed to the housing and a 6-tooth rotor that is pushing out oil equivalent to 7 chambers. When the
engaged with the stator. rotor rotates once, oil equivalent to 42 chambers (7
chambers x 6 turns) is pushed out.
- Half of the chamber formed by the stator and the
rotor is connected to the high-pressure side and the - For the motor, it has 6 times larger torque or a 1/6
other half to the low-pressure side. reduction effect.
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 dif-
ference).
- When overrunning the power assist capacity of the

gerotor due to very fast rotation or turning the steer-
ing 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.
42-59
Steering Valve (KVS32-A4.0/21)
To loading line
To reducing From pump 5

valve (G)
PC P
2
MR 3
A A
Pb Pa
B B
Pilot operation 1 Pilot operation

port T port
To loading line Tank port
(F)
P. B.
2
MR
A-A
Orifice
Cylinder port Cylinder port
(LC)
B A
4 4
BR AR
Pb Pa
Drain port Dr
B-B 1
1. Steering spool
2. Flow control spool
4. Overload relief valve (with make-up valve)
5. Gauge port
115V2U42001
42-60
AB 1. Steering spool
AR
The movement of the steering spool is controlled by
BR the pilot pressure from the pilot valve.
At the center of the spool, there is a variable orifice
Pa Pb with chamfers (throttle grooves). This orifice con-
trols the oil flow rate.
0.5 T Also inside the steering spools are check valves
RF
(G) MR which apply a back pressure to oil returning from
P. B.
3.0
the cylinders.
Orifice Pc
P
115V2E42031
2. Flow control spool
Hydraulic circuit
The flow control spool sends oil to the steering line
depending on the displacement of the steering
IMPORTANT spool.
Flow control plunger orifice must not be blocked. The excess oil goes to the loading line.
Pump damage may result.
The main relief valve controls the maximum operat-

ing 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
20.6 MPa
Main relief valve setting pressure (210 kgf/cm2)
(2,986 psi)
24.5 MPa
Overload relief valve setting pressure (250 kgf/cm2)
(3,555 psi)
42-61
Steering valve operation

Neutral position
(steering spool in "Neutral")
Loading circuit
A B
115V2E42015
- In the NEUTRAL position, steering spool (1) closes - When the pump line pressure increases to 0.63 MPa
all the ports to stop flow of the pressurized oil from (6.4 kgf/cm2) (91.4 psi), flow control spool (2) is
the steering pump. The pressure in the pump line, moved to the right due to the pressure difference
therefore, will rise. between chambers A and B.
Thus the flow control spool is opened, and all the oil
from the steering pump is sent to the loading line.
42-62
Left turn position
Loading circuit Pump 2
Pilot pressure
Check valve
1
Tank
Variable throttle
115V2E42016
- When steering spool (1) is pushed in to the left, the - During low-speed turning, displacement of steering
pressurized oil from the pump is sent to steering cyl- spool (1) is small. However, since the oil flow rate to
inders through the variable throttle section and the the steering cylinder is reduced at the variable throt-
check valve. The pressurized oil moves the cylinder tle section at the spool center, the pressure differ-
rods and the machine turns to the left. ence between the front and rear of the throttle
section is increased. When the pressure difference is
increased to 0.63 MPa (6.4 kgf/cm2) (91.4 psi), flow
control spool (2) is opened to discharge excess oil to
the loading line. In this way, the flow control spool
prevents extreme increase in the amount of the oil
from the steering pump, and adjusts the oil flow rate
to the cylinder.
42-63
- For high-speed turning, steering spool (1) is pushed Steering spool variable throttle
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.
PA PB
- At a low engine speed, the oil flow rate from the
steering pump is low, therefore the pressure differ-
ence between the front and rear of the throttle sec-
tion 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 differ-
ence between the front and rear of the throttle sec-
tion is increased to activate the flow control spool. As Variable throttle
a result, the excess oil is sent to the loading line.
115V2E42017
When the steering spool is pushed in, the variable throt-

tle is opened, and the pressurized oil from the pump
goes through the variable throttle, the pressure gener-
ated 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 open-

ing area of the variable throttle and the passing oil flow
rate, and the control pressure is set to 0.63 MPa (6.4
kgf/cm2) (91.4 psi).
42-64
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 pres-

sure 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 con-
stant in the steering circuit.
42-65
Steering valve main relief valve

When the pressure is at the preset value or
less
Loading circuit Pump Flow control spool
Filter
A
B
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.

42-66
When the pressure exceeds the preset

value
Loading circuit Pump Flow control spool
A
B
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 rela-
tively high, the flow control spool is shifted to the right,
and the oil sent from the pump flows into the loading cir-
cuit.
42-67
Steering valve overload relief

valve
External force
B A
Makeup function Overload relief function
Tank
115V2E42021
Overload relief valves with makeup valve are located in Overload relief function
the circuit between the steering cylinder and the steer-
ing spool on the both sides of the steering cylinder. In this situation, if an external shock (force) is applied to
one side of the cylinder (the bottom side in the figure
While the steering spool is located in the neutral posi- above) causing abnormally high pressure to build up in
tion, the steering cylinder circuits are closed. the circuit, the oil escapes through the valve on side A,
in order to prevent damage to the piping and the cylin-
der.
Makeup function
On the other side of the cylinder (the rod side in the fig-
ure 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 vac-
uum (negative pressure (or void)) from developing in
the circuit.
42-68
Overload relief valve operation Make-up valve operation
C K X K
A
Cylinder
Cylinder
E
D Tank 115ZV42052 Tank 115ZV42054
When the oil pressure is at the preset value or less When the cylinder pressure drops below the tank pres-
sure, sleeve K moves to the right due to the difference
The pressurized oil is sent to the internal space X in the pressure receiving area (G - A) between the left
through the orifice of the piston C. Because the oil pres- side and the right side of sleeve K, and the oil flows
sure is at the preset value or less, the poppet E is from the tank to the cylinder so that the cylinder pres-
closed and the area between the cylinder and the tank sure does not drop below the tank pressure.
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 K X
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 rela-

tively lower than that on the cylinder side, then the pis-
ton C moves to the right and fits in the pilot poppet E.
Because the internal space X leads to the tank, the pop-

pet D moves to the right and the high pressure oil
escapes from the cylinder to the tank.
42-69
Steering pilot circuit and its opera-

tion
From pump
Orbitrol
Reducing valve
To tank
Steering valve
Filter
To tank
From cylinder To cylinder Stop

Stop
B A valve
valve
End cover
End cover
Flow amp. notch
Pilot circuit
To tank
Pilot orifice
K115V2J42009
Oil flow orifice and flows to the end cover on the opposite
side, returning to the tank through the Orbitrol.
- Oil from the steering pump flows into the steering
valve. The oil flow direction is separated in the steer- - As the amount of oil flowing through the amplifier
ing valve. notch and the pilot orifice increases, the pressure of
The oil is supplied to the Orbitrol from the steering the oil inside the end cover increases, pushing in the
valve through the reducing valve where the oil pres- steering spool.
sure is reduced. The variable throttle opens, regulating the amount of
oil flowing to the cylinder circuit, depending on flow
- The hydraulic oil from the Orbitrol first enters the volume, and thus the distance the spool is pushed in.
end cover of the steering valve, then passes through
the steering spool flow amplifier notch and the pilot
42-70
Flow amplifier notch and pilot orifice
Return spring Return spring force Hydraulic force
Pilot pressure
Pilot oil
End cover
Pilot orifice
Flow amplifier notch Flow amp. notch opening

Pilot line K115V2J42005
Pilot orifice
80V2U42006
- 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 flow rises, as the opening of the flow
When pilot oil is sent from the Orbitrol the oil flows amplifier notch is narrow, the pressure inside the end
through the pilot orifice, the pressure of the oil inside cover is raised higher, pushing the spool in.
the end cover rises, pushing the spool and opening When the spool is pushed in, the opening of the flow
the flow amplifier notch. amplifier notch becomes larger, making it easier for
Then, the oil flows through the flow amplifier notch pilot oil to flow out ; thus, the rise in pressure stops
and the pilot orifice. 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.
Return spring force Hydraulic force

Pilot pressure
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.
42-71
Stop Valve
Stop Valve
17 (Full stroke)
From Orbitrol
(0.67")
To steering valve
7 3 8 2 1 6
DR
11 13 10 12 5 4 14 9
95V2E42038
1. Housing 9. Spring
2. Spool 10. Spacer
B 3. Check valve 11. Boot
4. Plug 12. U-packing
5. Washer 13. Dust seal
6. Plug 14. O-ring
7. Flange
8. Spring
A DR
97ZV42042
42-72
Stop Valve
Stop valve function Stop valve operation
Port B Port A
To From
steering valve Orbitrol
Stopper
(bolt) Spool
Installed on Check valve

front chassis Installed on rear chassis
90V2U42003
A stop valve is provided to reduce the impact caused to

the chassis steering stopper block when the machine is
making a full turn while the hydraulic pressure of the
steering cylinder is still working.
B A
Pb Pa
95V2E42049
Shortly before a full turn, the stopper installed on the

front chassis pushes the spool of the stop valve
installed on the rear chassis to shut down the port A and
the port B. As a result, the pilot line is closed, returning
the steering valve spool to the neutral position.
After a full turn, when the steering wheel is turned in the

opposite direction, the spool of the stop valve remains
pushed in, closing the line. As a result, the pilot oil
opens the check valve and flows out.
42-73
Reducing Valve (for Orbitrol)
Reducing Valve (for Orbitrol)
Spring
Sleeve (T)
Tank
Plunger
Passage Z
(A) TS
Pump B
B A
A
Passage Y
(TS) T
(B)
Orbitrol
90ZV42012
The oil fed from the pump flows into the Orbitrol circuit This oil is supplied from the Orbitrol to the steering
by way of passage Y and port A in the plunger. valve pilot port, and moves the spool.
When the oil pressure in the Orbitrol circuit reaches or Set pressure
exceeds the set pressure (spring force), the plunger is 3.5 MPa (36 kgf/cm2) (512 psi)
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.
42-74
Steering Line Filter
Steering Line Filter
From pump To
FILTER
(steering valve) reducing valve
1 3 4 2 5
70ZV42040
1. Case The line filter is integrated into the pilot line of the steer-
2. Nipple ing line, and prevents foreign objects from entering the
3. Strainer pilot line.
4. O-ring
5. O-ring Note
The line filter design shown above is also used for the
brake line.
The filter prevents debris from entering the brake accu-
ELS valve mulator reducing valve assembly.
These filters must be removed, inspected and cleaned
or replaced every 2,000 hours of operation.
Stop valve (RH)
Stop valve (LH)
Center pin
Center line
Reducing valve
Line filter
Steering valve
115V2E42006
42-75
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
Fast
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.
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 perfor-
When excavating and scooping mance of operating when excavating and scooping.
Switch Steering
Multiple
Boom
Fuel efficient mode switch is also installed at the instru-
control ment panel when operating at the time of fuel saving
pump valve Bucket
valve
driving. If the combination of ELS switch and fuel effi-
cient mode switch is selected properly, it can be able to
Main ELS improve the fuel consumption without reducing the
pump valve operation efficiency.
Hydraulic tank In addition, the height range of the boom that ELS oper-
ates can be set up to the arbitrary height depending on
setting of the variable kickout sensor.
When raising the boom
Multiple
Switch Steering Boom
control
pump valve Bucket
valve The operation condition of ELS
Main ELS The ELS switch ON

pump valve Shift lever Forward position
Machine speed Less than 5 km/h
Hydraulic tank The setting position of the variable kickout sensor
Boom height
is less than it.
Concept of the ELS operation 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 posi-
tion.
When the engine revolution becomes higher than 1,300
min-1, it stops working.
42-76
Mounting of the ELS valve
3 4
PG1
(P) (A) Multiple
From main pump control valve
(T1)
To hydraulic
tank
PG2 (T2)
2 1 From Orbitrol
Center pin Hydraulic line

Center line ELS valve
Rear chassis
PG2 P
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
42-77
Mounting of the variable kickout sensor
5 8 2
Apply grease
at area
Detail of grease applying
A
Boom
9
4 5,8
2 6
When the boom Chassis
is horizontal
3
1,7
1
Detail of A
85V2E42056
1. The variable kickout sensor

2. Link
3. Plate
4. Plate
5. Shaft
6. Ball bearing
7. O-ring
8. Spring pin
9. Rod
42-78
Efficient loading system operation

While the ELS is not operating While the ELS is operating
3 4 3 4
From main pump Multiple control From main pump

valve P line
To hydraulic
tank
2 1 2 1
115V2E42008 115V2E42009
The oil discharged from the switch pump flow into the When the ELS switch is turned on and the ELS opera-
steering valve P port. When the steering wheel is not tion condition set by the MCU is satisfied, the solenoid
turned, this oil is discharged from the steering valve P.B. valve in the ELS valve is energized and the spool is
port. moved.
On the other hand, the oil discharged from the main After that, the setting pressure of relief valve drops to
pump opens the check valve, because cracking pres- the hydraulic tank pressure level.
sure of check valve (3) is less than the setting pressure
of relief valve (2). Therefore, the oil discharged from the main pump
opens relief valve (2) that setting value dropped and all
Cracking pressure of check valve (3) the hydraulic oil from the main pump goes to the
0.2 MPa (2 kgf/cm2) (29 psi) hydraulic tank.
Setting pressure of relief valve (2) But the oil from the steering valve P.B. port cannot flow
20.6 MPa (210 kgf/cm2) (2,987 psi) into relief valve (2) because of check valve (3), and flow
into the multiple control valve P port.
The oil from switch pump and main pump are joined
together 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
Therefore it can be able to operate the boom and force by turning off the main pump and reducing the
bucket at normal speed. pump driving load on engine.
In addition, pressure sensor (4) is installed in the dis- In addition, it becomes easy to operate slightly by
charged side of the main pump and detects oil pressure reducing the quantity of total oil to the loading circuit,
of loading line and sends the signal to the MCU. and is improved the performance of operating when
excavating and scooping.
42-79
Fan Motor System
Fan Motor System
Mounting of fan motor
T1 L1 L2
T2 L1
115V2E42010
1. Fan motor
2. Fan
3. 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)
L1: Screw lock agent (Loctite 262)

L2: With lubrication oil (Engine oil or gear oil)
42-80
Fan Motor Line
Fan Motor Line

Fan revolution Engine coolant: High temperature
(min-1) [94C (201.2F)]
1,300
Stepless
control range
1,120
Middle range temperature

(900) [60~80C (160~180F)]
Low temperature
[below 60C (160F)]
0
725 1,200
(Hibernate mode) 925 (1,260) (1,787)
Engine revolution (min-1) Values inside ( ) are
offered as reference.
Fan revolution * (controlled by MCU)
* To shorten the warm-up time, when the engine water temperature is 60C (140F) 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. K115V2E42001
Fan motor (1) The cooling fan is driven by the hydraulic motor. The
Cooling fan 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.
The fan revolution is regulated by proportional relief

valve (2). The setting pressure of the proportional relief
valve is changed in proportion as the electric current
value from MCU.
To return From
filter unloader
Proportional relief valve (2) valve
95V2E42041
Note
Hydraulic oil temperature must be at operating tempera-
ture to do this fan revolution test.
When proportional relief wire is disconnected, fan revo-
lution should go to high speed mode.
42-81
Fan Motor Line
Output current F for control of

the fan revolution
Number of
Proportional Proportional Proportional
revolutions of
relief valve [mA] relief valve [mA] relief valve [mA]
fan (min-1)
About
1,120 270
F H/D
F T/M
F E/G
1,300 0
0
80 94 ( C) 110 115 ( C) 90 95 ( C)
(176) (201.2) ( F) (230) (239) ( F) (194) (203) ( F)
T E/G T T/M T H/D
The signal of the engine The signal of the torque The signal of the
coolant temperature converter oil temperature hydraulic oil temperature
Control of the fan revolution
K115V2E42002
When the input electric current value to proportional In normal condition, fan revolution is regulated by
relief valve (2) is maximum (approximately 270 mA), the engine water temperature. But when the torque con-
fan revolution is minimum value (1,120 min-1) because verter oil temperature exceeds 110C (230F) or the
bypass oil amount at proportional relief valve (2) is hydraulic oil temperature exceeds 90C (194F), in each
increased. When this value is minimum (0 mA), the fan signal input into a MCU from the engine water tempera-
revolution is maximum value (1,300 min-1) because ture, torque converter oil temperature and hydraulic oil
bypass oil amount at proportional relief valve (2) is temperature sensors, the lowest signal in the electric
decreased. current value is chosen (the fan revolution becomes
high to lift the cooling performance), and the control
When the engine water temperature is low, the electric electric current is input into proportional relief valve (2).
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 revolu-
tion becomes low.
For example, when the torque converter oil temperature

is below 110C (230F) and the hydraulic oil tempera-
ture is below 90C (194F), the fan revolution is con-
trolled only by engine water temperature.
42-82
Fan Motor Line
Hydraulic circuit (fan motor normal rotation)

Fan motor (1)
MB MA
Make-up valve (3)
Safety valve (4)
Proportional relief valve (2) MCU

(Engine water temp. sensor
T/C oil temp. sensor Brake
Hydraulic oil temp. sensor) circuit
For brake and pilot pump
Unloader valve
Hydraulic tank

95V2E42043
Make-up valve
When the pressure oil from the hydraulic pump is sup- Oil supply is stopped, however the fan is still turning by
plied to the inlet port P, the pressure in the MA side cir- the inertial force.
cuit of the fan motor will increase. The starting torque for
the fan motor is generated, and the motor starts to This condition generates negative pressure at the motor
rotate. The oil in the MB side circuit of the fan motor inlet port.
returns to the hydraulic tank via the outlet port T.
To prevent generation of negative pressure, make-up
When engine stops, the pressurized oil from the pump valve (3) opens so that the oil in the tank port flows into
is not supplied to fan motor (1) inlet port, as a result, the the fan motor inlet port.
fan motor revolution speed gradually decreases.
42-83
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 pres-

sure, safety valve (4) relieves the pressurized oil to the
tank port.
42-84
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 nor-
mally 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 Chamber A Solenoid

Body Lock nut
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 set-
ting pressure also decreases. Once a constant elec-
tronic signal is given, the pilot poppet is held in a given
potion, holding the setting pressure.
This is maintained by the balance between the elec-

tronic spring 2 force and inlet pressure.
42-85
Fan Motor Line
Plunger Chamber A Solenoid

Body Lock nut
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 pop-
pet 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 counterclock-
wise the adjusting screw to lower the set pressure
After adjustment, be sure to tighten the lock nut
High pressure set:

19.60.5 MPa (2005 kgf/cm2) (2,84471 psi)
at 0 mA
42-86
Fan Motor Line
Proportional relief valve (S/N 9051~)
7
(G1) (G1)
T1 P1
8 7 2
1
(T1) (P1)
(P2)
(G3/8) P2
PG2 (G1)
(PG2)
(T2) 3
(PG1) T2 PG1
(G1) 2 (G1/4)
6
Hydraulic line diagram
4 5
8 7 2
K115V2U42001
1. Block
2. Relief valve
3. Adapter
4. Elbow adapter
5. Plug (Gauge port)
6. Plug
7. Relief valve
8. Solenoid valve
42-87
Fan Motor Line
8 7 2
K115V2U42002
Adjusting set pressure
It is not possible to adjust the set pressure on the

machine. Replace relief valve cartridge (7), if neces-
sary.
: 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)
42-88
Fan Motor Line
Fan motor
Port P
B A
B A
Port Tc
Port T
115V2E42030
Fan motor specifications
Displacement capacity 90.3+2 3 3

-0 cm /rev (55.1 in /rev)
Pressure 21.3 MPa (217 kgf/cm2) (3,089 psi)

Rating Speed 1,600 min-1
Flow 144 L/min (38 gal/min)
Continuous variable control with the
Speed
Control method proportional valve (not included in
control
fan motor)
42-89
Fan Motor Line
Fan motor structure
1 2 3 4 5 6
11 9 7 8 13 12 10
A-A
14
P
MA MB
TC
T
17 16 15
B-B
K95V2J42001
1. Output shaft 10. Sub bearing

2. Case 11. Oil seal
3. Thrust plate 12. End cover
4. Piston assy 13. Center spring
5. Cylinder block 14. Make-up valve
6. Valve plate 15. Safety valve
7. Retainer guide 16. Main spool
8. Retainer shoe 17. Spring
9. Main bearing
42-90
Fan Motor Line
Fan motor function and the operation principle This hydraulic motor is swash plate type axial piston
motor. This converts the power of pressured oil sent
from the hydraulic pump into rotary motion.
Y
The oil sent from the hydraulic pump is led into cylinder
F3 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)
ri
process.
F3
The pressure a oil in a half of cylinder block, that is sep-
arated 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 compo-
nent 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
F1 linking a top dead center to a bottom dead center.
D P
F3
Resultant force of this torque (T= (F3 x ri)) goes
F2
through a piston as turning force and turns cylinder
block (5).
3 5 4 Because this cylinder block (5) is connected to the out-

85V2E42044
put shaft, the output shaft turns, and then torque is
transmitted.
4
5
Y 6
Supply side
3
Discharge side
Y 85V2E42045
42-91
Reversing Fan Motor Line (OPT)
Reversing fan motor function Functional limitation conditions:
When either one of the following temperature exceeds

the preset upper limit(s), the cooling fan reverse rotation
function does not work.
Switch 1. Signal of engine water temperature

> 94C (201.2F)
2. Signal of torque converter oil temperature

> 115C (239F)
3. Signal of the hydraulic oil temperature

> 95C (203F)
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 sec-

onds, the cooling fan reversal switch turns "OFF" and
the pilot lamp on the switch turns "OFF". Then the cool-
ing fan turns in the normal direction.
The cooling fan reversal switch can be operated any

time the engine is running. It is not necessary to stop
the machine to push the reversal cooling fan switch.
If the fan turns in reverse direction under the following

conditions, reverse control of fan is canceled. The
reversal fan indicator lamp flashes at 0.5 sec cycle (ON:
0.25 sec, OFF: 0.25 sec) for 3 seconds, and then the
lamp turns off and the fan turns in normal rotation.
42-92
Reversing fan motor (OPT)
This figure is shown the optional reversing fan motor.
Reversing solenoid
(Electrical connector)
Port P
Gauge port
B (M10 x 1.25)
A
B A
Port Tc
Port T
95V2E42046
Fan motor specifications
Displacement capacity 90.3+2 3 3

-0 cm /rev (55.1 in /rev)
Pressure 21.3 MPa (217 kgf/cm2) (3,089 psi)
Rating Speed 1,600 min-1
Flow 144 L/min (38 gal/min)
Continuous variable control with the
Speed
Control method proportional valve (not included in
control
fan motor)
42-93
Fan motor structure
1 2 3 4 5 6
11 9 7 8 13 12 10
A-A
20
14
P 18
MA MB
19
TC
T
17 16 15
B-B
K95V2J42002
1. Output shaft 11. Oil seal

2. Case 12. End cover
3. Thrust plate 13. Center spring
4. Piston assy 14. Make-up valve
5. Cylinder block 15. Safety valve
6. Valve plate 16. Main spool
7. Retainer guide 17. Spring
8. Retainer shoe 18. Filter (15 m) (*)
9. Main bearing 19. Selector valve (*)
10. Sub bearing 20. Reversing solenoid (*)
(*) Optional parts for reversing fan motor

42-94
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 FV1 t FV1
t FV2 t FV2
t AR2 t AR1 t AR2

ON
Reversing
fan switch OFF
2 sec
Switching timing chart of reversing fan 85V2E42047
t: sec
F: mA
t FV1 16
t FV2 18
t AR1 1,800
t AR2 60
F VR1 approx. 340
F VR2 0
42-95
Hydraulic circuit (Reverse rotation)
Fan motor (1)
MB MA
Reverse solenoid (6)
Selector valve (5)
To MCU
Make-up valve (3) (Reversing cooling
fan switch)
Safety valve (4)
MCU
(Engine water temp. sensor
Proportional relief valve (2) T/C oil temp. sensor Brake
Hydraulic oil temp. sensor) circuit
For brake and pilot pump
Unloader valve
Hydraulic tank
Hydraulic line (reverse revolution)

115V2U42025
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 selec-
tor valve (5) to the left. As a result, the fan motor turns
into reverse.
42-96
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 G1/2

steering motor G1/2 G3/8
and pump
F5
11.7MPa
(119 kgf/cm2)
(1696 psi)
16
M cm3/rev
G1/2
Check valve
Secondary G1/2
steering relay
+24 V
Secondary
steering motor
and pump
11.7MPa
(119 kgf/cm2)
(1696 psi)
16
M cm3/rev
90.7 90.7
M cm3/rev cm3/rev
Magnetic switch
(on motor and pump)
Steering pump
Hydraulic line
Electrical circuit
115V2E42025
42-97
Secondary Steering
Secondary steering operation Machine speed signal
Motor and Steering

Hose pump valve Check valve
The signal from MCU

to magnetic switch
ON
Check valve Machine speed

OFF
Hose (km/h)
1 2
85V2E42051
Hose
Block
Pump
Hose Motor and pump From

hydraulic tank
Secondary steering hydraulic line diagram

115V2E42026
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
42-98
Secondary Steering
Secondary steering motor and pump
CW rotation
Magnetic switch
Relief valve
+24 V
Motor Pump 85V2E42052
Customer's power Relief valve

+24 V connection 11.7 MPa
(119.3 kgf/cm2)
Customer's
MCU
connection
M 16
Customer's
ground
connection
Electric/Hydraulic schematic 85V2E42053
Secondary steering motor and pump
Model ND-K2-D
Discharge (cm3/rev) 16
Relief valve setting pressure

11.7 (119.3) (1,696)
MPa (kgf/cm2) (psi)
43-1
115ZV-2 Check & Adjustment Hydraulic Group
Check & Adjustment

Hydraulic Group
Loading/Steering Circuit Relief Valve/Ride Control Circuit Reducing Valve (OPT)

........................................................................... 43-2
Hydraulic Cylinder ................................................... 43-15
Stop Valve ............................................................... 43-17
43-2
Check & Adjustment Hydraulic Group
Loading/Steering Circuit Relief Valve/Ride Control Circuit

Reducing Valve (OPT)
Loading circuit relief valve setting Measurement instruments

pressures Pressure gauge
30 MPa (300 kgf/cm2) (5,000 psi)

WARNING (for loading line with 3 m (10 ft.) hose)
accident resulting in injury or death. 5 MPa (50 kgf/cm2) (1,000 psi)
Therefore, to provide repair service with the engine (for pilot line) with 2~3 m (6~10 ft.) hose
- Park the machine on level ground. Note
- Apply the parking brake. For safety purpose, route the gauge to an area where it
- Block the tires with chocks to prevent the tires from may be safely read by the person doing the test.
moving.
Gauge port
areas.
Gauge port location Port size
- Under the machine
- Around the engine Main relief pressure (1), (2), (3)
- In front of or behind the machine (1), (2), (3)
G (PF) 1/4 with O-ring
Overload relief
(1), (2), (3)
pressure
CAUTION
Pilot line pressure (4)
(4)
Be careful, you may get burned if the high pressure (Reducing valve) G (PF) 3/8 with O-ring
oil spouts out. To prevent such an accident, be sure
to release the residual pressure from the pipe, and
the plug from the pressure measurement port.
CAUTION
Do not touch the fan or V-belt of the engine or a high-
temperature section if the engine is running. An acci-
dent resulting in injury may occur.
access panel of the engine room. Keep all guards in
place.
engine is stopped.
43-3
Standard measurement value Measuring loading circuit main relief pres-

sure
Loading line main relief pressure 20.60.5
(at maximum speed) MPa (kgf/cm2) (psi) (2105) (2,98671)
1. Unload the bucket.
Loading line overload relief pressure 23.50.5
(at idling speed) MPa (kgf/cm2) (psi) (2405) (3,41371) 2. Press the brake pedal, and set and confirm the
3.5
Pilot line MPa (kgf/cm2) (psi)
(36) (512)
position.
Hydraulic oil temperature: 505C (1209F)
4. Press the brake pedal, and lower the boom to the
Reference lowest limit.
Releasing residual pressure from tank and pipes 5. Attach the pressure gauge 30 MPa (300 kgf/cm2)
(5,000 psi) to the bucket cylinder bottom side (2).
Keep the bottom surface of the bucket horizontal,
and stop the engine when the bucket is approxi- 6. Set the declutch ON/OFF switch to ON.
mately 30 cm (1 ft.) above the ground. Press down the brake pedal all the way to the floor
Tilt down the bucket until it comes in contact with
the ground. Place the bucket control lever in the Note
roll back position, and then lower the boom. In the fuel saving mode at idle time, the engine is not
Push down on, then open the cap of the hydraulic revolution.
tank to release the residual pressure.
7. Move the bucket control lever to the roll back posi-
tion. Hold the lever at that position.
8. Increase the engine speed to the maximum, and

measure and record the pressure using the pres-
sure gauge.
Adjusting main relief pressure
Loosen the lock nut and adjust the pressure by the

adjusting screw.
Turn clockwise the adjusting screw to raise the set pres-

sure, or turn counterclockwise the adjusting screw to
lower the set pressure.
IMPORTANT
At the completion of check and adjustment of main
relief valve pressure, be sure to tighten the lock nut.
43-4
Bucket cylinder Main relief valve
Note
North America equipped M/c's Cap
have a quick connector in port
Lock nut
(3) for testing.
(1)
Adjusting
screw
(2)
K115V2J43001 95ZV43004
Multiple control valve
Make-up valve
Overload relief
valve
Overload relief Main relief valve

valve
(3)
95ZV43002
Valve assembly
(4)
(PPI) (Z)
(Z2) (Z1)
(PA)
(PARKING) ACF (ACCF) (ACCR)
(TA)
(T) (P)
Reducing valve
(for pilot)
85V2E43006
43-5
Measuring loading circuit overload relief Adjusting overload relief pressure

pressure
adjusting screw.
1. Attach the pressure gauge to the port (3).
((1) for the rod side, (2) for the bottom side, (3) for
the both sides.)
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. IMPORTANT
At the completion of check and adjustment of over-
Bucket cylinder bottom side (gauge port (2) or (3))
load relief valve pressure, be sure to reset the main
relief valve to the original condition.
1. Lower the boom to the lowest limit.

tion. Overload relief valve
3. Keep the engine speed at low idle.
4. Hold the bucket control lever at the roll back posi- Lock nut
tion and record the pressure.
Bucket cylinder rod side (gauge port (1) or (3))
2. Move the bucket control lever to the roll back posi- Adjusting screw
tion.
3. Place the shift lever to the forward position. 95ZV43005
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 coditions:
- when the transmission shift lever is placed at N
position,
- the engine coolant temperature is higher than 60C
(140F), and
- the engine speed is held at 950 min-1 or less for 10
seconds.
5. Hold the bucket control lever at the roll back posi-

43-6
Measuring pilot circuit reducing valve pres- Adjusting pilot line pressure
sure
adjusting screw.
WARNING
Trapped pressure in brake circuit could cause serious Turn clockwise the adjusting screw to raise the pilot line
injury when the plug is removed. pressure.
Fully release all residual accumulator pressure
before servicing. IMPORTANT
After the completion of the adjustment of the pilot line
1. Attach the pressure gauge to port (4). pressure, be sure to tighten the lock nut.
2. Place the shift lever to the forward position.

Reducing valve
Note
Lock nut
position,
(140F), and
seconds.
Adjusting screw
3. Keep the engine speed at low idle (when the brake
line pressure is normal) and then measure and
record the pressure.
90ZVE43004
43-7
Ride control circuit reducing valve Measurement instruments

setting pressures (OPT) Pressure gauge
15 MPa (150 kgf/cm2) (3,000 psi)

WARNING (for ride control line) with 3 m (10 ft.) hose
accident resulting in injury or death. Note
Therefore, to provide repair service with the engine For safety, route the gauge to an area where it may be
running, be sure to observe the following items: safely read by the person doing the test.
Gauge port
moving.
areas. Reducing pressure AC2 G (PF) 1/4 with O-ring
- Under the machine
- Around the engine
- In front of or behind the machine
CAUTION
Be careful, you may get burned if the high pressure
CAUTION
place.
engine is stopped.
43-8
Standard measurement value Measuring ride control circuit reducing

pressure
Ride control line pressure (reducing valve) 8.340.3
MPa (kgf/cm2) (psi) (853) (1,20943.5)
X
Hydraulic oil temperature: 505C (1209F) T
Reference
Tank
H
Boom cylinder
bottom side
Valve assembly AC1

Reducing
(Reducing valve circuit) Valve assembly valve
(Accumulator circuit)
AC
AC2
Plug
Accumulator
Valve assembly (Accumulator circuit)
95V2E43003
Pump Tank Reducing valve

(T)
(P) Lock nut
115V2E43001
Adjusting screw
(R)
Releasing residual pressure from tank and pipes
(Ac1)
Keep the bottom surface of the bucket horizontal,

and stop the engine when the bucket is approxi- Air bleeder nipple
mately 30 cm (1 ft.) above the ground.

the ground. Place the bucket control lever in the
roll back position, and then lower the boom.
Valve assembly (Reducing valve circuit) 95V2E43004
Push down on, then open the cap of the hydraulic
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 mea-

sure and record the pressure.
43-9
Adjusting reducing valve pressure
Loosen the lock nut of the reducing valve and adjust the
pressure by the adjusting screw.

IMPORTANT
At the completion of check and adjustment of reduc-
ing valve pressure, be sure to tighten the lock nut.
43-10
Steering circuit relief valve setting Measurement instruments

pressures Pressure gauge
30 MPa (300 kgf/cm2) (5,000 psi)

WARNING (for loading line with 3 m (10 ft.) hose and steering line
Unexpected movement of the machine may cause an with 1.5~3 m (4~10 ft.) hose)
Therefore, to provide repair service with the engine 5 MPa (50 kgf/cm2) (1,000 psi)
running, be sure to observe the following items: (for pilot line) with 2~3 m (6~10 ft.) hose
- Apply the parking brake. Note
- Block the tires with chocks to prevent the tires from For safety, route the gauge to an area where it may be
moving. safely read by the person doing the test.
areas.
Gauge port
- Under the machine
- Around the engine
- In front of or behind the machine Main relief pressure
(1), (2) G (PF) 1/4 with O-ring
Overload relief
CAUTION pressure
Be careful, you may get burned if the high pressure

Reducing pressure (3) Rc (PT 1/8)
CAUTION
place.
engine is stopped.
43-11
Standard measurement value Steering valve
Steering line main relief pressure

20.60.5 Main relief valve
(at maximum speed)
(2105) (2,98671)
MPa (kgf/cm2) (psi)
Steering line overload relief pressure
24.5 +1.0
0
(at idling speed)
(250 +100 ) (3,555 +1420 )
MPa (kgf/cm2) (psi)
Pilot line 3.5

MPa (kgf/cm2) (psi) (36) (512)
Hydraulic oil temperature: 505C (1209F)
Reference
Releasing residual pressure from tank and pipes
Keep the bottom surface of the bucket horizontal, Overload relief

valve
and stop the engine when the bucket is approxi-
95ZV43006
mately 30 cm (1 ft.) above the ground.

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

43-12
Measuring steering circuit main relief pres- Adjusting steering line main pressure
sure
1. Unload the bucket. Steering cylinder
2. Press the brake pedal, and set and confirm the

(2)
position.
4. Press the brake pedal. Note (1)

North America equipped
M/c's have quick
5. Attach the pressure gauge to the gauge port ((1) or connectors at ports (1)
and (2). K115V2J43002
(2)).
6. Set the declutch ON/OFF switch to ON. Loosen the lock nut and adjust the pressure by the
Press down the brake pedal all the way to the floor adjusting screw.
Turn clockwise the adjusting screw to raise the steering
Note line main pressure.
In the fuel saving mode at idle time, the engine is not
revolution. Main relief valve
7. In case the pressure gauge is installed to (1), steer

the machine to the left until the front and rear chas- Lock nut
sis contact each other. Adjusting
Continue to hold the steering wheel fully turned. screw
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 artic-

ulation stopper or screw the stopper (bolt) in until the
front and rear chassis contact each other. 95ZV43007
WARNING
If the machine begins to move with the articulation
stopper applied, it may cause an accident resulting in
injury or death.
After the measurement, be sure to disconnect and
store the articulation stopper.
8. Increase the engine speed to high idle, and mea-

sure and record the pressure.
43-13
Measuring steering circuit overload relief Adjusting overload relief pressure

pressure
Lock nut
Adjusting
Port B to Port A from screw
steering valve pilot valve
Stopper
(bolt) Spool
Installed on
front chassis Installed on rear chassis 95ZV43008
115V2U43001

adjusting screw.
1. Attach the pressure gauge to the port ((1) for the
left turn, (2) for the right turn).
(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
If the machine begins to move with the articulation
contact each other. Continue to hold the steering
stopper applied, it may cause an accident resulting in
wheel fully turned.
injury or death.
After the measurement, be sure to disconnect and
Note
store the articulation stopper.
Because the stop valve is installed into the steering line,
oil pressure does not reach the set point when the
steering is fully turned.
IMPORTANT
When measuring oil pressure, be sure to apply the artic-
ulation stopper or screw the stopper (bolt) in until the At the completion of check and adjustment of over-
front and rear chassis contact each other. load relief valve pressure, be sure to reset the main
Note
position,
(140F), and
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.
43-14
Measuring pilot circuit relief pressure 4. Keep the engine speed at low idle and record the
(reducing pressure) pressure.

Adjusting screw
Adjusting pilot line pressure
Lock nut

adjusting screw.
Turn clockwise the adjusting screw to raise the pilot line

pressure.
(T) IMPORTANT
After the completion of the adjustment of the pilot line
(A) pressure, be sure to tighten the lock nut.
(3)
(TS)
(B)
115ZV43007
1. Attach the pressure gauge to the port (3).
Gauge port plug width across flat: 5 mm

tion.
Note
position,
(140F), and
seconds.
43-15
Hydraulic Cylinder
Hydraulic Cylinder
Cylinder natural drift Measurement procedure
1. Unload the bucket.

WARNING
2. Keep the boom and bucket horizontal.
Standing under the boom or bucket during service
work is dangerous. An accident resulting in injury or 3. Set the parking brake switch to the "ON" position.
death may be caused.
To prevent such an accident, be sure to lock the 4. Lock the boom and bucket control levers using the
boom and bucket control levers in the cab, securely safety lock.
support the boom, and remove the starter key.
In addition, hang a "DO NOT OPERATE!" tag on the 5. Stop the engine.
steering wheel.
6. Mark the cylinder rod at a point 100~150 mm (4~6
in) away from the cylinder head cover.
7. Measure the accurate distance from the cylinder
head cover to the vinyl tape. This is distance "A"
- Scale
mm (in). Measure the distance again 5 minutes
150~300 mm (1 ft.)
later. This is distance "B" mm (in).
- Stop watch
Cylinder drift (mm/min) A B (mm) (in)
= --------------
- Black vinyl "electrician's" type (in/min) 5 (min)
Note
Warm-up the hydraulic oil before measuring cylinder
drift.
Boom cylinder (mm/min) (in/min) 3 (1/8) or less

Bucket cylinder (mm/min) (in/min) 4 (5/32) or less
43-16
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 cylin-
der rod, the tape may be caught by the rod seal. The
tape will cause oil leakage from the rod seal. To pre-
vent oil leakage, be sure to remove the vinyl tape.
43-17
Stop Valve
Stop Valve
Stop valve adjustment procedure Reference dimension
Front chassis
Stop valve
Stopper (rear chassis)
(bolt)
(L.H, R.H)
Front chassis
Rear chassis
Reference dimension
23~27.5 mm Reference dimension
(0.9~1.1 in) 28~48 mm (1.1~1.9 in)
Stopper (bolt) length Clearance between machine body and stopper 115ZV43005
115ZV43004
Articulation angle ( ) 37 36 35
WARNING Clearance between machine body and 28 38 48
stopper (mm) (in) (1.102) (1.496) (1.890)
When the machine turns, the clearance in the articu- 23 25 27.5
Stopper (bolt) length (mm) (in)
lation area closes. As a result, people may be caught, (0.906) (0.984) (1.083)
leading to a severe accident. To prevent such an
accident, observe the following items strictly when *The target value should be the articulation angle "36",
adjusting the steering stopper. while not rolling machine.
- Stop the engine before starting adjustment of the
stopper bolt. - After adjustment, turn the steering wheel slowly at a
- When confirming the operation after setup, keep rate of 5 sec or more per turn, and confirm the clear-
proper distance from the articulation area of the ance between the machine body and the stopper.
machine.
- When adjustment is completed, tighten the lock nut
The stop valve works when the spool is pushed in 3 mm of the stopper (bolt).
(0.118 in).
: 90 N-m (9.2 kgf-m) (67 lb-ft)
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.
43-18
MEMO
52-1
115ZV-2 Function & Structure Brake Group

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
52-2
Function & Structure Brake Group
Brake System Outline
Brake System Outline

The brake system is the all-hydraulic type, and has two Service brake
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. 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
(Refer to "Hydraulic & Brake Circuit" page 92-4 and valve (22), and accumulated in accumulator (33) pro-
"Brake Circuit" page 92-5.) vided 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 pres-

sure
While the brake pedal is not pressed, the internal pres-
sure of the hydraulic tank is always applied on the brake
piston chamber, and there is a possibility that the brake
may drag.
To prevent the brake from dragging, the axle housing air

chamber is connected to the hydraulic tank air chamber
so that the pressure inside the axle housing becomes
equivalent to the pressure inside the hydraulic tank.
52-3
Brake Units Layout
Brake Units Layout

The brake system is the all-hydraulic type, and has two The service brake is the wet disc type. The parking
independent systems consisting of the front system and brake is the spring applied oil pressure released type.
the rear system for enhancing safety.
4 3 2 1
115V2E52001
1. Accumulator 4. Brake valve

2. Solenoid valve (for parking) 5. Parking brake
3. Solenoid valve (for auto-brake) 6. Unloader valve
52-4
Unloader Valve
Unloader Valve
(S/N 9001~9050)
To accumulator
6 To tank
B-B
22
24 To fan motor
7
21 23
B
20
8
10
1
19
9 A
Filter
3
18
17 5
Pilot port B
(accumulator 16 4
feedback port)
A-A 15
11 12
From pump
14 2
13 Fan motor port
Pump port A
Accumulator port
T 2
Fan motor port
Pilot port Tank port

(accumulator AC
feedback port)
Rc PP
Tank port
1/8
P
Pilot port Pump port
Accumulator port (accumulator
Hydraulic circuit diagram feedback port) Outline drawing
K115ZV52001
1. Body 9. Plug 17. Spring

2. Spring 10. Plug (gauge port) 18. Spring
3. Spool 11. Governor plunger 19. O-ring
4. O-ring 12. Spring 20. Plug
5. Plug 13. O-ring 21. Adjusting screw
6. Orifice 14. Plug 22. Lock nut
7. Orifice 15. Pilot valve 23. Packing
8. O-ring 16. Spring seat 24. Cap
52-5
Unloader Valve
(S/N 9051~)
To
accumulator
6 To tank
B-B To fan motor
21
22 20
8 7 25 B 10
1
26 19
9 18
17
A
3
16
Filter
4
15
5
12
2 B
Pilot port 11
(accumulator 13
feedback port) A-A From pump
A
Fan motor port
14 Accumulator port
Pump port T 2
Fan motor port

Pilot port AC
(accumulator Tank port
feedback port)
Rc PP
Tank port 1/8
P
Pilot port
Accumulator (accumulator Pump port
port feedback port)
Hydraulic circuit diagram K115ZV52002
1. Body 14. Plug

2. Spring 15. Pilot valve
3. Spool 16. Spring seat
4. O-ring 17. Spring
5. Plug 18. Spring
6. Orifice 19. O-ring
7. Orifice 20. Plug
8. O-ring 21. Adjusting screw
9. Plug 22. Lock nut
10. Plug (gauge port) 23.
11. Governor plunger 24.
12. Spring 25. Seat
13. O-ring 26. O-ring
52-6
Unloader Valve
The unloader valve controls the flow rate and the pres- Unloader valve operation
sure of the hydraulic oil sent from the pump to the accu-
mulator. Body (1) is equipped with ports (pump, fan
motor, accumulator, pilot and tank). While the unloader valve is not operating, spool (3) is
pushed back by spring (2) and the pump port to the fan
Spool (3) which opens and closes the pump port to the motor port is closed. Oil flowing from the pump port is
fan motor port, orifice (6) which regulates the flow rate sent to the accumulator port through orifice (6), and the
to the accumulator port with high priority, and the pres- pressure at the accumulator port increases accordingly.
sure governor mechanism which controls the pressure
on the accumulator port side are built in the unloader When an excess flow rate is generated, spool (3) moves
valve. 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 pres-
sure at the accumulator port starts to increase again
(cut-in pressure).
Setting OFF 11.80.5 MPa (1205 kgf/cm2) (1,70671 psi)

pressure ON 6.91.0 MPa (7010 kgf/cm2) (995142 psi)
52-7
Valve Unit
Valve Unit
4 Note
Loading line Unloader valve (PI)
pilot valve "Feed back" signal is
acquired from front
brake accumulator.
(PPI) (Z)
(Z2) (Z1)
(PA)
ACF (ACCF) (ACCR)
Unloader valve
(PARKING) (PI)
Wet type "feed back" sig-
parking brake (TA) nal.
(P)
Tank Pump port
(T) (from unloader
valve)
2 3 P=Pump supply
1 T=Tank circuit
PI=Pump feedback to unloader
(From ACCF circuit)
High pressure
ACCR=Accumulator circuit-rear
test ports
ACCF=Accumulator circuit-front
PPI=Pilot valve
85V2E52002
A B
ACCR
WARNING
P 3 4
A B
ACCF
To parking brake
ACF
PI Rc1/8
1
B
2 Injection Hazard
High pressure test ports contain accu-
P T mulator pressure [11.8 MPa (1,706 psi)]
B PA that can escape from these 2 plugs.
A Depress brake pedal 80~100 times to
Z2
T G1/4 completely discharge the brake accu-
mulators prior to removing these test
ACF T Z PPI TA Z1 plugs.
Rc1/8 G1/2 G1/4 G3/8 G3/8 G1/4 115V2U52002 135ZV52035
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
[3.90.5 MPa (405 kgf/cm2) (56971 psi)]
52-8
Valve Unit
Accumulator low pressure sensor
2
A 1 3
View A
1: Power (+)
2: Output (+)
3: Common
(V)
5
0 10 20 30 35 MPa
2
(102) (204) (306) (351) (kgf/cm )
(1422) (2844) (4351) (4991) (psi)
95V2E52095
52-9
Accumulator
Accumulator
7
2 4 1 3
13
10
12
11
9
6
95ZV52058
1. Body The accumulator holds a reserve of pressurized oil for

2. Hydraulic cap the brake circuit prevent disability of the brakes caused
3. Gas cap by a problem with the pump, etc. Two accumulators are
4. Piston provided in the service brake line. Nitrogen gas at 2.94
5. V-O-ring MPa (30 kgf/cm2) (427 psi) is charged in the gas cham-
6. Backup ring ber.
7. Wear ring
8. O-ring One accumulator of the same type is provided also in
9. Backup ring the dry type parking brake line, locate in the front chas-
10. Gas valve sis.
11. Gas valve O-ring
12. Gas valve guard
13. Bolt Accumulator specifications
Maximum operating pressure MPa 11.80.5

(kgf/cm2) (psi) (1205) (1,70671)
Nitrogen gas charging pressure MPa 2.940.1
(kgf/cm2) (psi) (301) (42714)
Nitrogen gas capacity L (gal) 3.0 (0.793)
52-10
Brake Valve
Brake Valve
B 37 38 36 35 39 40
44 46
35
A
31 42 41 43 45 47 48 49 50 52
28
55 A-A
29 34
17 54
53
16
30
15 51
A
18
14 32
Pilot port
19
20
33
23
26
21
25
22 Rear
brake port 24 Tank port
Accumulator
port
Universal joint assembly
10
2
12
Front brake 5
11 port
2
13 Accumulator
port 5
3 Pressure sensor port
B 4
1
8 B-B
9 7 6 115V2E52009
1. Body 12. Body 23. Spring 34. Pedal 45. Boot

2. Spool 13. Spring 24. Case 35. Roller 46. Snap ring
3. Spring seat 14. Cover 25. Snap ring 36. Spacer 47. Shaft
4. Snap ring 15. Oil seal 26. Spring 37. Pedal pin 48. Bolt
5. Plunger 16. Plate 27. 38. L-pin 49. Washer
6. Spring 17. C-ring 28. Seat 39. Washer 50. Nut
7. Plug 18. Spool input 29. Dust cover 40. Pin 51. Plate
8. O-ring 19. Spring seat 30. Mounting plate 41. Shaft 52. Spring
9. C-ring 20. Pilot piston 31. Pedal bush 42. Spacer 53. Screw
10. Orifice 21. Case 32. Bolt 43. Joint 54. Nut
11. O-ring 22. Spring 33. Spring washer 44. Pin 55. Pedal cover
52-11
Brake Valve
Brake valve performance chart

N
(kgf)
(lbf) 338 (34.5)
(75)
300
(30.6)
Pedal pressing force (F)
(67)
200
(20.4)
162(16.5)
(45) (36.4)
100 93.3(9.5)(21)
(10.2)
(22)
76.1
(7.76)
(17) 67.1(6.84)
(15)
( )
0 3.9 5 10 15 18.5 19
Pedal stroke
MPa
(kgf/cm2)
(psi)
4.90
(50.0)
Output oil pressure (Brake port)
4 (711)
(40)
(580)
2
(20)
(290)
1.57
(16.0)
(229)
0.36
(3.7)
(52)
( )
0 3.9 5 10 15 18.5 19
Pedal stroke
MPa
(kgf/cm2)
(psi)
4.94
(50.4)
4 (716)
(41)
Output oil pressure (Brake port)
(580)
2
(20)
(290)
MPa
0 (kgf/cm2)
0 0.41 2 4 5.35 (psi)
(4.2) (20) (41) (54)
(59) (290) (580) (768)
Pilot oil pressure (pilot port input)
K115V2U52006
52-12
Brake Valve
Brake valve outline While the valve is not operating
The brake valve is integrated into the pedal and con- B

verts the pump oil pressure into the pressure corre-
sponding 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 35
depressed, the movement of right side pedal is trans-
mitted 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. 18
Pilot port
23 20
26
22 B1 Rear brake
Accumulator A1
2
13 5
B2 Front brake
Accumulator A2 2
5
6 B
T Tank
Pressure sensor port

B-B 95V2E52003
52-13
Brake Valve
Between spool input (18) and spools (2) in the brake While the valve is operating
valve, springs (22)(23) which convert pedal pressing
force into output oil pressure are installed. When the brake pedal is pressed, spool input (18) and
pilot piston (20) are pushed by way of roller (35).
In addition, two spools (2) are installed for series in the
center of the main body of the brake valve. Plungers (5) Spool input (18) and pilot piston (20) lets each spool (2)
which transmit the control oil pressure to spool as the drop down by way of springs (22)(23). When spools (2)
hydraulic reactive force are built in each spool. are pushed down, at first the passage from out-port B1,
B2, and pressure sensor port to the tank port are shut
While the valve is not operating, each spool is returned down.
to the non-operation position by springs (6)(13).
When spools (2) are pushed down further, the passages
As a result, the passages from out-ports B1, B2, and from in-ports A1, A2 to out-ports B1, B2 are opened and
pressure sensor port to tank port are opened, and the pressure oil from the accumulator is sent to the brake
pressure inside the brake piston chamber becomes piston chamber to apply the brake.
equivalent to the pressure in the tank.
Pressure oil of in-ports A1, A2 side act on plunger (5)
In addition, oil sent from the pump is stored in the accu- inside the each spool (2) through the orifices and works
mulator, and sent to the in-ports A1 and A2. But the pas- as the hydraulic reactive force to return spools (2)
sages from in-ports A1, A2 to out-ports B1, B2 and upward.
pressure sensor port are shut down by each spool (2),
and high pressure oil from the accumulator is main- When the sum of hydraulic reactive force and spring
tained. 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). Com-
pressed 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.
52-14
Service Brake
Service Brake
Piston stroke adjuster Service brake operation
15 16 13
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.
7 6 8 9
Wheel hub 14
When the brake valves are depressed, the pressure oil
Brake oil in the accumulator enters the disc brake piston chamber
inlet port
for the front and rear wheels, pushes the piston, and
generates braking power.
While the brake pedal is not pressed, the internal pres-

sure 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.
12
Axle housing
1
5 4 2 3 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.
52-15
Service Brake
Service brake friction disc
6.8 0.1 mm (0.268 0.004 in)

5 0.15 mm (0.197 0.006 in)
430 mm (16.9 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 anti-
chatter mixture for at least 30 minutes prior to installa-
tion.
52-16
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, measure-
Spring pins ment of wear is disabled.
Therefore, this steel plate should be installed correctly

with regard to the tooth location so that the teeth cut-off
Friction disc
section is located (or indexed) as shown in the figure.
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. Care-
fully install the steel plates.
The steel plate shown in the upper figure should be

installed on the piston side. As to the installation direc-
tion, this steel plate can be installed either side inward
as there is no inward or outward direction.
52-17
Service Brake
Service brake piston
Upper side
A
3 5
1
4
4
3
2 2
6 6
A 4
A-A
3
6 115ZV52006
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 for prevention of close contact between piston
and internal gear hub
6. Cooling oil hole
52-18
Service Brake
Service brake pedal stroke adjust- Fig. 2

ing mechanism
1.8 mm
(0.07 in)
Brake stroke
adjusting
mechanism
115ZV52030
115ZV52007
When the brake disc wears and the brake piston is
shifted by approximately 1.8 mm (0.07 in) or more, the
This shows the automatic adjuster function which sleeve is gradually pulled out to the left by the socket
always offers a constant pedal stroke as the brake disc bolt by the amount corresponding to the wear. At that
wears. 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 Approx.

Tolerance ring 1.8 mm
1.8 mm
(0.07 in) (0.07 in)
Socket bolt
Bushing
115ZV52028
115ZV52031
When the brake disk is not worn and the hydraulic pres-
sure is not applied on the brake piston, the piston is When the brake pedal is released and the hydraulic
pulled back by the return spring. At that time, there is pressure is not applied on the brake piston, the brake
clearance of approximately 1.8 mm (0.07 in) between piston is pulled back by the return spring by approxi-
the sleeve and the socket bolt. mately 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 regu-
lated by the tolerance ring (spring). The sleeve is not
moved by the return spring force of the piston.
52-19
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 elas-
tic wave sheet steel.
Installation procedure
Boss (bushing) Tolerance ring
Shaft (sleeve)
95ZV52021
- Attach the tolerance ring to the boss (bushing).
- Press-fit the shaft (sleeve).

52-20
Service Brake
Brake circuit air bleeding proce-

dure WARNING
Unexpected movement of the machine may cause a
severe accident. To prevent such an accident, take
Valve assembly the following safety measures when performing air
(Brake manifold block assembly)
bleeding with the engine running.
- 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 acci-
Solenoid valve dent.
for auto brake
Solenoid - When moving up the boom, install a safety column
valve for under the boom.
parking
- 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 unsatis-
factory 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,
Auto brake solenoid valve shut off the engine.
3. Turn the parking brake solenoid valve release knob

counterclockwise, then, back to neutral, five times
at five-second intervals between each turn.
Position the knob back to the normal position when
finished.
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.
5. Press the auto-brake solenoid valve release button

Solenoid valve five times at five-second intervals between each
for auto-brake
Reducing valve turn. Position the knob back to the normal position
when finished.
Button
Solenoid valve 6. Close the bleeder nipple and remove the vinyl tube
pressure nut from the brake valve.
(diameter:
approximately
4 mm)
115V2E52002
52-21
Service Brake
Bleeding air from brake pipes and axle Bleeding air from parking brake housing
housing hubs
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 pro-

1. Connect a vinyl tube to the air bleeder nipple provided in the axle housing, and place an oil can for
vided in the axle housing, and place an oil can for hydraulic oil recovery.
hydraulic oil recovery. (The air bleeder nipple is equivalent to the one pro-
(The air bleeder nipple is equivalent to the one provided in the brake valve).
vided in the brake valve).
2. Loosen the air bleeder nipple a little. Turn the park
2. Loosen the air bleeder nipple a little. Press and brake solenoid valve release knob counterclock-
hold the left brake pedal until oil containing no air wise until oil containing no air comes from the air
comes from the air bleeder nipple. After that, bleeder nipple. After that, tighten the air bleeder
tighten the air bleeder nipple. nipple.
Perform this operation for each of the four wheels. : Air bleeder nipple
: Air bleeder nipple 9 N-m (0.9 kgf-m) (6.5 lb-ft)
9 N-m (0.9 kgf-m) (6.5 lb-ft) Position this release knob to the normal position
when finished.
52-22
Parking Brake
Parking Brake
(S/N 9001~9050)
2nd Propeller shaft
14 10 9 6 4 5
13
1
7
17 15
8
3 2
19
21
12
11
18
16
20
Front differential assy
115V2E52003
1. Housing 11. Friction disc 21. Spring

2. Piston 12. Separation disc
3. Housing 13. Flange nut
4. Spring 14. Nut
5. Spring 15. Gear
6. Head pin 16. Flange
7. Bolt 17. Oil seal (single lip)
8. Straight pin 18. Oil seal
9. O-ring 19. Pin
10. Back-up ring 20. Spring pin
52-23
Parking Brake
(S/N 9051~9100)
2nd Propeller shaft

9 4 6
1 5
14 2
19
12
8
3
11
16 10
13
18
17
15
K115V2J52003
1. Housing 11. Separation disc

2. Piston 12. Gear
3. Housing 13. Housing
4. Spring 14. Oil seal (single lip)
5. Spring 15. Oil seal
6. Head pin 16. Pin
7. Bolt 17. Spring pin
8. Straight pin 18. Spring
9. O-ring 19. Oil seal (double lip)
10. Friction disc
52-24
Parking Brake
(S/N 9101~)
2nd Propeller shaft
6 9 4
1 5
14 2
19
12
8
3
11
16 10
13
18
17
15
K115V2J52004
1. Housing 11. Separation disc

2. Piston 12. Gear
3. Housing 13. Housing
4. Spring 14. Oil seal (single lip)
5. Spring 15. Oil seal
6. Housing 16. Pin
7. Bolt 17. Spring pin
8. Straight pin 18. Spring
9. O-ring 19. Oil seal (double lip)
10. Friction disc
52-25
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 ON OFF

Solenoid valve Power OFF Power ON
Brake piston chamber Oil discharge Oil charge
Parking brake Braking Released
Turning the starter key off works the same as turning the
parking switch "ON".
(S/N 9001~9050)
(0.197~0.236 in)
14 4 5
13
5~6 mm
7
Brake oil
115V2U52005
52-26
Parking Brake
(S/N 9051~9100)
A
1
Brake oil
7
K115V2J52004
(S/N 9101~)
5
1
4
7
Brake oil
K115V2U52005
52-27
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

26.41.3 mm (1.0390.051 in) (S/N 9001~9100)
42.41.3 mm (1.6690.051 in) (S/N 9101~)
With completely worn out discs, and plates this mea-

sures
22.41.3 mm (0.8810.051 in) (S/N 9001~9100)
38.41.3 mm (1.5120.051 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 mea-

surement.
52-28
Parking Brake
Parking brake friction disc

Seven friction plates and seven steel plates are assem-
bled in the parking brake disc.
7.40.1 mm (0.2910.004 in)
5.00.1 mm (0.1970.004 in)

1
0.82 mm (0.032 in) or more

1.0 mm (0.039 in)
330 (13.0 in)

2
220 (8.7 in) 5.7 mm (0.224 in)

95V2E52009
1. Core plate
2. Lining (paper material)
Parking brake steel plate
5.00.1 mm (0.1970.004 in)

m
i n) 5 m
6
(14 .D 3
.4
P.C
394 (15.5 in)

220 (8.7 in)
Flatness: 0.5 mm (0.020 in) or less

95V2E52010
52-29
Parking Brake
Parking brake solenoid valve

Spring chamber (brake actuator)
B Solenoid Knob
Reducing P
valve
Manual release
T (counterclockwise
Spool rotation)
Seat Seat
face A face B Tank B
P T
Hydraulic circuit diagram 85V2E52007
Solenoid valve operation Solenoid valve specifications
Voltage DC 24 V
Current 0.92 A
Amp Resistance 26.2
a
0 a
Volt
Varistor
95ZV42079
While the parking switch is ON (that is, while the power

is not supplied to the solenoid), the seat face A is closed
and the seat face B is open. As a result, the spring
chamber port is connected to the tank, and the parking
brake is applied.
When the parking switch is set to OFF (that is, when the
power is supplied to the solenoid), the spool is pushed
to the left, the seat face A is open, and the seat face B is
closed. As a result, the oil from the reducing valve
enters the spring chamber, and the parking brake is
released.
Note
The varistor (variable resistor) is used for the solenoid
coil to protect the circuit.
52-30
Parking Brake Manual Release

If the park brake cannot be released due to an electrical (S/N 9001~9050)
problem, such as a failed park brake solenoid valve coil
or electrical circuit, perform the following operation.
14
13
WARNING
Sudden accidental movement of the machine could
1
result in serious injury or death.
Before manually operating the parking brake sole-
7
noid:
- 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.
WARNING
If the flange nuts are not returned to the original posi-
tion, the parking brake is disabled and may result in a 115V2E52005
severe accident.
Make sure to return the flange nuts to the original 1. Remove each of two places of lock nuts (14) from
position after manually releasing the parking brake. 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 park-
ing brake.
52-31
(S/N 9051~)
Top
Rubber cap
Hose band
A
7
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 park-
ing brake.
52-32
Brake Circuit Check Valve
Brake Circuit Check Valve
Poppet
(P) (T)
(TA)
Pump supply Seat face
(PARKING)
through reducing A (ACCR) (ACCF)
valve (PA)
(Z1) (Z2)
(ACF)
(Z) (PPI)
B (ACCF)
Reducing Accumulator
valve Valve assembly
P=Pump supply
T=Tank circuit
PI=Pump feedback to unloader
A B (from ACCF circuit)
ACCR=Accumulator circuit-rear
ACCF=Accumulator circuit-front
PPI=Pilot valve circuit 85V2E52010
The pressure oil fed from the pump pushes down the
poppet, opens the seat face, and flows into the accumu-
lator 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 accumu-
lator 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 accumula-

tor circuit and another for the rear.
52-33
Auto Brake
Auto Brake
When the traveling direction is switched over between Auto brake operation set value
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. 1. When the traveling direction is switched over
When the machine speed is too high, the auto brake is between forward and reverse at a machine speed
applied also to prevent problems caused by excess of 12 km/h (7.5 mph) or more while the shift lever is
speed in the engine and the transmission (over speed- set to position A.
ing).
2. When the machine speed is too high in each speed
range. Actual speed will vary with tire size.
Auto brake circuit Set value km/h (mph)

Speed range
F R
Approximately 13 Approximately 12
Shown in the "released" position 1st
(8.125) (7.5)
To rear To front
service brake service brake Approximately 22 Approximately 24
2nd
(13.75) (15.0)
23 Approximately 36 Approximately 36
3rd
(22.5) (22.5)
Approximately 39
4th/A
(24.375)
From unloader
29
valve (Pump)
MCU
signal
37 1.6 MPa
(16 kgf/cm2)
(230 psi)
From unloader valve
115V2E52012
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.
52-34
Auto Brake
Reducing valve (for Autobrake circuit)
Plunger Orifice 1
Orifice 2
B
Pilot oil circuit Seat face A
Z
From unloader
valve Brake valve
P C B
Tank Seat face B

P
T B
Spool Hydraulic circuit diagram
Reducing valve
(for autobrake)
Solenoid valve
Passage Y (for autobrake)
115V2U52004
This reducing valve provides pilot oil pressure to oper- As a result, the pressure in chamber C decreases, then
ate the auto brake. the plunger moves down and closes passage Z so that
the pressure on the pilot oil circuit side does not exceed
The oil fed from the unloader valve circuit flows into the the set pressure.
pilot oil circuit by way of passage Z. The oil pressure in
the pilot oil circuit is applied also on chamber C by way When the oil pressure on the pilot oil circuit side
of orifice 1. becomes less than the set pressure, the ball moves up
and the pressure at chamber C becomes equivalent to
When the oil pressure in the pilot oil circuit is at or the pressure on the pilot oil circuit side (B). As a result,
above the set pressure, the oil in chamber C unseats the plunger moves up by a spring, opens the passage Z,
the ball by way of orifice 2, and escapes to the tank by then introduces the unloader pressure to the pilot oil cir-
way of passage Y. cuit side so that the pressure is maintained at the speci-
fied value.
52-35
Auto Brake
When the solenoid valve for auto brake is energized Solenoid valve (for Autobrake cir-
and magnetized, this pressurized oil is supplied to the
brake valve through the solenoid valve for auto brake cuit)
and brake is applied.
When the auto brake actuation signal is not given by the
Set pressure MCU (that is, when the power is not supplied to the
1.3 MPa (13 kgf/cm2) (185 psi) 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 sole-
noid), 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.
Voltage DC 24 V
Current 0.92 A
Resistance 26.2
Amp
a
0 a
Volt
Varistor
95ZV42079
Note
The varistor (variable resistor) is used for the solenoid
coil to protect the circuit.
52-36
Pressure Sensor (for stop lamp and declutch)
Pressure sensor (for stop lamp)
Pressure sensor for stop lamp

and declutch
Left brake valve
115V2E52007
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.
52-37
2
A 1 3
View A
1: Power (+)
2: Output (+)
3: Common
85V2E52012
(V)
5
0 1 2 3 4 5 MPa
(10) (20) (30) (40) (50) (kgf/cm2)
(140) (285) (435) (570) (715) (psi)
65V2E52003
Pressure sensor (for Declutch)

Refer to "Electrical Group: Adjustable declutch preset
switch".
52-38
MEMO
53-1
115ZV-2 Check & Adjustment Brake Group
Check & Adjustment

Brake Group
Brake Circuit Oil Pressure ....................................... 53-2

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

Unloader valve setting pressure
WARNING
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. (PPI) (Z)
(Z2)
moving. (Z1)
(PA)
- Determine the signals between the service men.
ACF (ACCF) (ACCR)
(PARKING)
(TA)
(T) (P)
ACF port
Valve assembly
85V2E53001
WARNING
Injection Hazard
Depress brake pedal 80~100 times
to completely discharge the brake
accumulators prior to removing
these test plugs.
135ZV52035
Brake line main pressure is regulated by the unloader

valve.
53-3
Unloader valve setting pressure measure- Unloader valve setting pressure adjustment
ment
(S/N 9001~9050)
24
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
Cut-out 11.80.5 MPa (1205 kgf/cm2) (1,70671 psi) Pump port

2
Cut-in 6.91.0 MPa (7010 kgf/cm ) (995142 psi) Unloader valve
70ZV53001
Measurement procedure (S/N 9051~)
1. Lower the boom to the lowest limit, and tilt the 21 22

bucket down to the ground.
Fan motor port
Then set the parking brake switch to the "ON" posi-
tion.
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.
Pump port
: Port plug: 11.3 N-m (1.15 kgf-m) (8.3 lb-ft)
Unloader valve
K115ZV53002
4. Start the engine, and keep the speed at low idle.
Measure and record the pressure when the pointer
of the pressure gauge stops rising (cut-out pres- 1. Remove cap nut (24) and loosen lock nut (22).
sure).
2. Adjust the pressure by adjusting screw (21).
5. Keep the engine at low idle, and repeatedly Turn the screw clockwise to raise the pressure.
depress and release the brake pedal to reduce the
accumulator pressure. Measure and record the Note
pressure when the pointer of the pressure gauge In a case that the "ON" or "OFF" pressure does not
stops and then starts rising again (cut-in pressure). match the standard setting pressure, set the "ON" (cut-
in) pressure to the standard setting pressure.
Note
If the pressure gauge is not available, refer to the pres- : Lock nut (22): 16.7 N-m (1.7 kgf-m) (12.3 lb-ft)
sure value displayed on the MODM. : Cap nut (24): 78.5 N-m (8.0 kgf-m) (57.86 lb-ft)
Refer to "Brake Main pressure 1" "Brake Main pressure
2" of MODM "Input/Output Monitor" page 62-85 and 92-
45 for information.
53-4
Check & Adjustment Brake Group
Brake valve oil pressure Measurement procedure
1. Check to be sure the brake valve is fully released.
2. Press down the brake pedal to check that the oil

pressure rises in proportion to the pedal angle.
le
ng
Force
la
3. Release the brake pedal to check that the oil pres-

da
19
Pe
sure drops to zero in proportion to the pedal angle.

In addition, visually check for brake oil leakage.
15
0
m
Note
m
45
If the pressure gauge is not available, refer to the pres-

sure value displayed on the MODM.
Refer to "Brake Pedal Output Oil Pressure" of MODM
"Input/Output Monitor" page 62-85 and 92-45 for infor-
mation.
85V2E53002
Brake valve oil pressure measurement
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 posi-
tion.
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
53-5
Brake valve performance
MPa
(kgf/cm2)
(psi)
4.90
Output oil pressure (brake port)
(50.0)
4 (711)
(40)
(580)
2
(20)
(290)
1.57
(16.0)
(229)
0.36
(3.7)
(52)
( )
0 3.9 5 10 15 18.5 19
Pedal stroke
K115V2U53001
Refer to the curve shown in the above figure.
When the measured value does not match the per-

formance curve, check the following points.

Malfunctioning brake valve Repair or replacement
Brake line oil pressure low
Check and repair
(Pump, reducing valve malfunction)
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.
53-6
Service Brake
Service Brake
Service brake performance check Method 2
If no test course available as described "Method 1",

Method 1 carry out the following method.
WARNING IMPORTANT
Separate the test course by using rope etc. and keep The following method is easy and simple, however it
persons away from the test course. In addition, post is not an accurate way, because the braking force
persons in several positions near the course to warn and rim-pull may vary on each machine. Confirm
others and avoid an accident while checking the ser- engine & transmission performance via using a stall
vice brake performance. test. See page 03-3.
Reconfirm the brake performance by the method 1 as
soon as possible.
Condition
1. Test course WARNING

Level, straight, dry and the paved ground.
2. Run the machine and depress the brake pedal at accident resulting in injury or death.
35 km/h (22 mph). Before starting brake performance check, be sure to
Measure and record the braking distance. observe the following items:
- Place the machine on level ground.
- Check that there is enough clearance for brake
Standard measurement value performance check around the machine.
- During performance check, prohibit any person to
Braking distance walking near the machine.
20 m (22 1/4 yard) or shorter
1. Lower the boom to the lowest limit, and roll back
the bucket fully until the bucket contacts to the stop-
Possible causes of extremely long braking distance per.
Possible cause Solution 2. Set the parking brake switch to the "OFF" position.
Low brake line pressure Check and repair
Friction plate wear Check and repair 3. Set the declutch switch to OFF, and then depress
Brake valve malfunction Check and repair the brake pedal all the way to the floor.
Note 4. Set the shift lever to 2nd reverse speed.

The brake performance check condition and standard
measurement value are based on the law and the regu- 5. Gradually increase the engine speed. The machine
lation in Japan. should not move at the maximum engine speed.
When checking the service brake performance, follow
the law and/or local regulation in your country, state, or Possible cause of machine moving during brake
province. performance check.

Low brake line pressure Check and repair
Friction plate wear Check and repair
Brake valve malfunction Check and repair
53-7
Service Brake
Service brake friction plate wear measurement
A
Air bleeder nipple 200 mm
slide caliper
Slide
A caliper
Steel plate Brake

backing
plate
Friction plate
115ZV53002
IMPORTANT
After inserting calipers, do not rotate the wheels. If
Top Internal gear
Oil inlet port the wheels are rotated, the calipers may be caught
about
2.5 Spring pin and broken by the reduction gear. In this case, the
Spring pin
reduction gear must be disassembled.
Outer steel
Inner steel plate
Measurement procedure
plate
Turn the planetary gear so that the oil supply plug is
115ZV53003 positioned at 2.5 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).
WARNING Insert calipers to the inner steel plate to measure the

dimension A.
Unexpected movement of machine could cause seri-
ous injury or death. To prevent such an accident,
Note
observe the following items before checking the
During measurement, be sure the service brake is
brake friction plate wear:
applied.
The wear limit for dimension A is 35.2 mm (1.386 in).
- Stop the engine.
Note that dimension A is 40.4 mm (1.590 in) when the
- Determine the signals between the persons related
plate is new and unused.
to this work for engine starting to prevent an acci-
dent.
Note
- Prohibit any person from walking into the danger-
To aid quick measurement on the front axle-raise the
ous area.
front of the machine so the front tires clear the ground
by about 25 mm (1 in). This allows easy rotation of the
wheel to align the gear teeth.
53-8
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

A (Dimension A is correct) remove all four bolts.
B
Wheel hub 5. After finishing the installation work, bleed air com-
pletely from the brake line.
Brake piston
115V2E53002
53-9
Parking Brake
Parking Brake
Parking brake performance check Method 2
If no test course available as described "Method 1",

Method 1 carry out the following method.
WARNING IMPORTANT
Unexpected movement of the machine may cause an The following method is easy and simple, however it
accident resulting in injury or death. is not an accurate way, because the braking force
Before starting brake performance check, be sure to and rim-pull may vary on each machine.
observe the following items: Confirm engine & transmission performance via stall
- Check that there is enough clearance for brake test. See page 03-3. Reconfirm the brake perfor-
performance check around the machine. mance by the method 1 as soon as possible.
walking near the machine.
WARNING
Condition accident resulting in injury or death.
Before starting brake performance check, be sure to
1. Test course observe the following items:
1/5 slope (Approx. 11 19') - Place the machine on level ground.
- Check that there is enough clearance for brake
2. Bucket empty performance check around the machine.
3. Parking switch ON walking near the machine.
1. Set the parking brake switch to the "ON" position.

2. Disconnect the cable connector of parking brake
No movement on 1/5 slope solenoid valve.
3. Set the parking brake switch to the OFF position.

Possible cause of machine moving during brake
performance check 4. Place the shift lever to the 3rd reverse position.
Possible cause Solution 5. Gradually increase the engine speed. The machine
Wear or breakage of brake disc Check and repair should not move at the maximum speed.
Parking brake switch malfunction Check and repair
Parking brake solenoid valve malfunction Check and repair
IMPORTANT
Note If the machine begins to move with the parking brake
The brake performance check condition and standard applied, the brake discs are worn.
measurement value are based on the law and the regu- At the completion of parking brake test, be sure to
lation in Japan. connect the connector of electrical line to the sole-
When checking the service brake performance, follow noid valve again.
the law and/or local regulation in your country, state, or
province. 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
53-10
MEMO
62-1
115ZV-2 Function & Structure Electrical Group

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 .... 62-35
Instrument Panel and Switch................................... 62-60
MODM ..................................................................... 62-65
Electrical Detent Circuit ........................................... 62-104
Diode ....................................................................... 62-110
62-2
Function & Structure Electrical Group
How to Use Electrical Wiring Diagram
How to Use Electrical Wiring Diagram

Example
10 6 5 1
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
21
40 39 32 31
40 36 35 31
WIDTH LAMP RIDE CONTROL NEUTRAL BACK LAMP HORN RELAY MCU FAULT
RELAY RELAY RELAY RELAY RELAY
A520 RB RB LgSb YV RL SbP RL LB GW GL B LgW

C201 B611 H133 E214 H610 E220 H128 E219 H127 B501 E218
H129
R R Br Lg G L R Lg G G LgW L
D114 D114 D112 D103 D102 D002 D111 D103 D107 D107 A405 D001
2 1 2 1 2 1 2 1 2 1 2 1
(BLACK) (BLACK) (BLACK) (BLACK) (BLACK) (BLUE)
F5 F0 F6 F7 F8 F9
(1)
(2)
H1
10 6 5 1
D507 A306 F306 A905 A503 D112 E802 E803

OR RO RW RLg YB Br GL GO
C206 A302 F303 E312 E523 G302 E804

PB RBr RY WO SbY BrB WY
C205 F504 F704 F804 E109 G402 A105 E522

PL RB RL GW W BrW WP BrL
E501 C801 A005 B304 E520 E108 F004 E601

WL RG RGy LgG LgL W LgSb BrR
40 36 35 31
(3) 95ZV62001
The address method is used for electrical wiring dia- Example 3

grams. For this method, a symbol is attached to each Checking the other connector terminal where F704 RL
connector and connector terminal in order to easily (item (3)) is connected:
locate the other terminal where the other end of the
cable is connected. 1. F704
Shows that the terminal is connected to the 4th ter-
Example 1 minal of the F7 connector.
Symbol under (or above) connector, such as F6: Check the description in the 4th terminal of the F7
Shows the address of the connector. connector (F704), it shows that the F704 terminal is
connected to H128. This means that the 4th termi-
Example 2 nal of the F7 connector is connected to the 28th ter-
Symbol at the multi-terminal connector, such as 1 and minal of the H1 connector.
10: 2. RL
Shows the terminal number and the numbering direc- Shows the color of the wire "RL" represents that the
tion. insulation color is red, and "L" represents a blue
stripe is on the red insulation.
62-3
Utilisation des schmas des cblages lectriques (FRANAIS)
Utilisation des schmas des cblages lectriques

(FRANAIS)
Exemple
10 6 5 1
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
21
40 39 32 31
40 36 35 31
Relais de la lampe Relais du Relais de la lampe Relais de dfaillance

d cartement contrle de marche Relais neutre arrire Relais du klaxon du contrleur

C201 B611 H133 E214 H610 E220 H128 E219 H127 B501 E218
H129
D114 D114 D112 D103 D102 D002 D111 D103 D107 D107 A405 D001
2 1 2 1 2 1 2 1 2 1 2 1
(Noir) (Noir) (Noir) (Noir) (Noir) (Blue)
F5 F0 F6 F7 F8 F9
(1)
(2)
H1
10 6 5 1
D507 A306 F306 A905 A503 D112 E802 E803

C206 A302 F303 E312 E523 G302 E804

C205 F504 F704 F804 E109 G402 A105 E522

E501 C801 A005 B304 E520 E108 F004 E601

40 36 35 31
(3) 95ZV62001
Les schmas des cblages lectriques sont bass sur Exemple 3

la mthode de ladressage. Suivant cette mthode, un Contrle de la borne du connecteur laquelle F704 RL
symbole correspond chaque connecteur et chaque (point (3)) est connecte:
borne du connecteur de manire localiser facilement
la borne de connection de lautre extrmit du cble. 1. F704
Indique que la borne est connecte la 4me
Exemple 1 borne du connecteur F7.
Symbole au-dessous (ou au-dessus) du connecteur, Contrlez la description de la 4me borne du con-
comme F6: necteur F7 (F704), elle indique que la borne F704
Il indique ladresse du connecteur. est connecte H128. Ceci signifie que la 4me
borne du connecteur F7 est connecte la 28me
Exemple 2 borne du connecteur H1.
Symbole sur le connecteur multibornes, comme 1 et 10: 2. RL
Il indique le numro de la borne et le sens de la Indique la couleur du fil. RL signifie que la couleur
numrotation. de lisolation est rouge, et L que la raie bleu est
sur lisolation rouge.
62-4
Verwendung des elektrischen Schaltplans (DEUTSCH)
Verwendung des elektrischen Schaltplans (DEUTSCH)

Beispiel
10 6 5 1
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
21
40 39 32 31
40 36 35 31
Breitenleuchtenrelais Fahrtsteuerrelais Neutrales Relais Rckleuchtenrelais Hupenrelais Reglerfehlerrelais

C201 B611 H133 E214 H610 E220 H128 E219 H127 B501 E218
H129
D114 D114 D112 D103 D102 D002 D111 D103 D107 D107 A405 D001
2 1 2 1 2 1 2 1 2 1 2 1
(Schwarz) (Schwarz) (Schwarz) (Schwarz) (Schwarz) (Blau)
F5 F0 F6 F7 F8 F9
(1)
(2)
H1
10 6 5 1
D507 A306 F306 A905 A503 D112 E802 E803

C206 A302 F303 E312 E523 G302 E804

C205 F504 F704 F804 E109 G402 A105 E522

E501 C801 A005 B304 E520 E108 F004 E601

40 36 35 31
(3) 95ZV62001
Fr den elektrischen Schaltplan wird die Adressenmeth- Beispiel 3

ode verwendet. Damit wird jeder Steckvorrichtung und berprfung der anderen Steckvorrichtungsklemme, wo
jeder Anschluklemme ein Symbol zugeordnet, damit F704 RL (Artikel (3)) angeschlossen ist:
die Klemme, an die das andere Ende des Kabels ange-
schlossen werden mu, leicht gefunden werden kann. 1. F704
Zeigt, da die Klemme an die vierte Klemme der
Beispiel 1 F7-Steckvorrichtung angeschlossen ist.
Symbol unterhalb (oder oberhalb) der Steckvorrichtung, berprfen Sie die Beschreibung in der vierten
wie z. B. F6: Klemme des F7-Steckvorrichtung (F704). Zie gibt
Zeigt die Adresse der Steckvorrichtung an. an, da die Steckvorrichtung F704 an H128 ange-
schlossen ist. Dies bedeutet, da die vierte
Beispiel 2 Klemme der F7-Steckvorrichtung an die 28.
Symbol an der Mehrklemmen- Anschlustelle, wie z. B. Klemme der H1-Steckvorrichtung angeschlossen ist.
1 und 10: 2. RL
Zeigt die Klemmennummer und die Zhlrichtung an. Zeigt die Farbe des Kabels an. RL bedeutet, da
der lsolierdraht rot ist, und L bedeutet, da sich
auf dem roten lsoliermaterial ein blauer Streifen
befindet.
62-5
Modalit di utilizzo dello schema dei collegamenti elettrici (ITALIANO)
Modalit di utilizzo dello schema dei collegamenti elettrici

(ITALIANO)
Esempio
10 6 5 1
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
21
40 39 32 31
40 36 35 31
Rel di larghezza Rel di controllo Rel della lampada Rel del controller
della lampada della guida Rel neutro posteriore Rel del clacson d errore

C201 B611 H133 E214 H610 E220 H128 E219 H127 B501 E218
H129
D114 D114 D112 D103 D102 D002 D111 D103 D107 D107 A405 D001
2 1 2 1 2 1 2 1 2 1 2 1
(Nero) (Nero) (Nero) (Nero) (Nero) (Blu)
F5 F0 F6 F7 F8 F9
(1)
(2)
H1
10 6 5 1
D507 A306 F306 A905 A503 D112 E802 E803

C206 A302 F303 E312 E523 G302 E804

C205 F504 F704 F804 E109 G402 A105 E522

E501 C801 A005 B304 E520 E108 F004 E601

40 36 35 31
(3) 95ZV62001
Per gli schemi elettrici si utilizza il metodo degli indirizzi, Esempio 3

in base al quale a ciascun connettore e a ogni suo con- verifica del contatto dellaltro connettore cui collegato
tatto viene associato un simbolo che permette di identifi- F704 RL (elemento (3)):
care agevolmente il contatto cui collegata laltra
estremit del cavo. 1. F704
Indica che il terminale collegato al contatto n. 4
Esempio 1 del connettore F7.
simbolo al di sopra o al di sotto del connettore, ad Verificare la descrizione del contatto n.4 del con-
esempio F6: nettore F7 (F704): essa mostra che il contatto F704
Mostra lindirizzo del connettore. collegato a H128. Ci indica che il contatto n.4
del connettore F7 collegato al contatto n. 28 del
Esempio 2 connettore H1.
simbolo presso un connettore a pi contatti, ad esempio 2. RL
1 e 10: Indica il colore del cavo: RL significa che il colore
Mostra il numero del contatto e il senso di numerazione. dellisolante rosso, e L rappresenta che una
linea blu presente sullisolazione rossa.
62-6
Cmo utilizar un Diagrama de Alambrado Elctrico (ESPAOL)
Cmo utilizar un Diagrama de Alambrado Elctrico

(ESPAOL)
Ejemplo
10 6 5 1
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
21
40 39 32 31
40 36 35 31
Rel de la lmpara Rel de control Rel de la lmpara Rel de fallos

ancha de recorrido Rel neutro trasera Rel de la bocina del controlador

C201 B611 H133 E214 H610 E220 H128 E219 H127 B501 E218
H129
D114 D114 D112 D103 D102 D002 D111 D103 D107 D107 A405 D001
2 1 2 1 2 1 2 1 2 1 2 1
(Negro) (Negro) (Negro) (Negro) (Negro) (Azul)
F5 F0 F6 F7 F8 F9
(1)
(2)
H1
10 6 5 1
D507 A306 F306 A905 A503 D112 E802 E803

C206 A302 F303 E312 E523 G302 E804

C205 F504 F704 F804 E109 G402 A105 E522

E501 C801 A005 B304 E520 E108 F004 E601

40 36 35 31
(3) 95ZV62001
El mtodo de direccin se utiliza para diagrama de Ejemplo 3

alambrado elctrico. Para este mtodo, se pega un Comprobando el otro terminal de conector donde se
smbolo a cada conector y terminal de conector a fin de conecta F704 RL (tem (3)):
localizar fcilmente el otro terminal al cual se conecta el
otro extremo del cable. 1. F704
Muestra que el terminal est conectado al terminal
Ejemplo 1 4o del conector F7.
Smbolo debajo (o encima) de conector, tal como F6: Compruebe la descripcin en el terminal 4o del
Muestra la direccin del conector. conector F7 (F704). Esto muestra que el terminal
F704 est conectado a H128 y significa que el ter-
Ejemplo 2 minal 4o del conector F7 est conectado al terminal
Smbolo en el conector del multiterminal, tal como 1 y 28o del conector H1.
10: 2. RL
Muestra el nmero de terminal y la direccin de numer- Muestra el color del alambre RL y representa que
ado. el color aislante es rojo, y L representa que una
raya azul est en el aislamiento rojo.
62-7
Como Utilizar o Diagrama de Ligaes Elctricas (PORTUGUS)
Como Utilizar o Diagrama de Ligaes Elctricas

(PORTUGUS)
Exemplo
10 6 5 1
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
21
40 39 32 31
40 36 35 31
Rel de luz Rel de controlo Rel de controlo

de largura de viagem Rel do ponto morto Rel da luz traseira Rel da buzina de falha

C201 B611 H133 E214 H610 E220 H128 E219 H127 B501 E218
H129
D114 D114 D112 D103 D102 D002 D111 D103 D107 D107 A405 D001
2 1 2 1 2 1 2 1 2 1 2 1
(Preto) (Preto) (Preto) (Preto) (Preto) (Azul)
F5 F0 F6 F7 F8 F9
(1)
(2)
H1
10 6 5 1
D507 A306 F306 A905 A503 D112 E802 E803

C206 A302 F303 E312 E523 G302 E804

C205 F504 F704 F804 E109 G402 A105 E522

E501 C801 A005 B304 E520 E108 F004 E601

40 36 35 31
(3) 95ZV62001
O mtodo de endereamento utilizado para os diagra- Exemplo 3

mas de ligaes elctricas. Para este mtodo, cada Verificar o outro terminal de conectores, no qual F704
conector e terminal de conector tem um smbolo acop- RL (item (3)) ligado:
lado para facilitar a localizao do outro terminal onde a
outra extremidade do cabo deve ser ligada. 1. F704
Ilustra que o terminal ligado ao 4o terminal do
Exemplo 1 conector F7.
Smbolo por baixo (ou por cima) do conector, como F6: Verifique a descrio no 4o terminal do conector F7
Indica o endereo do conector. (F704), indica que o terminal F704 est ligado ao
H128. Isto significa que o 4o terminal do conector
Exemplo 2 F7 est ligado ao 28o terminal do conector H1.
Smbolo no conector de multiterminais, como 1 e 10: 2. RL
Indica o nmero do terminal e a direco da numer- Indica a cor do fio. RL representa que a cor do
ao. isolamento vermelha e L representa uma faixa
azul est no isolamento vermelho.
62-8
Electrical Cable Color Codes
Electrical Cable Color Codes
Color of
stripe Y G Sb Br L W R B O Lg P Gy V
Color of (yellow) (green) (sky blue) (brown) (blue) (white) (red) (black) (orange) (light green) (pink) (grey) (violet)
insulation
Y (yellow) Y YG YSb YBr YL YW YR YB YO YGy YV
G (green) GY G GL GW GR GB GO
Sb (sky blue) SbY SbG Sb SbW SbR SbO SbLg SbP
Br (brown) BrY BrG Br BrL BrW BrR BrB
L (blue) LY LG LBr L LW LR LB LO LLg LP
W (white) WY WG WBr WL W WR WB WO WP WV
R (red) RY RG RBr RL RW R RB RO RLg RGy
B (black) BY BG BL BW BR B BO BLg BP BV
O (orange) OY OG OSb OL OW OR OB O
Lg (light green) LgY LgG LgSb LgBr LgL LgW LgR LgB Lg
P (pink) PG PL PW PB P
Gy (grey) GyY GyG GyL GyW GyR GyB GyO Gy
V (violet) VW VR V
Insulation color
Stripe color
70ZV62001
62-9
Electrical Circuit Symbols
Electrical Circuit Symbols
Name Symbol Name Symbol
Direct current Motor M
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 Pressure switch or

resistor Temperature switch
Inductance or Electromagnetic Negative -positive-negative

coil (NPN) transistor
Positive -negative-positive
Battery or Direct voltage source
(PNP) transistor
62-10
Sensor Mount
Sensor Mount
3 2 7
5
For air conditioner
1. Machine speed sensor

2. T/C oil temperature sensor 4
3. Air cleaner sensor
4. E/G coolant temperature sensor (S/N 9001~9050)
5. Hydraulic oil level sensor 8
6. Hydraulic oil temperature sensor
A-Detail
7. Coolant level alarm sensor
8. Cold starter temperature switch
115V2E62001
62-11
Fuse
Fuse
The following fuses are provided to protect electrical cir- Fuse box
cuits.
For chassis
Fusible link
70 A x 2, 30 A x 1 Fuse
Fuse No. capacity Protective circuit
(A)
Fuse box LIGHTING
15 fuses x 2 (for chassis and cab) 1 20A
HEAD LIGHT
6 fuses x 1 (for engine controller ECM) 2 15A R. WORK LIGHT SPARE
BOOM KICKOUT
3 10A 30A
(For installation positions, refer to "Electrical Equipment BUCKET LEVELER
Layout".) 4 15A TURN SIGNAL SPARE
PARKING BRAKE
5 30A 20A
MCU (MACHINE)
CAUTION 6 15A F. WORK LIGHT SPARE
Possible burn hazard. Before replacing a fuse, be 7 10A AIR SUS. SEAT (OPT)
15A
sure to turn off the starter switch. 8 15A SPARE
9 15A SPARE SPARE
4WAY FLASHER
IMPORTANT HORN
10 15A 5A
ROOM LAMP
Replace a fuse with the same capacity. RADIO
If a fuse blows immediately after replacement, the 11 10A SPARE
electric system is defective. Locate the defective part, 12 15A COLD STARTER
and then repair it.
BUZZER
13 5A MONITOR
(MCU)
14 5A NEUTRAL RELAY
BATTERY RELAY
15 5A
ECM (ENGINE)
For cab
Fuse
Fuse No. capacity Protective circuit
(A)
16 5A SPARE
17 5A SPARE SPARE
Fuse box for cab Fuse box for chassis
18 5A R. WIPER / WASHER
20A
19 10A F. WIPER / WASHER
20 10A MODM SPARE
21 15A SPARE
15A
22 3A DC-DC CONVERTER
23 10A SPARE SPARE
24 10A SPARE
10A
25 20A AIRCON
26 5A SPARE SPARE
27 5A SPARE
5A
28 10A SPARE
29 20A AIRCON
30 20A SPARE
90V2E62002
62-12
Fuse
Fusible link Problems caused by blown fusible link
Fuse Problem (symptom)

Fusible link damaged During engine operation During engine stop
Cover
Fuse - Engine will stop auto- - All the electrical circuit
element matically. will not function.
30A - All the power for all - Engine can not be
electrical circuit will be started.
OFF.
- The same conditions
- Horn [and opt. flasher]
as "During engine oper-
will operate.
ation".
- All the others will not
- Engine can not be
operate and the
started.
70A machine can not be
(1) operated.
- Engine will not stop
automatically but can
Box for fusible link Fusible link be stopped with starter
70ZV62010
switch OFF.
- The machine can be - The same conditions

(900)
(081) (085)
W W [W5] 100
12V 12V
operated but the batter- as "During engine oper-
30A 70A
ies can not be charged ation".
BATTERY (2)
(060) (901)
W [W5]
ECM(H)
and the batteries will be
R1 BR
B AC
(065) (015)
WR1.25 F15 WR
(708)
WP TO MCU discharged soon.
R2 C 5A WV
(700)
(064) (063)
G1.25 WR1.25
IMPORTANT
F14
F13
5A
5A
(014) (013)
G1.25 (Lg) BATTERY STARTER
RELAY
70A
(1)
[R5] x 6
B C
When replacing fusible link, you may want to discon-
nect the battery negative terminal to avoid arcing out
(910~
915) MAGNETIC
S/W (702)
a circuit and damaging wire.

[R5] (701) 5 [BW ]
VOLTAGE
RL1.25 (703) WG(704) RELAY
NR
If so, after you reconnect battery, do following:
1. Turn on key
(013) (705)
(Lg) (WG) (707)
F13 WL
2. Press throttle pedal fully down and up 3 times in

CHARGE LAMP (706)
WL1.25
70A
20
B
R
E
I 5~6 seconds.
(2)
ALTERNATOR 20
3. Turn off key switch.
(005-a)
(L) ES
F5 M1
M2
100 M1 SECONDARY
M STEERING PUMP
M2 SECONDARY
M STEERING PUMP
THERMO
(062) (012) (722) SWITCH (721) ETHER KIT
BW F12 BW BrB (BrR)
15A COLD
STARTER
SWITCH
B ACC E
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.
62-13
Engine Start Circuit
Engine start circuit diagram
Starter switch
B BR ACC R1 R2 C
Off
On
Start
MCU
E05 E06 E17 E04 E12
E03 E11 12V 12V
Shift lever F/R position
B18 30A
E24
B12 Fusible link Battery
Shift lever
D11 B11 ECM
D04
F N R F15 Diode unit
F14
5A
5A
1
23A
D12
D05
Battery Starter motor
D03
relay
70A
D10
(1)
+24 V B C
Magnetic
switch Voltage
relay
3 4
2 1
Neutral relay
F13 MCU
+24 V Charge lamp E24
(F5)
* When shift lever is in F/R position: OFF
When shift lever is in N position: ON (2)
R
70A B I
E
Alternator
115V2E62033
62-14
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 neu-
tral (N) position.
Shift lever neutral (N) position
When the starter switch is turned to the ON position

while the shift lever is located in the N position, the coil
actuation circuit of the neutral relay is connected to the
ground of the MCU unit and the contact of the neutral
relay is switched over to ON.
When the starter switch is turned to the START position,

the start command current flows from the starter switch
terminal C to the neutral relay, the magnetic switch and
the voltage relay. As a result, the magnetic switch turns
ON, the starting current flows in the starter motor, and
the engine starts.
Shift lever forward/reverse (F/R) position
While the shift lever is located in the F or R position, the

power is not supplied to the neutral relay coil, and the
main contact is OFF. As a result, the starting current
from the starter switch terminal C does not flow in the
magnetic switch, and the engine does not start.
62-15
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 cir-
cuits.
Start
Starts the engine.
Starter switch
Control box
Starter switch location

85V2E62002
OFF
30
ON
35
Start
B
C
AC BR
R1
R2
W3 Connection table
W5
B BR AC R1 R2 C
Off
BW R1 BR WR x 2
B AC WB x 2 On
BBG
G R2 C G Start
To battery relay
To neutral relay
From battery
1.25
BW WR WR G W5
BG WB WB W3
115V2E62004
62-16
ECM safety features Battery relay

The ECM is equipped with safety functions that are
designed to limit engine revolution (min-1) in certain situ-
ations.
Terminals for coil Moving contact
energizing current
The zero point of the pedal is recalibrated every time (4 mm) Main contacts
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.) BR
This permits the ECM to see the signal and set the
engine revolution (min-1) appropriately. Terminals for
main current
Coil for energizing (8 mm)
This function is set to turn on 1 second after the key is 95ZV62017
set to the ON position, then adjustment is completed in
3 seconds and this function is turned off. When the starter switch is placed to the ON position or
the start position, the battery relay is turned on. When
Note the starter switch is set to the OFF position, the alterna-
There is no indication on the instrument panel or MODM tor stops generating power, and the battery relay is
that this function turns either on or off because there automatically turned off so that the electrical circuits will
is no engine abnormality to call out or indicate. not function.
Effect on the machine If the battery relay was not used, a large amount of cur-
(a) If the throttle pedal is applied while turning the key rent would be directly sent through the starter switch
switch to the start position, the engine maximum when it is turned on. However, use of the battery relay
speed will only increase to 80% of high idle. reduces the amount of current because this relay needs
(b) If the throttle pedal is applied while the engine is only a small amount of current to energize it.
starting, this function will turn ON 1 second after
releasing the pedal and engine speed will only
increase 80% of high idle.
Battery relay operation
To avoid these troubles, the following steps are impor-
Starter switch
tant;
1. Wait one second before turning the key from the From AC B
ON to the START position. charge
circuit Battery relay
2. Do not step on the pedal while the engine is start-
(B)
ing, nor just after the engine starts.
To main (E)
circuit
Battery
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.
Suppression
diode 85V2E62014
Battery relay
Rated voltage DC 24 V
Minimum operating voltage 20 V or less
Release voltage 9 V or less
When current flows from the starter switch terminal AC,

the coil will be energized, and the moving contact will
lower to close the main contact. As a result, current will
flow from the battery to the main circuit.
62-17
Alternator I terminal wire Diode unit

12V 12V
30A
ECM Battery
(1)
R1 BR F15 WR (2) (3) WP WV:To battery relay
B AC
R2 C 5A
(2)(3): Diode unit WV WR:To starter switch terminal AC (VIA F15) and
WR WP to ECM
Suppression diode WP:To alternator
F14
F13
5A
5A
Charge From
circuit alternator
I terminal Diode storage section
B Neutral
relay 70ZV62017
115V2E62005
Engine motion-active circuit: (1) The diode unit is incorporated in the milky white connec-
tor near the battery relay. It is provided for the following
When the starter switch is turned OFF, the battery relay purpose.
is automatically turned OFF since the command current
from the starter switch terminal AC stops flowing and 1. Diode (2)
the coil is demagnetized. Then the charging circuit from This diode is provided to prevent the roundabout
the alternator is shut down. current from the alternator to the ECM. If this diode
is not provided (or is defective), the ECM does not
However the alternator is still generating power and the turn OFF and the engine cannot be stopped.
load dump surge may be generated. This may damage
the related circuits and equipment. In order to prevent 2. Diode (3)
this trouble, this circuit (1) is provided to hold the battery This diode is provided to prevent the roundabout
relay in the "ON" position. current from the starter switch AC to the alternator I
terminal.
62-18
Neutral relay
1 2
SbP
L
RL
G
4 3
Internal connection dia.

Body black
85V2E62016
Position of shift Between Between Rating DC 24 V

Starting
lever 1 and 2 3 and 4 Operating voltage 16 V or less
F or R Not energized OFF Impossible
Reset voltage 2.4 V or more
N Energized ON Possible Coil resistance 320
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.
62-19
Magnetic switch
Rating 24V x 200A

M C
C C
M
M C
70ZV62019
Note
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.
62-20
Voltage relay Note

(S/N 9001~9006) Once the engine is started, the alternator starts generat-
ing electric power.
1 When electric current is supplied from the alternator R

2 3
terminal to the voltage relay, the voltage relay is magne-
tized and is turned OFF.
2
Consequently the magnetic switch turns OFF and no
3 electric current flows to the starter motor terminal C, dis-
engaging the starter motor.
1 4
4
70ZV62020
Voltage relay
Contact point closed 6V
Contact point open 9V
(S/N 9007~)
Blue
K70V2J62005
Voltage relay
Contact point closed 6V
Contact point open 8V
62-21
Power Generating/Charging Circuit
Power Generating/Charging Circuit

Alternator
Engine Mechanical energy supply
The alternator driven by the engine rectifies, with 6

diodes, full waves in three phases of the AC output gen-
erated in the stator coil by the three-phase start connec-
tion (Y connection) into DC output, then supplies it as
Alternator Electrical energy conversion the electric power to the battery and the machine load.
In the electricity generated in the alternator, the voltage

Rotor coil fluctuates depending on the number of revolutions of
excitation current Generated power the engine and the load size if no measures are taken.
IC regulator
To prevent fluctuation, a regulator is integrated so that
Voltage adjustment the voltage supplied to the battery and the load circuit is
For battery relay
For rotor coil always constant.

initial excitation
Adjusted
voltage
operation
For battery relay

operation
Starter
Load circuit operation
switch
Battery charge
<Load>
For rotor coil Battery

initial excitation 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.
62-22
ECM (Engine Controller)
Function of ECM
- Stops the engine.
- Operates the engine.
- Monitors the engine, and diagnoses it for faults.
Connection diagram
B
16 PIN
(081)
W F
10A
(085)
W A E
B
10A
B J
(015) K
WR
F15 H L
23 PIN
(751)
GR (742) GyR
L A EP E/G OIL PRESS.
GY (743)
M
BG (744) E
N W (745)
X BO
(GW) (212)
(A25) O
THROTTLE PEDAL 31 PIN

(730) STOP (013)
THROTTLE OPENING BrW (733) (BrR) (Lg)
SENSOR 20 16 F13
YV (734)
21 (731) WARNING
BLg (735) (BrB)
22 17
(732) MAINTENANCE
IDLE S/W (BrW)
18
OFF IDLE GyY (736)
9
GyW(737)
10
IDLE
(741)
BL
11
E (161) W
31 (E15)
DIAGNOSTIC S/W
BrG (738)
1 S2H
S2L
INC/DEC S/W CAN
S2S
INC PG (739)
(m) 23
PW (740) RESISTOR
24
DEC B
(060)
AI SbY (209) 9 PIN W
14 B
S2H
TC Sb (205) C C
E 12 S2L
D D
DC SbW(207) S2S
13 E E
(YL) (747)
F F
RLg (206) (Y0) (748)
8 G G
A
E
DATA LINK
CONNECTOR
E/G ECM connection diagram
115V2E62006
62-23
Monitor lamp test
ON
Key switch Approx.
OFF
2 sec
ON
Engine maintenance lamp Orange
OFF
ON
Engine warning lamp Lights when
abnormality Yellow
OFF
occurs.
ON
Engine stop lamp Red
OFF
95ZV62025
10 20
F
E
0 30
-1
x100min
STOP
Engine maintenance lamp
Engine warning lamp
Engine stop lamp

115V2E62007
When the starter switch is set to ON, three engine mon-

itor 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 corre-

sponding monitor lamp lights.
62-24
Failure diagnosis The diagnosis for the engine failure should be done by
the following steps.
Engine diagnostic switch (option)
Step 1. Starter switch key "OFF"
Step 2. Diagnostic switch "ON"
Diag. switch Inc./Dec. switch
(Part Number: 35010-60130) (Part Number: 35010-60180) Step 3. Starter switch key "ON"
The engine warning lamp flashes with these conditions.

To diagnose the engine failure, convert the flashing pat-
tern to the 3-digit fault code.
The following shows how to convert the flashing pattern

to the 3-digit fault code.
G R R
Note
L W G Y
These code are quickly retrievable with Cummins
Quickcheck hand held analyzers or with the MODM on
the machine.
Cable assembly
(Part Number : 33191-49150) Refer to the "QUANTUM FAULT CODE INFORMA-
70ZV62069 TION" for details.
This switch is used to check the engine failure when any
one of the engine warning lamps is turned on. 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
0.5 sec
ON
OFF
Red Second
First digit digit Third digit
1 sec 1 sec
Fault code Fault code (continued)
115V2E62008
62-25
Failure diagnostic chart
ON
Key switch
OFF
ON
Diagnostic switch
OFF
[When there is no fault code]

ON
Orange
OFF
ON
Engine warning lamp
OFF
Yellow
ON
Engine stop lamp STOP
OFF
Red
[When there is fault code]
ON
Orange
OFF
1 sec 1 sec
ON
Engine warning lamp
Yellow
OFF
ON
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
Orange
OFF
1 sec 1 sec
ON
Engine warning lamp
Yellow
OFF
ON
Red
OFF
1 3 1
Following page explains more.
115V2E62009
62-26
Increment decrement switch (option) - Adjusting the engine idle revolution
When the diagnostic switch is OFF (Starter switch

Diag. switch Inc./Dec. switch key "ON"), the engine idle revolution can be adjusted
(Part Number: 35010-60130) (Part Number : 35010-60180) in 25 rpm by using the increment / decrement switch
(650 rpm 800 rpm 1,000 rpm). Move the incre-
ment / 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
G R
L W
R
G Y
1,000 min-1 (rpm) or to below 650 min-1 (rpm) even
though this switch is moved to "+" or "-".
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 convert-

ing the flashing pattern to 3-digit fault code.
Refer to the "Quantum fault code information" for

details.
62-27
Quantum fault code information

These codes show the fault codes for the engine failure Please note that not all are used in the ZW550
displayed on the MODM error log monitor, or checked machine application. Refer to Cummins Engine trouble-
by the diagnostic switch (option). shooting fault codes list for more information.
FAULT
CODE/ DESCRIPTION
LAMP
ZW550
EG111
Engine Control Module (ECM) - critical internal failure.
Red
EG113
Engine Timing Actuator Circuit - shorted high.
Yellow
EG114
Engine Timing Actuator Circuit - shorted low.
Yellow
EG115 Engine Speed / Camshaft Position Sensor Circuit - lost both of two signals from
Red the magnetic pickup sensor.
EG121 Engine Speed / Position Sensor Circuit - lost one of two signals from the
Yellow magnetic pickup sensor.
EG122
Intake Manifold Pressure Sensor #1 Circuit - shorted high.
Yellow
EG123
Intake Manifold Pressure Sensor #1 Circuit - shorted low.
Yellow
EG124
Intake Manifold Pressure - above normal operation.
Yellow
EG131
Accelerator Pedal Position Sensor Circuit - shorted high.
Red
EG132
Accelerator Pedal Position Sensor Circuit - shorted low.
Red
EG133
Remote Accelerator Pedal Position Sensor Circuit - shorted high.
Red
EG134
Remote Accelerator Pedal Position Sensor Circuit - shorted low.
Red
EG135
Engine Oil Pressure Sensor Circuit - shorted high.
Yellow
EG141
Engine Oil Pressure Sensor Circuit - shorted low.
Yellow
EG143
Engine Oil Pressure Low - warning.
Yellow
EG144 Engine Coolant Temperature Sensor Circuit - voltage above normal or shorted
Yellow high.
EG145 Engine Coolant Temperature Sensor Circuit - voltage below normal or shorted
Yellow low.
EG146
Engine Coolant Temperature High - warning.
Yellow
EG151
Engine Coolant Temperature High - critical.
Red
EG153 Intake Manifold Air Temperature Sensor Circuit - voltage above normal or
Yellow shorted high.
EG154 Intake Manifold Air Temperature Sensor Circuit - voltage below normal or
Yellow shorted low.
EG155
Intake Manifold Air Temperature Sensor High - critical.
Red
EG166
Rack Position Sensor #1 Circuit - shorted high.
Yellow
EG172
Rack Actuator Position #1 Circuit - grounded circuit.
Red
62-28
FAULT
CODE/ DESCRIPTION
LAMP
ZW550
EG173
Rack Actuator - mechanically stuck open.
Yellow
EG184
Engine Control Module Identification Input State Error.
Yellow
EG185
Engine Control Module Network Communication Error.
Yellow
EG187
Sensor Supply Voltage #2 Circuit - shorted low.
Yellow
EG212
Engine Oil Temperature Sensor Circuit - shorted high.
Yellow
EG213
Engine Oil Temperature Sensor Circuit - shorted low.
Yellow
EG214
Engine Oil Temperature High - Critical.
Red
EG221
Ambient Air Pressure Sensor Circuit - shorted high.
Yellow
EG222
Ambient Air Pressure Sensor Circuit - shorted low.
Yellow
EG227
Sensor Supply Voltage #2 Circuit - shorted high.
Yellow
EG231
Engine Coolant Pressure Sensor Circuit - shorted high.
Yellow
EG232
Engine Coolant Pressure Sensor Circuit - shorted low.
Yellow
EG233
Engine Coolant Pressure Low - warning.
Yellow
EG234
Engine Speed High - critical.
Red
EG238
Yellow
EG254
Fuel Shutoff Valve Circuit - shorted low.
Red
EG255
Fuel Shutoff Valve Circuit - shorted high.
Yellow
EG259
Fuel Shutoff Valve - stuck open.
Red
EG261
Fuel Temperature High - warning.
Yellow
EG263
Fuel Temperature Sensor Circuit - shorted high.
Yellow
EG265
Fuel Temperature Sensor Circuit - shorted low.
Yellow
EG266 Engine Fuel Temperature - data valid but above normal operational range - most
Red severe level.
EG271
Fuel Control Actuator Circuit - shorted low.
Yellow
EG272
Fuel Control Actuator Circuit - shorted high.
Yellow
EG281
Injection Pump Mechanical System - signal not in range from ECM.
Yellow
EG284 Engine Speed / Position Sensor #1 (Crankshaft) Supply Voltage Circuit - shorted
Yellow low.
EG285
SAE J1939 Data Link Multiplexing PGN Timeout Error.
Yellow
62-29
FAULT
CODE/ DESCRIPTION
LAMP
ZW550
EG286
SAE J1939 Data Link Multiplexing Configuration Error.
Yellow
EG287
SAE J1939 Multiplexing Accelerator Pedal Sensor System Error.
Red
EG295
Ambient Air Pressure Sensor Circuit - data incorrect.
Yellow
EG299
Engine stopped not using Starter Switch.
Yellow
EG311
Injector Solenoid Valve Cylinder #1 Circuit - grounded circuit.
Yellow
EG312
Yellow
EG313
Yellow
EG314
Yellow
EG315
Yellow
EG319
Real Time Clock - power Interrupt.
Yellow
EG321
Yellow
EG322
Injector Solenoid Valve Cylinder #1 Circuit - open circuit.
Yellow
EG323
Yellow
EG324
Yellow
EG325
Yellow
EG331
Yellow
EG332
Yellow
EG334
Coolant Temperature Sensor Circuit - data erratic, intermittent, or incorrect.
Yellow
EG341
Engine Control Module - data lost.
Yellow
EG342
Engine Control Module - out of calibration.
Red
EG343
Engine Control Module - warning internal hardware failure.
Yellow
EG346
Engine Control Module - warning software error.
Yellow
EG351
Injector Power Supply.
Yellow
EG352
Yellow
EG378
Fueling Actuator #1 Circuit - open circuit.
Yellow
EG379
Fueling Actuator #1 Circuit - grounded circuit.
Yellow
EG386
Yellow
62-30
FAULT
CODE/ DESCRIPTION
LAMP
ZW550
EG387
Accelerator Pedal Position Sensor Supply Voltage Circuit - shorted high.
Yellow
EG394
Timing Actuator #1 Circuit - open circuit.
Yellow
EG395
Timing Actuator #1 Circuit - grounded circuit.
Yellow
EG396
Fueling Actuator #2 Circuit - open circuit.
Yellow
EG397
Fueling Actuator #2 Circuit - grounded circuit.
Yellow
EG398
Timing Actuator #2 Circuit - open circuit.
Yellow
EG399
Timing Actuator #2 Circuit - grounded circuit.
Yellow
EG415
Engine Oil Pressure Low - critical.
Red
EG418
Water in Fuel Indicator High - maintenance.
Yellow
EG419
Intake Manifold Boost Pressure Imbalance.
Yellow
EG423
Fuel Timing Pressure or Timing Actuator Stuck.
Yellow
EG428
Water in Fuel Sensor Circuit - shorted high.
Yellow
EG429
Water in Fuel Sensor Circuit - shorted low.
Yellow
EG431
Accelerator Pedal Idle Validation Circuit - data incorrect.
Yellow
EG432
Accelerator Pedal Idle Validation Circuit - out of calibration.
Red
EG433
Intake Manifold Pressure Sensor Circuit - data incorrect.
Yellow
EG434
Voltage to ECM less than 6 V
Yellow
EG435
Engine Oil Pressure Switch Circuit - data incorrect.
Yellow
EG441
Battery #1 Voltage Low - warning.
Yellow
EG442
Battery #1 Voltage High - warning.
Yellow
EG443
Accelerator Pedal Position Sensor Supply Voltage Circuit - shorted low.
Yellow
EG449
Fuel Pump Delivery Pressure High - warning.
Yellow
EG451
Injector Metering Rail #1 Pressure Sensor Circuit - shorted high.
Yellow
EG452
Injector Metering Rail #1 Pressure Sensor Circuit - shorted low.
Yellow
EG465
Turbocharger #1 Wastegate Control Circuit - shorted high.
Yellow
EG466
Turbocharger #1 Wastegate Control Circuit - shorted low.
Yellow
EG482
Fuel Pressure Low - warning.
Yellow
62-31
FAULT
CODE/ DESCRIPTION
LAMP
ZW550
EG483
Injector Metering Rail #2 Pressure Sensor Circuit - shorted high.
Yellow
EG484
Injector Metering Rail #2 Pressure Sensor Circuit - shorted low.
Yellow
EG485
Injector Metering Rail #2 Pressure High - warning.
Yellow
EG486
Injector Metering Rail #2 Pressure Low - warning.
Yellow
EG488
Intake Manifold Temperature High - warning.
Yellow
EG491
Turbocharger #2 Wastegate Control Circuit - shorted high.
Yellow
EG492
Turbocharger #2 Wastegate Control Circuit - shorted low.
Yellow
EG496
Engine Speed / Position Sensor #2 (Camshaft) Supply Voltage.
Yellow
EG524
OEM Alternate Droop Switch Validation - data incorrect.
Yellow
EG527
Auxiliary Input / Output #2 Circuit - shorted high.
Yellow
EG528
OEM Alternate torque validation switch - data incorrect.
Yellow
EG529
Auxiliary Input / Output #3 Circuit - shorted high.
Yellow
EG546
Fuel Delivery Pressure Sensor Circuit - shorted high.
Yellow
EG547
Fuel Delivery Pressure Sensor Circuit - shorted low.
Yellow
EG551
Accelerate Pedal Idle Validation Circuit - shorted low.
Yellow
EG553
Injector Metering Rail #1 Pressure High - warning level.
Yellow
EG554
Fuel Pressure Sensor Error.
Yellow
EG559 Injector Metering Rail #1 Pressure Low - data valid but below normal operational
Yellow range - moderately severe level.
EG596
Electrical Charging System Voltage High - warning level.
Yellow
EG598
Electrical Charging System Voltage Low - critical level.
Red
EG689
Crankshaft Engine Speed Signal Error.
Yellow
EG731
Mechanical Timing Misalignment.
Yellow
EG753 Crankshaft Position Sensor and Camshaft Position Sensor - data erratic,
Yellow intermittent, or in correct.
EG757
Electronic Control Module Data Lost.
Yellow
EG758
Injector Metering Rail #2 Pressure Malfunction.
Yellow
EG778
Engine Speed Sensor (Camshaft) - data erratic, intermittent, or incorrect.
Yellow
EG951
Cylinder Power Imbalance Detected.
None
62-32
FAULT
CODE/ DESCRIPTION
LAMP
ZW550
EG1117
Power Lost with Ignition ON - data erratic, intermittent, or incorrect.
None
EG1358 Accelerator Pedal Position Sensor 1 Circuit - voltage above normal or shorted
Yellow high.
EG1359 Accelerator Pedal Position Sensor 1 Circuit - voltage below normal or shorted
Yellow low.
EG1361 Remote Accelerator Pedal Position Sensor 1 Circuit - voltage below normal or
Yellow shorted low.
EG1376 Engine Camshaft Speed / Position Sensor - data erratic, intermittent, or
Orange incorrect.
EG1595 Remote Accelerator Pedal Position Sensor 1 Circuit - voltage above normal or
Yellow shorted high.
EG1597 Engine Control Module Critical Internal Failure - bad intelligent device or
Orange component.
EG1845 Water in Fuel Indicator Sensor Circuit - voltage above normal or shorted to high
Orange source.
EG1846 Water in Fuel Indicator Sensor Circuit - voltage below normal or shorted to low
Orange source.
EG1852 Water in Fuel Indicator - data valid but above normal operational range -
Yellow moderately severe level.
EG1911
Injector Metering Rail 1 Pressure - above normal operating range.
Yellow
EG2185
Yellow
EG2186
Yellow
EG2215 Fuel Pump Delivery Pressure - data valid but below normal operational range -
Yellow moderately severe level.
EG2249
Fuel Pump Delivery Pressure Sensor Circuit - shorted low.
Yellow
EG2261 Fuel Pump Delivery Pressure - data valid but above normal operational range -
Orange least severe level.
EG2262 Fuel Pump Delivery Pressure - data valid but below normal operational range -
Orange least severe level.
EG2265
Fuel Priming Pump Control Signal Circuit - shorted high.
Yellow
EG2266
Fuel Priming Pump Control Signal Circuit - shorted low.
Yellow
EG2311
Fueling Actuator #1 Circuit Error - condition exists.
Yellow
EG2321
Engine Speed Sensor #1 - data erratic, intermittent, or incorrect.
None
EG2322
Engine Speed Sensor #2 - data erratic, intermittent, or incorrect.
None
EG2697 Accelerator Pedal Position Sensor Circuit and Idling Position Detection Switch
Orange Circuit - data erratic, intermittent, or incorrect.
EG2963
Engine Coolant Temperature High - warning.
None
EG2964
Intake Manifold Temperature High - warning.
None
EG2973
Intake Manifold Pressure Sensor Circuit - data erratic, intermittent, or incorrect.
Yellow
(09D20E)
62-33
Accelerator pedal
Pedal
A-Black-APS signal
B-White-APS ground
C-Red-APS supply (5 V)
Throttle pedal
D-Green-Throttle active
Throttle E-Blue-Idle active
opening sensor BrW (733)
20 F-Orange-IVS supply (5 V)
R YV (734)
21
B BLg (735)
22
W E 35
IDLE S/W C
OFF IDLE GyY (736) M
9
G
GyW (737)
10
IDLE L
BL (741)
11
Circuit diagram Note

APS-Acceleration Position Signal
IVS-Idle Validation Switch
Connector
(G) 6 1 (B)
(L) 5 2 (W)
(O) 4 3 (R)
1-Black-APS signal
2-White-APS ground A
3-Red-APS supply (5 V) View A
4-Orange-IVS supply (5 V)
5-Blue-Idle active
6-Green-Throttle active
115V2E62010
Note Pedal Test.

Typical pedal potentiometer resistance at 18C (65F).
To calibrate a new pedal to the ECM, do the following Wire colors are at the pedal harness with accelerator pedal
within about a 5 or 6 second time frame. unplugged.
- Turn "on" key switch Wire colors at pedal up position at pedal down position
- Stroke the pedal fully up and down 3 times. R-B 1,540~2,310 260~390
- Turn "off" the key switch W-B 260~390 1,540~2,310
R-W 2,000~3,000 2,000~3,000
Potentiometer voltage (V)
G-O Open 0
Input 5
L-O 0 Open
Up position 3.75~3.95
Down position 0.55~0.75
62-34
When the accelerator pedal is pressed, the voltage cor- Accelerator pedal installation
responding to the pressing angle is input as a signal
from the potentiometer to the ECM (engine controller) to Throttle pedal sends electrical signal to the engine
control the engine revolution. 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
Pedal Stroke Pedal angle below) is indicated follow these steps within a time
stop frame of about 5 or 6 seconds to initialize the throttle
17 pedal with the ECM*.
Installation
angle
45 1. Shut off the engine
28
2. Turn the key to "ON"
3. Fully depress and release the throttle pedal three

times.
Pedal Angle
4. Turn the key to "OFF".
The throttle pedal and ECM* have now been initialized

Between terminal 9 (YV-B) and 23 (BLg-W)
Refer to circuit diagram for details. or calibrated. The engine may be restarted and retested
5V for proper performance.
If the problem continues disconnect the wiring harness

when plugged in, key "ON"
4
connector at the throttle pedal and inspect both sides.
Potentiometer Voltages
The pins and sockets should be clean, dry and straight.

3
If there is a problem correct it, reconnect the connector,
follow the steps above and retest.
2
Using the Quantum fault code information section the
1 following fault codes may indicate a non-initialized throt-
tle pedal:
0
0 17 - Fault Code 132
Pedal Angle - Fault Code 134
- Fault Code 287
- Fault Code 431
- Fault Code 432
85V2E62019
- Fault Code 443
If the problem is not corrected contact your Cummins

Engine distributor for assistance.
*Engine Control Module; Computer that controls engine

functions, and monitors engine faults.
62-35
Transmission Control Circuit and Monitor Circuit
Machine control unit (MCU)
To S5 To S6 To S7 To S8 To S9
85V2E62041
62-36
Connector
MCU
MCU
A 1.2S_SO A16.TT_L A31.1/4_L B12.X_R E 1.SSR_SO E16.SPD E31.TT_SE C 1.2S_SE C16.EP C31.BSL D12.SL_A
A 2.2_SO A17.D_SO A32.FR_L B13.F_SO E 2.FC_SO E17.BATT E32.OT_SE C 2.DSUB2 C17.F C32.EG_M D13.SS_N
A 3.ES_R A18.1_SO A33.3/4_L B14.B_SO E 3.KEY E18.CANL1 E33.OUT_RSE C 3.DSUB4 C18.ASUB1 C33.DD_S D14.KD
A 4.DD_SO A19.EP_L A34.EG_SW1 B15.EG_SW2 E 4.KEY E19.SS_P E34.ET_M C 4.BSL- C19.ASUB2 C34.AFR D15.INCH_S
A 5.3_SO A20.AB_L B 1.H_SO B16.RIN1 E 5.GND E20.CANLO C 5.TT C20.1/2 D 1.PRK D16.OD_SW
A 6.HM A21.A_L B 2.PWM_SO B17.OUT_MD2 E 6.GND E21.TM_M C 6.AC C21.1/8 D 2.AM_SW D17.SH
A 7.LU_SO A22.1/2_L B 3.IP_SO B18.N_R E 7.GND E22.B_SE2 C 7.ET C22.2S D 3.SL_2 D18.SS_SW
A 8.4_SO A23.E_L B 4.R_SO B19.BR_L E 8.GND E23.WT_SE C 8.BL C23.EG_H D 4.SL_R D19.SS_F
A 9.OTH_OUT A24.SS_L B 5.MO_SO B20.CAN_R1 E 9.+5V E24.ALT C 9.BD C24.IP_SW D 5.SL_3 D20.TMP
A10.R_L A25.SC_SW B 6.FR_SO B21.CAN_R2 E10.TGEG E25.RXD1 C10.DSUB1 C25.FR D 6.S_UP D21.INCH
A11.F_L A26.TF_L B 7.SSL_SO B22.DOUT1 E11.KEY E26.TGSP C11.DSUB3 C26.KO_P D 7.S_DOWN D22.KO_S
A12.ST_L A27.AC_L B 8.BSL_SO B23.OUT_FEW E12.KEY E27.INCH_SE C12.DR C27.ES_SE D 8.EG_SW D23.SC
A13.WL_L A28.BP_L B 9.BZ B24.MT E13.CANH1 E28.SC_P C13.BSL+ C28.3/4 D 9.M_SW D24.AR
A14.CW_L A29.N_L B10.BSL_R B25.ET_SE E14.EGR2 E29.CANHO C14.TF C29.1/4 D10.SL_1 D25.SM_SW
A15.ET_L A30.SC_L B11.KO_R B26.TXD1 E15.EGR1 E30.B_SE1 C15.WL C30.DC D11.SL_F D26.SS_R
A1 A2 A3 A4 A5 A6 A7 A8 A9 B1 B2 B3 B4 B5 B6 B7 E1 E2 E3 E4 E5 E6 E7 E8 E9 C1 C2 C3 C4 C5 C6 C7 C8 C9 D1 D2 D3 D4 D5 D6 D7
A10 A11 A12 A13 A14 A15 A16 A17 B8 B9 B10 B11 B12 B13 E10 E11 E12 E13 E14 E15 E16 E17 C10 C11 C12 C13 C14 C15 C16 C17 D8 D9 D10 D11 D12 D13
A18 A19 A20 A21 A22 A23 A24 A25 B14 B15 B16 B17 B18 B19 E18 E19 E20 E21 E22 E23 E24 E25 C18 C19 C20 C21 C22 C23 C24 C25 D14 D15 D16 D17 D18 D19
A26 A27 A28 A29 A30 A31 A32 A33 A34 B20 B21 B22 B23 B24 B25 B26 E26 E27 E28 E29 E30 E31 E32 E33 E34 C26 C27 C28 C29 C30 C31 C32 C33 C34 D20 D21 D22 D23 D24 D25 D26
Connector details
115V2E62028
62-37
MCU connection diagram
ACC (L) (005-b) E

TO PARKING S/W
(005)
F5 L2 (L) (005-a)
30A
G (010)
F10
E
ACC
LX4 (005-A~005-D)
E/G DROOP
E05 E06 E17 E04 E12 SELECTION 1
E03 E11
(SbP) (145) NEUTRAL RELAY
WL (707) B18 NR
E24
LgW (101) MCU FAILURE RELAY
B12 X
LR (126) BrB (258) LIFT KICKOUT RELAY
D11 B11 KO
LBr (128) L (273)
D04 LOWER KICKOUT RELAY
F N R B10 BS
SHIFT LEVER
OPT
MACHINE CONTROL UNIT (MCU)

A03
YGy (242)
ES
SECONDARY STEERING
MOTOR RELAY COIL
1 (146) LR
23A LW (120)
B13 L SOLENOID VALVE
D12 (147) LB
LO (123)
D05
B01 H SOLENOID VALVE
LG (122) (148) LBr
D03 B04 R SOLENOID VALVE
LY (121)
D10 (141) LY
A18 1ST SPEED SOLENOID VALVE
YO (232)
S/S SHIFT S/W F D19 (LY)
YW (233)
S/S SHIFT S/W R D26
A02
(142) LG
2ND SPEED SOLENOID VALVE
(LG) 4S (132)(LG)
YV (231)
S/S SHIFT D18 (143) LO
SELECTION S/W (OPT) F5 A05 3RD SPEED SOLENOID VALVE
LB (230)
ARMREST S/W (OPT) D24
(LO)
LG (122) (144) LW
SHIFT UP S/W (OPT) D06 A08 4S 4TH INDICATOR RELAY
LY (121)
SHIFT DOWN S/W (OPT) D07
(LW)
LP (149)
(YL) (124)
D14
A17 D SOLENOID VALVE
DOWNSHIFT BUTTON
WR (170)
YSb (125) B14 BRAKE SOLENOID VALVE
SHIFT HOLD S/W (OPT) D17
LP (168) LLg (140)

DECLUTCH SET-UP D15 A07 LU SOLENOID VALVE (OPT)
(GW) (210) LgL (261) RIDE CONTROL
TRACTION D23 A04
CONTROL S/W SOLENOID VALVE
LIFT KICKOUT BrG (255) GB (267) EFFICIENT LOADING SYSTEM
D22 A01
SET-UP SELECTION SOLENOID VALVE
BW (271) GB (278)
LOWER KICKOUT SET-UP C13 B03 PRESSURE INTENSIFYING
C31
SOLENOID VALVE (OPT)
LOWER KICKOUT S/W LgL (225)
B06 REVERSAL FAN SOLENOID VALVE
PRESSURE INTENSIFYING (GB) (277)
C24 (154) (150) (OPT)
S/W (OPT) LgR LgR
Lg (222)
B05 SPPC SOLENOID VALVE
REVERSAL FAN S/W (OPT) C25 1A
(236)
AUTO FAN REVERSAL LgY (223) BR
C34 E01 S/S SOLENOID VALVE R (OPT)
S/W (OPT) (237)
1A
BL
(Y) (105) B07 S/S SOLENOID VALVE L (OPT)
RECALL S/W C30 1A
(R) (106) (226) (221)
RESET S/W C12 LgB LgB
E02 FAN SPEED CONTROL SOLENOID
LLg (165) 1A
D21 VALVE
(013)
E F13 GO (164) (Lg)
D01
F13
(013) GyW (200) (LgR) (130)
(Lg) C23 A21 AUTO SHIFT INDICATOR LAMP
GL (265) (GR) (135)
C22 A29 NEUTRAL INDICATOR LAMP
YO(176) (GyW ) (260)
C33 (GyB) (103)
(LgY) (167) A14 CENTRAL WARNING LAMP
EP Gy (750) (LgY) (173)
E/G OIL PRESS S/W C16 A28 BRAKE OIL PRESS. WARNING LAMP
DECLUTCH S/W DECLUTCH A19
(Gy) (749)
E/G OIL PRESS. WARNING LAMP
BrY (181) (GyG) (753)
HYD. OIL LEVEL S/W C11 A15 E/G COOLANT TEMP. WARNING LAMP
(163)
(SbW) (GyL) (190)
ON
AIR CLEANER LgL (182) A16 T/M OIL TEMP. WARNING LAMP
C06 (LgW) (192)
OFF
CLOGGING S/W A27 AIR CLEANER WARNING LAMP
(162) (O) (241)
PARKING SOL LgG ON (005-b) A12 STEERING OIL PRESS.
(L) WARNING LAMP
F5
OFF
PARKING S/W
FUEL EFFICIENT MODE S/W
EFFICIENT LOADING SYSTEM S/W
RIDE CONTROL S/W

X (LgW) (102)
MCU
FAILURE
(LgSb) (112) BZ
WARNING
BUZZER
K115V2E62001
62-38
(153) (152)
P PB
T/M ACC. LIMIT S/W D20 (SbO) (193)
A26 T/M OIL FILTER WARNING LAMP
SbO (183) (Sb) (194)
T/M OIL FILTER S/W C14 A13 RADIATOR COOLANT LEVEL WARNING LAMP
MACHINE CONTROL UNIT (MCU)

(GY) (169)
A20 AUTO BRAKE INDICATOR LAMP
RADIATOR WATER Sb (184)
C15 (OSb) (211)
LEVEL S/W A30 TRACTION CONTROL INDICATOR LAMP
YR (405)
FUEL LEVEL F C17 (RL) (235)
YB (406) A32 REVERSAL FAN INDICATOR LAMP (OPT)
FUEL LEVEL 3/4 C28
(LgB) (224)
YL (407) A24 S/S INDICATOR LAMP (OPT)
FUEL LEVEL 1/2 C20
YBr (408) (YR) (410)
FUEL LEVEL 1/4 C29 A11 FUEL LEVEL F
YG (409) (YB) (411)
FUEL LEVEL 1/8 C21 A33 FUEL LEVEL 3/4
(YL) (412)
A22 FUEL LEVEL 1/2
E (YBr) (413)
A31 FUEL LEVEL 1/4
V (100) (YG) (414)
E09 (+5V) A23 FUEL LEVEL E
S/S POTENTIOMETER (OPT) B09
LgBr (104)
BZ BUZZER RELAY
G (234)
E19
BOOM ANGLE SENSOR
BrR (251) (YB) (401)
C26 E34 E/G COOLANT TEMP. GAUGE
DECLUTCH SENSOR
(LgR) (166) (BrW) (402)
E27 E21 T/M OIL TEMP. GAUGE
BRAKE OIL
PRESS. SENSOR 1 SbY (171) E30
BRAKE OIL B24
(WL)(400) METER OUTPUT
PRESS. SENSOR 2 (TACHOMETER)
SbY (172) E22
(420)
OSb (+) ()
E10 TACHOGRAPH E/G SPEED (OPT)
EFFICIENT LOADING SYSTEM
OIL PRESS. SENSOR GyB (266) (421)
C01
OB (+) ()
SECONDARY STEERING E26 TACHOGRAPH MACHINE SPEED (OPT)
PRESS. SENSOR SbR (240)
C27
GyG (754) YSb (403)
E/G COOLANT TEMP. SENSOR B25 A06 HOUR METER DRIVE
GyL (180)
T/M OIL TEMP. SENSOR E31 SbR (208)
B08 AI E/G IDLE SELECTION
(G) (415)
OUTSIDE AIR TEMP. SENSOR E32 SbP (202)
A09 TC E/G TORQUE SELECTION
GyO (220)
HYD. OIL TEMP. SENSOR E23 SbW (203)
B15 DC F5 E/G DROOP SELECTION 1
BY (114)
E07 A34 E/G DROOP SELECTION 2
Y (160) (GW) (212)
MACHINE SPEED SENSOR E16 A25 ECM(O) TRACTION CONTROL SELECTION
W (161)
E/G SPEED SENSOR ECM(31) E15 E
(LB) (138)
Y (159) A10 TO BACK-UP LAMP
E08 (RG) (331)
B19 TO BRAKE LAMP
(100)
(E09) V
+5V
YB (115)
(OUT_FEW)B23 FEW
YG (116)
(OUT_RES)E33 RESET
YL (117)
(RXD0)E25 RXD MCU PROGRAM REWRITE
YO (118)
(TXD0)B26 TXD
YBr (119)
E (OUT_MD2)B17 MD2
P (107) GND
DESTINATION SWITCH 1 C02 E
PL (108)
DESTINATION SWITCH 2 C03
GL (810)
PG (109) (RIN1)B16
A/MSELECTION D02
GR (811) RS232C
PB (110) (DOUT1)B22
ODMETER SELECTION D16
TIRE DIA. SELECTION D25
(CANH0)E29
S2H
SPEED SENSOR SELECTION D08 S2L
(CANL0)E20 CAN
S2S
METER SELECTION D09
E E
MAIN MCU
K115V2E62002
62-39
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
F R L Solenoid valve
+24 V Modulation for clutch
mechanism
Shift lever
H Surge
suppression
R diode
(incorporated
in solenoid Clutch Clutch
A valve) valve piston
1
23 1
Speed indicator Torque
lamp converter During energized: Clutch is engaged.
(instrument panel) pump During de-engaged: Clutch is disengaged.
Downshift +24 V 2
button Direct charge Lockup clutch
valve
Machine with lockup clutch: piston
MCU
3 To solenoid valve
for each clutch
Machine speed
sensor
LU
ECM Solenoid
valve
Solenoid valve
Modulation
Engine speed for clutch
mechanism
sensor
+24 V
Clutch Clutch
AUTO indicator lamp valve piston
ON when shift lever in A position
Torque
Direct charge converter During energized: Clutch is engaged.
valve pump During de-engaged: Clutch is disengaged.
115V2E62013
Each clutch has one solenoid valve for transmission Operation error preventive function
control. When electric current flows through the sole- (Simultaneous input of two or more commands)
noid valve, the clutch oil is fed into the clutch piston
chamber through the modulation mechanism and the If both the forward and reverse commands are input at
clutch valve. When the piston operates, the clutch is the same time due to a problem, the transmission is set
engaged. When the current stops flowing through the to the neutral position. In addition, if two or more speed
solenoid valve, the oil is drained from the clutch piston commands are input at the same time, the speed range
chamber through the clutch valve, and the clutch is dis- previously engaged is selected.
engaged.
When the starter switch is at OFF position, if both the
Input detection forward and reverse commands are input at the same
time due to a problem, the engine does not start even if
When the shift lever is set to the F (forward) position, the starter switch is placed in the start position. This is
electric current for input detection signal is sent from the because the neutral relay does not work.
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.
62-40
Shift lever
2 1
Forward F
KNIGHT BEAM CO,LTD

JAPAN
>PAMXD6-G50<
Neutral N
BM51-111
Reverse R
1st speed
2nd speed
3rd speed
Auto
Grounding for
speed change side (B)
3
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 Operator controlled shifting from 2 1 2 in either "2"

2. Grip or "A" is done by momentarily depressing the downshift
3. Connector button on the boom lever.
The shift lever has two direction and four speed posi- Shift lever neutral (N) position
tions; forward and reverse (F and R) and "1", "2", and
"3" speed positions are respectively used for 1st, 2nd, The shift lever has no neutral (N) contact.
and 3rd fixed speeds. The "A" speed position is used for
the variable speed where the 2nd through 4th speed Therefore, if neither the forward nor the reverse (F and
clutches are automatically changed in both the forward R) signal is input, the MCU will judge that the shift lever
and reverse operation. The lockup clutch (OPT) is auto- is at the neutral (N) position.
matically engaged or disengaged in the forward opera-
tion only.
62-41
Operation of solenoid valve Automatic shift
Clutch solenoid valve

Shift up
A 10.8 N-m (1.1 kgf-m) (8 lb-ft) Shift down
Speed
F4
3
+ side
K W E 6 K- 21/ 2
- N
SKM6
G24D
12.0 10.0 0 10.0 11.0 17.0 19.0

side
Reverse Speed km/h Forward
View from A
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 3
Coil resistance value Approx. 27
2
When the input signal is transmitted, the output circuit of
the corresponding solenoid valve is connected to the
11.5 9.5 0 9.5 10.5 16.5 18.5
grounding circuit. As a result, power is supplied to the
solenoid valve and the clutch is engaged. At the same Reverse Speed km/h Forward
time, the speed indicator lamp in the cab lights. Automatic shift map (Fuel efficient mode) 115V2E62015
Note that when the parking brake or the auto brake is When the shift lever is set to A position, the AUTO indi-
actuated or the declutch brake is applied, the forward or cator lamp in the cab will light and one of the solenoid
reverse (F or R) clutch solenoid valve is turned off and valves will be automatically energized according to the
the transmission is set to neutral. 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.
62-42
Automatic shift (with lock-up solenoid)
Shift up
Speed Shift down
F4L
F4
F3L
3
12.0 10.0 10.0 11.0 13.5 15.5 20.5 21.5 26.5 28.5
Automatic shift map (Normal mode) 115V2E62016
Shift up
Speed Shift down
F4L
F4
F3L
3
11.5 9.5 9.5 10.5 12.0 14.0 20.0 22.0 24.0 26.0
Automatic shift map (Fuel efficient mode) 115V2E62017
62-43
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 * 2.30.2 k (25C) (77F)
* Internal resistance changes greatly with temperature. At lower tem-

perature the resistance is lower. At operating temperature the resis-
tance 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.
62-44
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
YL
BY
70ZV62031
Max. voltage DC 24 V
Allowable value
Current 10 mA
The downshift button is of the momentary type. It is

spring loaded to the "OFF" position.
62-45
Modulation at clutch switching
MCU
N Modulator valve
F R Output
B05
current
Clutch selection
+ 24 V control
Shift lever
input signal
1 A
2 3
T/M accumulator
limit switch
E/G speed sensor ECM
115V2E62024
To T/C
ACC2 ACC1 P3 P2
PG
9 10
6
0.007 MPa
(0.07 kgf/cm2)
(0.1 psi)
5 0.39 ~ 2.65 MPa

(4 ~ 27 kgf/cm2) Drain (T/M side)
(56.8 ~ 384 psi)
To T/C return line

PG P4
PG 8
30L/min
4.0
To T/M lubrication line
0.88 MPa P5
7 (9 kgf/cm2)
(128 psi)
34
PG PM P1 P PG
Drain (T/M side) Drain (T/M side)
To T/M solenoid
valves
From pump
115V2E62025
The rise time of clutch oil pressure is controlled by mod-

ulator valve (proportional relief valve) (6) to shorten the
time lag and reduce shock that occurs when shifting
between forward and reverse, and between gears.
62-46
Modulator valve operation Initial oil charging (t1) into the clutch piston
chamber
When the shift lever is shifted from the neutral to the 1st
Modulation chart (Neutral1st forward) speed forward, the low range clutch solenoid valve is
energized and oil in the accumulator flows into the
empty clutch piston chamber first.
ON
Low range clutch OFF Then, oil under pressure flows into the clutch piston
solenoid valve chamber. After a given time, the control current to the
1st speed clutch ON modulator valve is reduced. Accordingly the main clutch
solenoid valve oil pressure is reduced, concluding the initial oil charg-
Oil filling completed Engagement
(clutch) (Acc.) completed ing into the clutch chamber.
Modulator The time taken for this initial charging, which depends
valve Current on the capacity of the clutch piston chamber, is con-
(mA)
trolled by a MCU.
0
Clutch piston chamber filling (t2)
To reduce clutch engagement shock, it is necessary to

engage the clutch while allowing some slippage of it. To
do this, the current to the modulator valve is held low for
Main a given time. The torque converter gear pump fills the
pressure Pressure P1
P2
oil both into the accumulator and into the clutch piston
MPa
(kgf/cm2) chamber. During this time, the clutch piston moves
(psi) while compressing the piston return spring.
0
The holding pressure in this time depends on the speed

Low range
clutch of the engine: lower pressure with lower engine speed,
Pressure
pressure MPa higher pressure with higher engine speed.
(kgf/cm2)
(psi) This time is also controlled by the MCU.
0
t2
t1 t3
t4 Accumulator filling (t3)
The pump continues to fill the oil into the accumulator.

When shifted Shift completed
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)

Initial charging Changes with combination of
t1 time clutches
0~0.12 sec
Low pressure Less than Since the accumulator is completely accumulated at the
t2 holding time
Changes with engine speed
0.5 sec start point of t4, the limit switch is turned ON, sending
Pressure rise Changes with combination of the signal to the MCU. At that point, the clutch piston
t3 0.3~0.7 sec
time clutches comes into contact with the clutch plate and the clutch
t4 Restoration time
Changes with combination of
0.5~1.3 sec
plates start to transmit power. The MCU recognizes that
clutches the accumulator is at the full accumulation by this sig-
nal, and gradually increases the driving current to the
P1 0.5~1.5 MPa (6~15 kgf/cm2) (85~213 psi) modulator valve.
P2 2.6~2.9 MPa (27~30 kgf/cm2) (384~427 psi)
Then, the hydraulic pressure for the clutch will conse-
- E/G high idle quently increases to complete the clutch engagement.
62-47
Adjustable declutch preset switch

200
Clutch OFF
Clutch ON
0 310 510 (kPa)
Declutch sensor
85V2E62028
Declutch selector
Declutch sensor Transmission clutch
switch
More than 510 (kPa) Disengage
ON
Less than 310 (kPa) Engage
Adjustable declutch preset switch is used to change the

angle of the left brake pedal (Declutch pedal) to disen-
gage the transmission clutch.
Pressure sensor for stop lamp With the engine running, step on the left brake pedal
and declutch
Left brake valve (Declutch pedal) up to the desired angle and press the
switch to set the brake pedal (Declutch pedal) angle.
95V2E52014
Switch
115V2U62019
62-48
Back-up alarm
Back-up lights
N
F R
Back-up alarm
Shift lever
+24 V
A10
MCU
1 A
2 3
85V2E62027
When the shift lever is set to the reverse (R) position,

the back-up lamp will light, and the buzzer will sound.
62-49
Parking brake
5A
+ 24V
F13
P Monitor lamp
Parking brake
Parking (ON)
Running (OFF)
Parking
switch
L
ON
OFF H
D01 P
MCU
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 When the power of the solenoid valve is turned on, oil
oil will be fed to the piston chamber of the parking will be fed into the piston chamber, the spring is com-
brake. The piston presses the brake disc with the spring pressed, and the parking brake is released.
force to actuate the parking brake. If the transmission
shift lever is set to the forward or reverse (F or R) posi-
tion, the buzzer will sound and the clutch will not be
engaged.
Parking brake operation
Parking brake solenoid

Parking switch Monitor lamp Buzzer
valve
"Parking" position Sounds when shift lever is
Parking * P No electric power supply
(pulled up) set to F or R
"Running" position
Running Off No buzzer Electric power supply
(pushed in)
*When the parking switch is set to "parking", the forward or reverse clutch is disengaged and set to neutral.
62-50
Solenoid valve for parking brake
Spring chamber (brake actuator)

B Solenoid Knob
Reducing P
valve
Manual release
(counterclockwise
T rotation)
Spool
Seat Seat
face A face B Tank 115V2E62020
Rated current 0.92 A
B Resistance 26.2
P T
95ZV52045
Valve assembly
Front
Solenoid valve
for auto brake Solenoid
valve for
parking
115V2E62021
62-51
Auto brake
Input side Output side

MCU
Solenoid valve for auto brake
+24V
Shift lever position

F R B14
selector signal
1 23A
Shift lever
Auto brake monitor lamp, buzzer
+24V
A20
Machine speed
Machine speed Solenoid valve for forward/reverse clutch

B13 L
sensor
B01 H
B04 R
Installation position of solenoid valve for auto brake.

Refer to the description on the solenoid valve for parking brake.
95V2E62015
Shown in the "released" position When the traveling direction is switched over between
To rear service To front
forward and reverse at a machine speed of 12 km/h (7.5
brake service brake mph) or more, the auto brake is applied to protect the
transmission clutches.
23
When the machine speed is too high, the auto brake is
applied also to prevent troubles caused by excess
speed in the engine and the transmission.
When the auto brake signal enters from the 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
29 valve (23) through reducing valve (37) (setting pressure:
From unloader
valve (Pump) 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
37 coming from the pump through the unloader valve
1.3 MPa
(13 kgf/cm2) enters the front and rear brake piston chambers to apply
(185 psi)
the service brake.
From unloader valve
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 for-
K115V2U52001 ward/reverse clutches of the transmission are disen-
gaged and kept in the neutral status until the actual
machine speed decreases and reaches the set value.
62-52
When the traveling direction is switched over When machine speed is excessive
between forward and reverse at a machine speed of
12 km/h (7.5 mph) or more Operation chart
(Example: Machine speed excessive in forward direction)
Operation chart Machine T/M in neutral

(Example: Shifting from forward to reverse) speed
ON ON
Machine Machine F solenoid valve
speed speed
OFF
Shifting between 5 km/h 2 km/h
forward and reverse (3.12 mph) (1.25 mph)
ON
Speed clutch
Machine
solenoid valve
speed
Brake solenoid ON
valve
ON
F solenoid valve OFF
Monitor lamp OFF
OFF Buzzer
Neutral
T/M in neutral ON indicator lamp Service brake operating 115ZV62067
OFF
R solenoid valve
ON When the machine speed reaches or exceeds the set
Neutral value, the service brake is applied as in the above case.
indicator lamp OFF OFF When the machine speed drops below the specified
Brake solenoid ON value, the service brake is released.
valve
Monitor lamp
OFF OFF During service brake application, the transmission is
Buzzer placed in neutral.
Service brake operating
95V2E62017
Set value km/h (mph)
Speed range
F R
Approximately 13 Approximately 12
When the traveling direction is switched over between 1st
(8.125) (7.5)
forward and reverse at a machine speed 12 km/h (7.5 Approximately 22 Approximately 24
2nd
mph) or more at any speed position, the power of the (13.75) (15.0)
solenoid valve for auto brake turns on and the service Approximately 36 Approximately 36
3rd
brake is applied until the machine speed is reduced to 2 (22.5) (22.5)
km/h (1.25 mph). At the same time, the power of all 4th/A
Approximately 39

(24.375)
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. (How-
ever, the brake remains applied until the machine speed
becomes approximately 2 km/h (1.25 mph).
62-53
Auto brake solenoid valve
Pilot oil circuit Seat face A
From unloader
valve Brake valve
P
B
Tank Seat face B

P
T B
Spool Hydraulic circuit diagram
Reducing valve
(for autobrake)
Solenoid valve
(for autobrake)
115V2E52006
Valve assembly
Solenoid valve
for auto brake Solenoid
valve for
parking
115V2E62021
Rated current 0.92 A
Resistance 26.2
62-54
Machine control unit (MCU) failure warning
Should the MCU stop working due to the following

cause, a dash mounted monitor lamp lights up to give
warning.
MCU failure monitor lamp
If a warning is given as a result of self-diagnosis of Body blue

the MCU
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 1 2
LgW
MCU are turned OFF.
L
MCU replacement
LgW
B
4 3
If the monitor lamp lights up under the cause above, it is
an indication that the MCU's program has malfunctioned
Electrical Chassis side
and the MCU assembly must be replaced. circuit coupler
When installing a new MCU on the machine, all specifi-

85V2E62030
cations must be registered into the MCU through the
MODM.
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)

62-55
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 G1/2

steering motor G1/2 G3/8
and pump
F5
11.7MPa
(119 kgf/cm2)
(1696 psi)
16
M cm3/rev
G1/2
Check valve
Secondary G1/2
steering relay
+24 V
Secondary
steering motor
and pump
11.7MPa
(119 kgf/cm2)
(1696 psi)
16
M cm3/rev
90.7 90.7
M cm3/rev cm3/rev
Magnetic switch
(on motor and pump)
Steering pump
Hydraulic line
Electrical circuit
115V2E42025
In normal operation, the oil from the steering pump As a result, the secondary steering motor and pump are
flows into the steering valve through the check valve. driven. Then it is ready to steer the machine.
And the signal of the pressure sensor is always sent to
the MCU. Pressure sensor preset value
With some problems, as the steering hydraulic pressure Steering hydraulic pressure
goes down while the engine is running, the pressure ON: at 0.3 MPa (3 kgf/cm2) (44 psi) or lower
sensor signal becomes less than the preset value at the OFF: at 0.4 MPa (4 kgf/cm2) (58 psi) or higher
MCU. In this condition, if the machine speed is more
than 2 km/h, the MCU sends a signal to the magnetic
switch.
62-56
Machine speed signal

The signal from MCU
to magnetic switch
ON
Machine speed
OFF
(km/h)
1 2
85V2E42051
62-57
Monitoring system
If a problem of a unit is detected while the engine is run-
ning, 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 Operation condition Buzzer Lamp test Remarks
Lighting Symbol
color
1 Machine control unit (MCU) Defective machine control unit (MCU)

(red)
Unloader valve accumulator port oil pressure

2 Brake oil pressure is lower than 3.90.5 MPa (403 kgf/cm2)
(red) (56971 psi)
While engine running, 0.1 MPa (1.1 kgf/cm 2)

3 Engine oil pressure
(16 psi) or less for more than 2 seconds
(red)
1012C or more (2144F or more) for more

4 Engine coolant temperature
than 2 seconds
(red)
Torque converter oil 1205C or more (2489F or more) for more

5
(transmission) temperature than 2 seconds
(red)
Filter resistance: 63558 mmAq or more (25

6 Clogged air cleaner
inches H2O) for more than 2 seconds
(red)
Pressure difference at 502C (1224F) or

Clogged transmission oil
7 more
filter
(red) 0.3 MPa (454 psi) or more
8 Charging condition Defective charge system

(red)
9 Central alarm For items 1~7, 10 Flashing type

(red)
When operates steering pressure is less than

10 Steering oil pressure 0.4 MPa (4 kgf/cm2) (57 psi), machine speed
(red) is more than 2 km/h.
When engine cooling water level drops

11 Engine cooling water level
(before start up only)
F/R: No buzzer
12 Auto brake operation When auto-brake works
sounds
(red)
62-58
Monitor lamp
No. Item to be monitored Operation condition Buzzer Lamp test Remarks
Lighting Symbol
color
(red)
Hydraulic oil level is low when the engine is
13 Hydraulic oil level
stopped
(red)
14 Engine protection lamp

(orange)
Any fault in engine detected by ECM

15 Engine warning lamp
(Engine controller) (2 sec.)
(yellow)
16 Engine stop lamp

(red)
62-59
Operation monitor lamps
Monitor lamp
No. Monitor item Lighting condition Remarks
Lighting Symbol
color
1 Parking Red When parking brake switch is set to ON
2 Declutch Green When declutch switch is set to ON
When working light (rear) switch is set

3 Working light Green
to ON
4 K-Lever indicator Green When K-Lever system is ON.
5 Turn signal indicator (left) Green When turn signal lever (left) is actuated
When turn signal lever (right) is

6 Turn signal indicator (right) Green
actuated
7 High beam Blue When head lamp is set to high beam
When transmission shift lever is set to

8 Auto shift Green
automatic position

9 Neutral Green
neutral position

10 Transmission status Yellow
corresponding gear (1~4)
11 Reversal fan Green When the reversal fan switch is ON.
Caution on storage of individual instrument panel
Pointer axis
IMPORTANT Gauge pointer
Axis hole
When storing the instrument panel individually, make Main body
sure that the panel face (transparent face) faces frame
upward.
If the panel face faces below the vertical direction, the
damper oil may leak from meter pointer axis holes.
Damper
oil Magnet
Meter
70ZV62039
62-60
Instrument Panel and Switch
Instrument panel
21 20 6 17 9 19 5 18 2 23
1 4 10
11(37)
12
30 26
28 27
13
34
14
35 15
36
16
38
STOP
39
29 33 32 31 24 25 22 8 7 3
(37)
115V2E62022
1. Tachometer 21. Neutral indicator lamp

2. Engine coolant temperature gauge 22. Transmission status monitor
3. Transmission oil temperature gauge 23. Hour meter
4. Fuel gauge 24. Reversal fan pilot lamp (option)
5. Parking brake indicator lamp 25. Secondary steering warning lamp (option)
6. Auto brake indicator lamp 26. Working light switch (front)
7. Declutch selector lamp 27. Working light switch (rear)
8. Working light indicator lamp (rear) 28. Fuel efficient mode switch
9. Central warning lamp 29. F/R switch indicator lamp (option)
10. Machine control unit (MCU) warning lamp 30. Four-way flasher switch (option)
11. Brake oil circuit warning lamp 31. Engine protection lamp
12. Engine oil pressure warning lamp 32. Engine warning lamp
13. Engine coolant temperature warning lamp 33. Engine stop lamp
14. Transmission oil temperature warning lamp 34. Efficient loading system switch
15. Air cleaner clogging warning lamp 35. Cold start (ether injection) switch
16. Charge warning lamp 36. Selection switch for shift lever or F/R switch
17. Turn signal indicator lamp (left) (option)
18. Turn signal indicator lamp (right) 37. Hydraulic oil level warning lamp
19. High beam indicator lamp 38. Transmission oil filter warning lamp
20. Auto shift indicator lamp 39. Coolant level warning lamp
62-61
Instrument panel rear surface
CN4
CN1 CN3
1 4 L11 L13 29 48
L12
L1
8P 58 57 L20 12P 16P
5 8 L14 L10 35 56
Hour L10 L10
L2 meter
L10 L15 S
L21
L3
L16 E V
L4 S
L17 L10
L5 E V
Engine water
temperature sensor L18
L6 L10 L10
L19
L7 S
CN2
L8 9 18 L22 L23 L24 L25 L26 L27
E V 20P
Transmission oil
L9 temperature sensor 19 28
Layout of connector pins (Instrument panel side)
CN1(8P) CN2(20P) CN3(12P/16P) CN4(2P)

A5 A6 A7 A8 A9
1 2 3 4 9 10 11 12 13 14 15 16 17 18 29 30 31 32 33 34 41 42 43 44 46 47 48 58
5 6 7 8 19 20 22 23 24 25 26 27 28 35 36 37 38 39 40 49 50 53 54 55 56 57
115V2E62027
Pin Lamp Pin Lamp Pin Lamp

Signal Signal Signal
No. No. No. No. No. No.
1 Engine water level alarm L9 21 41 AUTO lamp L20
2 Charge lamp L7 22 42 Auto brake L16
3 Air cleaner clogging alarm L6 23 Fuel level lamp (F) 43 Converter (+)
4 T/M oil temperature alarm L5 24 Fuel level lamp (3/4) 44 Converter ()
5 Engine water temperature alarm L4 25 Fuel level lamp (1/2) 45
6 Engine oil pressure alarm L3 26 Fuel level lamp (1/4) 46 Declutch lamp L17
7 Brake oil pressure alarm L2 27 Fuel level lamp (E) 47 L19
8 MCU failure alarm L1 28 GND () 48 Work lamp L18
9 +24 V power supply 29 +24 V power supply 49 Central alarm lamp L14
10 Secondary steering L22 30 50 GND ()
11 Reversal fan (option) L23 31 51
12 Engine warning lamp L25 32 52
13 Engine protection lamp L24 33 53 High-beam lamp L12
14 Engine stop lamp L26 34 Neutral L21 54 Turn signal (left) lamp L13
15 L27 35 +24 V power supply 55 Turn signal (right) lamp L11
16 E/G water temperature gauge 36 1st speed indication 56
17 T/M oil temperature gauge 37 2nd speed indication 57 Hour meter ()
18 38 3rd speed indication 58 Hour meter (+)
19 Instrument panel illumination L10 39 4th speed indication
20 T/M oil filter clogging alarm L8 40 Parking brake lamp L15
62-62
Gauge circuit
Controller
Grounding S Power supply

24V
E V 15V
Viewed from rear surface of instrument panel

K90ZV62016
Sensors respectively detect the temperature and fuel

level, and then convert them into electric signals. The
signals are transmitted to the corresponding gauges
that indicate the transmitted values.
Note
If a gauge is removed from the panel, the resistance
between the terminals will differ from the standard value
shown in the table.
Gauge Engine water temperature T/C, T/M oil temperature
110C(230F)
97C(206F) 100C(212F)
100C(212F) 120C(248F)
35C(95F) 103C(217F)
50C(122F)
125C(257F)
Indication
White Red Red

White
Resistance between
120~125 75~80
S and E ()
Resistance between
120~125 85~90
S and V ()
Resistance between
170~190 130~150
E and V ()
62-63
Temperature sensor
(For engine water temperature (S/N 9001~9050),
torque converter oil temperature and hydraulic oil
temperature)
115V2E62023
Temperature of 80 90 100 120

detection part (C) [176F] [194F] [212F] [248F]
Resistance (k) 6.2~6.9 4.7~5.2 3.6~3.9 2.1~2.4
62-64
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 transmit-
MCU
Level ted to the MCU, electrically processed, then only one
sensor lamp corresponding to the gauge level lights on the
C14 instrument panel.
C15
Indicator
FUEL LEVEL F
YR (405)
C17
lamps +24V Float switch switching and indicator lamp lighting status
YB (406)
FUEL LEVEL 3/4 C28
FUEL LEVEL 1/2
YL (407)
C20 Indicator lamp
YBr (408) Float switch
FUEL LEVEL 1/4 C29 : Flashing : Lit
YG (409) : ON : OFF
FUEL LEVEL 1/8 C21
A11
(YR ) (410)
(YB) (411)
FUEL LEVEL F : Extinguished
E A33 FUEL LEVEL 3/4
A22
(YL) (412)
FUEL LEVEL 1/2 E 1/4 1/2 3/4 F E 1/4 1/2 3/4 F
(YBr) (413)
A31 FUEL LEVEL 1/4
A23
(YG) (414)
FUEL LEVEL E F or more
Actual fuel level

From F to 3/4
From 3/4 to 1/2
From 1/2 to 1/4
A
From 1/4 to E
E or less
Any other pattern
Example of failure:
When the wire of the "1/2" float switch is broken, the indicator
lamps for "1/4" and "E" do not light even if the fuel amount
1L
becomes 1/2 or less.

2L
Float switch
3L
F
4L
ON
5L
3/4
L
ON
1/2
ON
1/4
ON
1/8
ON
Fuel level sensor
(Brown) (Black) 3/4
E (Yellow) (White) 1/2
1/8 (Green) (Red) 1/4
View A K115V2E62003
62-65
MODM
MODM
(Machine Operation Diagnostic Module) Monitor Changeover
Replacement Fault log

[ ]button [ ]button monitor monitor
Information Input/Output
monitor monitor
Display window [ (step back)] [ (step forward)] Specification Parameter

button button setting monitor setting monitor
90ZV-262001
Change over the monitor using the following procedure:

MODM function
When the starter switch is ON, the MODM software ver-
The MODM has the following functions: sion displays for 3 seconds.
- Information monitor
Displays outside air temperature, machine speed 80V2U62001

and engine speed, engine coolant temperature,
transmission oil temperature, hydraulic oil tempera-
ture and miles driven etc. After this, machine information screen displays informa-
tion relative to the machine function.
- Replacement monitor
Allows check of the replacement time for the parts

and oil periodically replaced, allows setting of the 80V2U62002
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.

62-66
MODM
Changing display from one function to next From Information monitor to Replacement
monitor:
Press both the [ (step back)] button and [ (step
forward)] button at the same time to change over the Press both the [ (step back)] and [ (step for-
monitor mode in sequence "Information monitor ward)] buttons at the same time.
Replacement monitor Fault log monitor Input/Out-
put monitor Parameter setting monitor Specifica- Display should now appear as shown below.
tion setting monitor Information monitor".
However the monitor mode can not be changed in

reverse such as "Information monitor Specification 90ZV-262034
setting monitor Parameter setting monitor ....."
The display will not be changed to the next monitor By pressing the [ (step forward)] button or [
when you hold the buttons. (step back)] button you may then continue to navigate
through the items that should be replaced at given ser-
For the display sequence, refer to "Outline of MODM vice intervals.
(Machine Operation Diagnostic Module) Operation"
page 92-40. From Replacement monitor to Fault log moni-
tor:
Press both the [ (step back)] and [ (step for-

ward)] buttons at the same time.
70V2U62016
Display should appear as shown.

(Example: Downshift button malfunction)
This screen shows fault logs or inactive fault codes and

provides a chronological date and time line of when they
occurred.
By pressing the [ (step forward)] button or [

(step back)] button you may then continue to navigate
through inactive codes.
Up to 100 are stored. In the upper left corner you will

notice a numerical sequence of number between
01~00. This represents faults 1~100 as they have been
logged.
62-67
MODM
From Fault log monitor to Input/Output moni- From Specification setting monitor to Informa-
tor: tion monitor:
Press both the [ (step back)] and [ (step for- Press both the [ (step back)] and [ (step for-
ward)] buttons at the same time. ward)] buttons at the same time.
80V2U62004 80V2U62002
With the shift lever in "Neutral" and "Automatic", the While in default temperature screen, the password input
screen should appear as above. screen can be seen by simultaneously pressing the [ ]
and [ ] buttons. When the password input is finished,
This screen shows the "Input and Output" signal data. fuel consumption can be seen. Pressing [ ] button tog-
gles between metric and US values.
From Input/Output monitor to Parameter set-
ting monitor:

80V2U62005
Display should appear similar to above.
This screen shows "Parameter settings" and may be

used to make changes in an already validated parame-
ter.
From Parameter setting monitor to Specifica-

tion setting monitor:

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 invali-
date a given parameter; effectively turning ON or OFF
the function of an option.
62-68
MODM
Information Monitor 1. Outside air temperature

(Refer to page 92-42)
Information monitor display

90ZV-262024
The following items are displayed:

The monitor displays the current outside air temperature
When the starter switch is ON, the software version dis- when the starter switch is ON.
plays for 3 seconds, then shows default screen.
Press the [ ] button to change over the display unit
from "C" to "F". Press the [ ] button again to return
the display unit from "F" to "C".
90ZV-262024
2. Machine speed and engine speed
To toggle between metric standard values (C, MPa,
Press the [ (step forward)] button and release.
km/h, etc.) and US standards (F, PSI, MPH, etc.), press
the [ ] button.
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 This indicates the actual machine speed and engine

revolutions. This is useful for determining items like shift
mapping patterns in relationship to speed range selec-
When the password input is finished, you will now be at
tion.
the screen shown below.
For speed to be accurate, the correct tire size must be
entered into the main MCU via this MODM unit.
80V2U62007 Press the [ ] button to change the display unit from

"km/h" to "mph"
To leave this screen, press the [ ] and [ ] buttons
Press the [ ] button again to return the display unit
simultaneously again.
from "mph" to "km/h".
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 tempera-
ture" 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 92-40 and 92-42.
62-69
MODM
3. Current engine coolant temperature and 4. Current transmission oil temperature and
maximum engine coolant temperature maximum transmission oil temperature
recorded (which can be reset) recorded (which can be reset)
Press the [ (step forward)] button and release. Press the [ (step forward)] button and release.
90ZV-262026 90ZV-262027
You will now be at the screen shown above. You will now be at the screen shown above.
The monitor displays the current engine coolant temper- The monitor displays the current transmission oil tem-
ature in the "EG COOLANT" line and maximum engine perature in the "TC OIL" line and maximum transmis-
coolant temperature for the day in the "MAX" line. This sion oil temperature for the day in the "MAX" line. This
self resets daily at 24:00 (12:00 Midnight). self resets daily at 24:00 (12:00 Midnight).
Even if the engine is stopped once and then started Even if the engine is stopped once and then started
again, if the time is before 24:00, the monitor displays again, if the time is before 24:00, the monitor displays
the maximum engine coolant temperature recorded on the maximum transmission oil temperature recorded on
the day. the day.
The maximum engine coolant temperature is automati- The maximum transmission oil temperature is automati-
cally reset everyday at 24:00, whether the engine starter cally reset everyday at 24:00, whether the engine starter
switch is turned on or off. switch is turned on or off.
Immediately after reset, the engine coolant temperature Immediately after reset, the transmission oil tempera-
at the time of reset is displayed as the maximum engine ture at the time of reset is displayed as the maximum
coolant temperature. In other words, the current engine transmission oil temperature. In other words, the current
coolant temperature is equivalent to the maximum transmission oil temperature is equivalent to the maxi-
engine coolant temperature. mum transmission oil temperature.
To manually reset, press the [ ] button to reset the To manually reset, press the [ ] button to reset the
maximum engine coolant temperature. Immediately maximum transmission oil temperature. Immediately
after reset, the engine coolant temperature at the time after reset, the transmission oil temperature at the time
of reset is displayed as the maximum engine coolant of reset is displayed as the maximum transmission oil
temperature. temperature.
Press the [ ] button to change over the display unit Press the [ ] button to change over the display unit
from "C" to "F". Press the [ ] button again to return from "C" to "F". Press the [ ] button again to return
the display unit from "F" to "C". the display unit from "F" to "C".
62-70
MODM
5. Current hydraulic oil temperature and max- 6. Odometer (total miles driven) and trip
imum hydraulic oil temperature recorded meter (which can be reset)
(which can be reset)
90ZV-262029
90ZV-262028

The monitor displays the total number of miles that
The monitor displays the current hydraulic oil tempera- machine is operated in top line and miles for operator
ture in the "HYD OIL" line and maximum hydraulic oil selected time frame the trip meter in lower line. This
temperature for the day in the "MAX" line. This self logs miles in forward and reverse.
resets daily at 24:00 (12:00 Midnight).
Press the [ ] button to reset the trip meter displayed in
Even if the engine is stopped once and then started lower line.
again, if the time is before 24:00, the monitor displays
the maximum hydraulic oil temperature recorded on the Press the [ ] button to change over the display unit
day. from "km" to "mile". Press the [ ] button again to return
the display unit from "mile" to "km".
The maximum hydraulic oil temperature is automatically
reset everyday at 24:00, whether the engine starter 7. Number of cycles and cycle time
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. 90ZV-262030
To manually reset, press the [ ] button to reset the You will now be at the screen shown above.
maximum hydraulic oil temperature. Immediately after
reset, the hydraulic oil temperature at the time of reset The monitor displays the number of cycles in the upper
is displayed as the maximum hydraulic oil temperature. line and the time required for one cycle (moving forward
and backward twice) in the lower line.
Press the [ ] button to change over the display unit
from "C" to "F". Press the [ ] button again to return This can be used to determine comparative production
the display unit from "F" to "C". data between operators and between working sites.
Press the [ ] button to reset both the number of cycles

and the cycle time.
After reset, the monitor displays newly the number of

cycles in the upper line and the time required for one
cycle in the lower line.
62-71
MODM
8. Hydraulic system oil pressure Unit conversion and language selection

Press the [ (step forward)] button and release. Select the unit and language using the [ ] button.
Unit conversion (for traveling distance, temper-

ature and pressure)
80V2U62008
Press the [ ] button once to change the display unit.

You will now be at the screen shown above. Press the [ ] button again to return to the previous dis-
play unit.
The monitor displays the unloader pressure of the effi-
cient loading system (ELS). Language selection
Press the [ ] button to change over the display unit Press and hold the [ ] button for 3 seconds or longer to
from "MPa" to "psi". Press the [ ] button again to return get language selection screen.
the display unit from "psi" to "MPa".
9. Voltage
80V2U62009
English is selected as the initial setting.

90ZV-262032
Japanese, French, German, Italian, Spanish, Turkish,

You will now be at the screen shown above. Dutch and English can also be selected.
Shows complete electrical system voltage as is seen at Press the [ (step forward)] button or [ (step
the battery level. back)] button to view the language selections.
Note For returning to the information monitor after selecting

If voltage drops below 27 V DC, the hibernate mode the desired language, press and hold the [ ] button for
(lowers RPMs to conserve fuel) will not work. 2 seconds or longer.
For returning to the information monitor without select-

10. Hour meter (total operating hours) and trip ing another language, press the [ ] button.
meter (which can be reset)
Refer to "Main Menu" page 92-41.
90ZV-262033
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.
62-72
MODM
Replacement Monitor 2. Fuel filter

(Refer to page 92-43) 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
The display window displays remaining time until next
monitor.
replacement of fuel filter cartridge.
Note
If an exclamation mark shows before the numbers that
90ZV-262034 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 70V2U62018
engine oil sulfur content is less than 0.5%. If engine oil
sulfur content exceeds 0.5%, this interval must be cut in
Note
half.
Make sure to set the replacement interval (timer reset)
whenever the fuel filter is replaced.
Note
If an exclamation mark shows before the numbers that
It may be necessary to change this filter more fre-
indicate hours, this shows how many hours overdue the
quently, depending on fuel cleanness.
filter is.
80V2U62079
Note
whenever the engine oil filter is replaced.
62-73
MODM
3. Coolant filter (80ZV-2 ~ 135ZV-2 only) 4. Torque converter and transmission filter
80V2U62011 80V2U62012
The display window displays remaining time until next The display window displays remaining time until next
replacement of the engine coolant filter cartridge. replacement of the torque converter and transmission
filter cartridge.
Note
If an exclamation mark shows before the numbers that Note
indicate hours, this shows how many hours overdue the If an exclamation mark shows before the numbers that
filter is. indicate hours, this shows how many hours overdue the
filter is.
70V2U62019
70V2U62020
Note
Make sure to set the replacement interval (timer reset) Note
whenever the coolant filter is replaced. Make sure to set the replacement interval (timer reset)
whenever the torque converter and transmission filter is
It may be necessary to change this filter more fre- replaced.
quently, depending on engine coolant condition.
It may be necessary to change this filter more fre-
quently, depending on transmission oil cleanness.
62-74
MODM
5. Hydraulic return filter 6. Engine oil
80V2U62013 80V2U62014
replacement of hydraulic return filter. replacement of engine oil.
Note Note
If an exclamation mark shows before the numbers that If an exclamation mark shows before the numbers that
indicate hours, this shows how many hours overdue the indicate hours, this shows how many hours overdue the
hydraulic return filter change is. oil change is.
Ex. "!12 h" indicates that it is 12 hours overdue. Ex. "!12 h" indicates that it is 12 hours overdue.
70V2U62021 70V2U62022
Note Note
Make sure to set the replacement interval (timer reset) Make sure to set the replacement interval (timer reset)
whenever the hydraulic return filter is replaced. whenever engine oil is replaced.
It may be necessary to change this oil more frequently,

depending on work site conditions, oil sampling results
and oil cleanness.
62-75
MODM
7. Torque converter and transmission oil 8. Axle oil
80V2U62015 80V2U62016
replacement of torque converter and transmission oil. replacement of both front and rear axle and planetary
unit oils.
Note
If an exclamation mark shows before the numbers that Note
indicate hours, this shows how many hours overdue the If an exclamation mark shows before the numbers that
oil change is. indicate hours, this shows how many hours overdue the
oil change is.
70V2U62023
70V2U62024
Note
Make sure to set the replacement interval (timer reset) Note
whenever torque converter and transmission oil is Make sure to set the replacement interval (timer reset)
replaced. whenever axle oil is replaced.
It may be necessary to change this oil more frequently, It may be necessary to change this oil more frequently,
depending on work site conditions, oil sampling results depending on work site conditions, oil sampling results
and oil cleanness. and oil cleanness.
62-76
MODM
9. Hydraulic oil Replacement interval set (timer reset)

Press the [ (step forward)] button and release. When the machine is shipped, the standard replace-
ment interval is set as the initial setting.
Press and hold the [ ] button for 2 seconds or more on

80V2U62017
the replacement monitor screen to display the timer
reset screen.
You will now be at the screen shown above. The timer reset screen displays the standard replace-
ment interval.
The display window displays remaining time until next
replacement of hydraulic oil. For setting the standard replacement interval, press the
[ ] button.
Note
If an exclamation mark shows before the numbers that Then, the standard replacement interval is set, and it
indicate hours, this shows how many hours overdue the returns to the replacement monitor screen again.
oil change is.
70V2U62025
Note
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.
62-77
MODM
Example: Engine oil Replacement interval pop-up
When the remaining time until the next replacement

interval reaches " 0 " (or 0 hours), the replacement pop-
90ZV-262037 up appears and flashes in the display window.
For setting the replacement interval other than the stan-

dard 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 contin-
uously. 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 contin- When two or more replacement pop-ups occur at the
uously in the same manner. same time, the corresponding items flash in turn.
After setting the replacement interval, press and hold After the remaining time for the next replacement
the [ ] button for 2 seconds or more. reaches " 0 ", the corresponding pop-up appears up to
three times when the starter switch is ON.
The replacement interval is reset, and the display
returns to the replacement monitor screen again. (The MODM software version is displayed for 3 sec-
onds, 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) proce-
dure above.
62-78
MODM
Display language Fault Log Monitor

The same language selected in the information monitor
is used as the display language for the replacement
Start from key ON. Press the [ (step back)] button
monitor.
and [ (step forward)] button together twice to get to
this point.
For selecting the display language, it is necessary to
return to the information monitor.
The display language can be selected only on the infor-

mation monitor screen.
Fault log history check
1. Active faults
For returning from the replacement monitor to the infor-
mation monitor, change the monitor in turn as described Up to 100 machine faults and 100 engine faults can be
in the sequence "Replacement monitor [ ][ ] recorded in fault log (200 total).
(pressing them at the same time) Fault log monitor
[ ][ ] (pressing them at the same time) Input/ Failure codes that begin with CN are machine faults.
Output monitor [ ][ ] (pressing them at the same (CN=Chassis fault #)
time) Parameter setting monitor [ ][ ] (pressing
them at the same time) Specification setting monitor Failure codes that begin with EN are engine faults.
[ ][ ] (pressing them at the same time) Infor- (EN=Engine fault #)
mation monitor".
What is shown
For the display sequence, refer to "Outline of MODM The following list of items are shown. Fault descriptor,
(Machine Operation Diagnostic Module) Operation" fault code number, date of occurrence and hour-minute-
page 92-40. second of occurrence. Examples shown below.
This shows fault CN321. This is caused by an engine

coolant temperature fault (open circuit). Note descrip-
tions.
Fault descriptor Fault code
Date Time in 24:00 hour scale

July 20, 2006 3:27:32 PM
80V2U62018
This shows fault EG146. This is caused by an engine

coolant temperature fault (overheat condition).
80V2U62019
Fault codes are split into input and output signals.

62-79
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).
You can toggle between viewing the engine faults or
machine faults.
Failure codes that begin with CN are machine faults.
Failure codes that begin with EN are engine faults. Machine fault
What is shown When the machine fault log screen is displayed, press
The following list of items are shown. Order of occur- and hold the [ (step forward)] button for 2 seconds
rences, fault code number, date, hour-minute-second, or more to display the engine fault log screen which
and quantity of occurrence. Examples shown below. shows the latest engine fault code.
This shows fault CN321. This is caused by an engine

coolant temperature fault (open circuit). Note descrip-
tions.
80V2U62022
Order of occurrences A=Active fault Engine fault

100 total 01~00 Fault code number 002 is qty of occurrences
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.

July 20, 2006 3:27:32 80V2U62023
80V2U62020
The machine fault log screen and engine fault log

This shows fault EG146. This is caused by an engine screen can be distinguished as follows:
coolant temperature fault (overheat condition). Note
descriptions. Displayed fault code:
CN ..... Machine fault log screen
EG ..... Engine fault log screen
Order of occurrences A=Active fault
100 total 01~00 Fault code number 016 is qty of occurrences

July 25, 2006 1:31:38
80V2U62021
..... If still active, shows "A" before fault number.

62-80
MODM
Machine fault log navigation Clear fault log

Clear inactive fault log
When two or more fault codes are recorded, press the
[ (step forward)] button to display the next latest Fault codes can be cleared by pressing the [ ] button
fault code. and holding it for more than 2 seconds while in the
engine fault mode, or in the machine fault mode
Press the [ (step back)] button to display the fault screens.
code in chronological order.
Press and hold the [ ] button for 2 seconds or more to
clear the entire fault log.
Engine fault log navigation When there are two or more fault codes recorded, all
fault codes recorded are cleared by performing the clear
When two or more fault codes are recorded, press the fault log operation once.
[ (step forward)] button to display the next latest
fault code. Press the [ ] button not to clear the fault log and to
return to the machine fault log screen again.
Press the [ (step back)] button to display the fault
code in chronological order. 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 mem-

ory, in case you need that information later.
After engine fault codes (EGXXX) or machine fault

codes (CNXXX) have been cleared, the buzzer will
sound to alert that the code has been erased from
memory. If you do not hear the buzzer, the fault codes
have not been erased from memory history.
62-81
MODM
Clear active fault log (error pop up)
When a fault occurs, the corresponding fault code is

forcibly displayed on the screen.
When two or more active faults occur, up to 5 fault

codes each are displayed repeatedly. (Up to total 10
fault codes for CN and EG errors together)
For deleting the displayed fault codes, press one of the

[ (step forward)] button, [ (step back)] button,
[ ] button or [ ] button.
80V2U62024
Then, the screen displayed before the active fault codes

appears again.
Active fault codes are displayed repeatedly when the

starter switch is ON and will continue to display until the
cause of each fault code is eliminated.
If there is a fault that has been erased, and the cause is

not repaired, the fault will quickly reappear in the screen
due to being active.
It will continue to reappear until the underlying cause of

the fault is eliminated.
62-82
MODM
Failure code (Input side)
Code Failure Detection condition (In case of)

Shift lever F & R contact ON at the same time
CN121 Shift lever F & R switch malfunction
Failure continues for more than 3 seconds
Shift lever any of more than two 123A contact ON at the same time
CN122 Shift lever 123A switch malfunction (1)
CN123 Shift lever 123A switch malfunction (2) All 123A signal OFF continues for more than 3 seconds
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
Shift-up switch & shift-down switch contact ON at the same time
CN143 Shift-up switch & shift-down switch malfunction
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
T/M oil pressure switch malfunction
CN151 Signal OFF continues for more than 10 seconds during engine running
(This applies to the model 115ZV-2/135ZV-2 only)
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
No E/G speed sensor input for more than 3 seconds when E/G speed sen-
CN163 E/G speed sensor 1 (ECM output) malfunction (1)
sor selection is OFF (Input circuit is disconnected)
Input value is more than 3,000 min-1 for more than 3 seconds when E/G
CN164 E/G speed sensor 1 (ECM output) malfunction (2)
speed sensor selection is OFF
E/G speed sensor 2 (Sensor output) malfunction No E/G speed sensor input for more than 3 seconds when E/G speed sen-
CN165
(1) sor selection is ON (Input circuit is disconnected)
E/G speed sensor 2 (Sensor output) malfunction Input value is more than 3,000 min-1 for more than 3 seconds when E/G
CN167
(2) 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
Secondary secondary steering oil pressure sensor
CN251 Voltage is lower than 0.2 V for more than 3 seconds
malfunction(1)
Secondary steering oil pressure sensor malfunc-
CN252 Voltage is larger than 4.6 V for more than 3 seconds
tion (2)
Oil pressure sensor detects secondary steering oil pressure below
CN254 Low secondary steering oil pressure 306 kPa (3.1 kgf/cm2) (44 psi) for more than 3 seconds during engine run-
ning
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
Efficient loading system hydraulic oil pressure sen-
CN271 Voltage is lower than 0.2 V for more than 3 seconds
sor malfunction (1)
Efficient loading system hydraulic oil pressure sen-
CN272 Voltage 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
CN351 Hydraulic oil temperature sensor malfunction (1) Input voltage is larger than 3.56 V for more than 3 seconds
62-83
MODM
Code Failure Detection condition (In case of)

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
Brake oil pressure sensor 1 detects pressure below 4,081 kPa (41.6 kgf/
CN412 Abnormal brake oil pressure (1)
cm2) (592 psi) for more than 1 second during engine running
Brake oil pressure sensor 2 detects pressure below 4,081 kPa for (41.6
CN413 Abnormal brake oil pressure (2)
kgf/cm2) (592 psi) more than 1 second during engine running
Brake oil pressure difference switch is in abnormal condition for more than
CN414 Abnormal brake oil pressure difference
1 second
CN415 Abnormal brake oil amount Brake oil amount switch is in abnormal condition for more than 1 second
Engine oil pressure switch is OFF for more than 2 seconds during engine
CN421 Abnormal engine oil pressure
running
CN431 Abnormal engine coolant temperature (1) Engine coolant temperature switch is ON for more than 2 seconds
Engine coolant temperature sensor is in 101 deg. C (214 deg. F) condition
CN432 Abnormal engine coolant temperature (2)
for more than 2 seconds
CN451 Abnormal T/M oil temperature (1) T/M oil temperature switch is ON for more than 2 seconds
T/M oil temperature sensor is in 122 deg. C (252 deg. F) condition for more
CN452 Abnormal T/M oil temperature (2)
than 2 seconds
Hydraulic oil temperature sensor is in 100 deg. C (212 deg. F) condition for
CN461 Abnormal hydraulic oil temperature
more than 2 seconds
30 minutes after starter switch is ON, T/M oil filter switch is ON for more
CN471 Clogged T/M oil filter 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
Radiator cooling water level switch is OFF for more than 2 seconds when
CN491 Abnormal cooling water level in radiator
the engine is off.
CN496 Abnormal hydraulic oil level Hydraulic oil level switch is in abnormal condition for more than 30 seconds
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 301 V
Voltage is lower than 220.5 V for more than 10 seconds during engine
CN913 Abnormal MCU voltage (2)
running
Fuel level display table

Input Output
1/8 1/4 1/2 3/4 F E 1/4 1/2 3/4 F
x x x x x
x x x x
x x x
x x
x

Other than above
: No input signal given : Lamp on : Lamp flashing
x : Input signal given : Lamp off
Note
This table applies to ZW550 units.
62-84
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
Speed change control solenoid valve malfunction
CN536 Speed change control solenoid valve is short-circuited
(1)
Speed change control solenoid valve malfunction
CN537 Speed change control solenoid valve is disconnected
(2)
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
Efficient loading system selection solenoid valve Efficient loading system selection solenoid valve is short-circuited or dis-
CN681
malfunction connected
CN693 Lower kickout relay malfunction (1) Lower kickout relay (coil) is short-circuited
CN694 Lower kickout relay malfunction (2) Lower kickout relay (coil) is 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
Failure code (Engine)
Refer to "Quantum fault code information" page 62-27.

62-85
MODM
Input/Output Monitor By pressing the [ (step forward)] button, you will

arrive at a window as shown below.
Input/Output monitor display

80V2U62026
1. Input signal monitor
This is because in window 2, it shows the parking brake
From a position of turning on the key switch, press both as being released and the corresponding slot would
the [ (step back)] and [ (step forward)] buttons have a 1 in that place. In other words, the parking brake
simultaneously 3 times, you will arrive at the screen coil has been energized and the slot has a 1 in it indicat-
shown below. ing that it is energized and the parking brake is
released.
Now press the [ (step forward)] button once. You

80V2U62025 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)

Nothing in this case is activated, so all of the slots are
This monitor displays the ON/OFF status of the shift occupied with the number 0.
lever, setting switches, pressure switches, etc.
There are seven input groups from INPUT 1 to INPUT 7. 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 corre-

sponding item number. 80V2U62028
When input signal is OFF, "0" is displayed under corre- The screen indicates that ride control and ELS are acti-
sponding item number. vated, or the switch for each one is energized.
Refer to "MODM: Input/Output Monitor - Input/Output Now press the [ (step forward)] button once. You
Signal Correspondence Table" page 92-49. will arrive at the screen shown below.
As shown in table of section "MODM: Input/Output Mon-
itor - 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
62-86
MODM
Now press the [ (step forward)] button once. You 2. Current output monitor
will arrive at the screen shown below.
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
Note
The [ (step back)] or [ (step forward)] button
This indicates that there are no inputs happening in this must be held for 2 seconds or more with each change. If
situation. not, it will not move to next item.
Now press the [ (step forward)] button once. You If the feature is set to "Invalid" in specification setting,
will arrive at the screen shown below. the following items will be skipped.
- STEERING PRESS - SP7 (EMG steering)
- BOOM ANGLE - SP15 (Lift kickout)

80V2U62031
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 90ZV-262019
position.
This area is called the "Current Output Monitor". As
Now press the [ (step forward)] button once. You seen, it first shows actual front brake circuit pressure.
will arrive back the screen shown below.
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 following screen is seen.
lever, setting switches, pressure switches, etc.
- 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 cor- following screen is seen.
responding item number.
- When input signal is OFF, "0" is displayed under cor-

responding item number.
80V2U62034
For more clarification, refer to "MODM: Input/Output

Monitor - Input/Output Signal Correspondence Table".
62-87
MODM
Next, by pressing the [ (step forward)] button, the 3. Output signal monitor (D1~D6)
following screen is seen.
This monitor displays the ON/OFF status of the trans-
mission forward/backward solenoid valves, speed range
solenoid valves, indicator lamps and warning lamps on
the instrument panel, etc.
80V2U62035
There are six output groups from OUTPUT 1 to OUT-

Note PUT 6.
Brake main pressure 1 is accumulator oil pressure for
rear accumulator which serves only the rear brake cir- Each group has eight items from item 0 to 7.
cuit. Brake main pressure 2 is accumulator oil pressure
for front accumulator which serves the front brake circuit When output signal is ON, "1" is displayed under corre-
and all pilot derived pressures; these are pilot oil pres- sponding item number.
sure for the pilot control valves, auto brake, park brake
release, etc. The actual real-time pressures are shown When output signal is OFF, "0" is displayed under corre-
in these fields. sponding item number.
Next, by pressing the [ (step forward)] button, the Refer to "MODM: Input/Output Monitor - Input/Output
following screen is seen. Signal Correspondence Table" page 92-49.
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

80V2U62036
Output Monitor" part of the "Input and Output Monitor"
section.
This shows the 2nd speed solenoid coil and the forward
All of the aforementioned screens can be seen in coil outputs have been applied, as the transmission is in
reverse order by using the [ (step back)] button. forward and automatic.
Holding this button in for longer than 2 seconds will take
you to the input signal monitor screen section. 1st, 3rd, 4th, reverse, high, and autobrake solenoid coils
are not energized and show no application signal.
Next press the [ (step forward)] button to show the

following screen.
80V2U62037
Again, note that all values except the last are 0, and
only the brake lamp output is in the "ON" position.
62-88
MODM
Next press the [ (step forward)] button to show the 4. Electric current output monitor
following screen.
This indicates the milliamps (mA) of electric current that
are being sent to the fan solenoid valve from the MCU.
Press the [ (step forward)] button for 2 seconds or

80V2U62038
longer to show the following screen.
All values are at 0 as there are no outputs needed in this

scenario.
80V2U62042
following screen.
This current output will vary as demands for fan revolu-
tions change, according to amount of heat that is being
generated. This heat must be discharged to cool the
system that is heating back down.
80V2U62039
When the machine systems are cold and the machine is

Note that the place under slot 5 is occupied by a 1, as in warm up mode, the mA level will be higher than when
MCU failure relay should be energized by MCU if MCU the machine has worked for a time and has become
passes software logic test at MCU boot-up that occurs heat saturated.
with the key in the "ON" position.
Note
Next press the [ (step forward)] button to show the Disconnecting the fan solenoid wire will increase the
following screen. fans 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.
80V2U62040
Refer to fault code table for the chassis side for more
Note that the place under slot 1 is occupied by a 1, as detail.
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.

following screen.
80V2U62041
Note that this shows no input signal at this time.

62-89
MODM
Parameter Setting Monitor 1. Shift inhibitor

(Refer to page 92-46) From turning on key switch which would default to
screen shown below.
Parameter setting monitor display
This monitor allows check of parameters that are cur-

rently set.
80V2U62002
Value levels to set parameter for items like ride control,

tire ratios, date/time clock (used to log faults), declutch Pressing both the [ (step forward)] and [ (step
pressures, secondary steering, detent values sensor, back)] buttons simultaneously, 4 times once after
etc. another, arrive at the screen shown below.
Note
If the feature is set to "Invalid" in specification setting
view, the following items will be skipped in the parame-
80V2U62005
ter setting monitor view.
- RIDE CONTROL - SP5 (Ride control) The transmission changes the speed range automati-
cally according to the machine speed. If the machine
- EMG STEERING - SP7 (EMG steering) speed sensor is disconnected when the machine is run-
ning high, the machine speed is suddenly reduced
- K-LEVER - SP8 (K-Lever) because of that the transmission is automatically shifted
to the low range. As a result, the operator becomes very
- TRACTION CONTROL - SP11 (Traction control) unstable condition by rapid deceleration. This device
prevents the above.
- 2 STAGE - SP13 (Efficient loading system)
By pressing the [ (step forward)] button, you will
- BOOM SOFT LAND - SP14 (Lower kickout) arrive at a window as shown below.
- KICK OUT - SP15 (Lift kickout)
80V2U62043
62-90
MODM
2. Ride control Press the [ (step forward)] button to add "1" to a

numerical value.
will arrive at the screen shown below. Note
Value for "ON" must be 1 km/hr or more greater than
"OFF".
The numerical value will increase as you press the [

80V2U62044
(step forward)] button as follows;
The screen should appear similar to what is shown. This 0 1 2 ..... 9 0 1 2 .....
shows the speed at which ride control turns on and per-
mits the base end oil to work against the accumulator Press the [ (step back)] button to subtract "1" from a
piston. numerical value.
Now press the [ (step forward)] button once. You The number then decreases as follows;
will arrive at the screen shown below.
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 val-
80V2U62045
ues and return to the parameter setting screen.
The screen should appear similar to what is shown. This Press the [ ] button to return to the parameter setting
shows the speed at which ride control turns off and does screen without changing parameter values.
not permit the base end oil to work against the accumu-
lator 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 sec-
ond).
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, press-
ing [ ] 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.
62-91
MODM
3. Meter division ratio 4. Tachograph
Next, by pressing the [ (step forward)] button, the Next, by pressing the [ (step forward)] button, the
following screen is seen. following screen is seen.
80V2U62046 80V2U62048
The screen should appear similar to what is shown. This Next, by pressing the [ (step forward)] button, the
is the speed division ratio for the smaller tire. This per- following screen is seen.
mits the speed reading to be accurate when equipped
with smaller tires.

80V2U62049
5. Secondary steering
80V2U62047 Next, by pressing the [ (step forward)] button, the

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. 80V2U62050
Note
The screen should appear similar to what is shown and
indicates the engagement speed.
Tire size
Model
Small size (B) Large size (A)
When this option is on the machine, this screen will per-
ZW550 29.5 35/65 mit the technician to see the engagement speeds. This
will engage when the machine loses power to the
Note that the 1/12 ratio is the small size (B), and the 1/ engine, or if the steering pump were to fail and hydraulic
11 ratio is the large size (A). 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.

80V2U62051
62-92
MODM
6. K-Lever (stick steering) Review the following screens that are able to be seen
by pressing the [ (step forward)] button. (A setting
Next, by pressing the [ (step forward)] button, the 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 moni-

80V2U62057
tor display.
i=Signal intensity (or mA)
Review the following screens that are able to be seen
by pressing the [ (step forward)] button. (A setting A Type
shown.)
Solenoid valve Current (mA) Solenoid valve

LH side RH side
imax
i2
80V2U62053
80V2U62054
i1
V=Voltage
Potentio-
meter (V)
The screen should appear similar to what is shown and 2.5

0 V1 V1 5
indicates the K-Lever mA signal strength or intensity.
V2 V2
Vmax Vmax
Note
The default setting for K-Lever is to the "A" type. 80V2U62077
The voltage settings are displayed in the MODM moni-

tor display. Initial set values
K-LEVER V1 0.25 V
K-LEVER V2 2.0 V
K-LEVER Vmax 2.4 V

K-LEVER i1 290 mA
K-LEVER i2 450 mA
K-LEVER imax 470 mA

62-93
MODM
B Type 7. Traction control

Solenoid valve
LH side
Current (mA) Solenoid valve
RH side
imax
i3
i2
80V2U62058
This indicates parameter of 1.0 second when in forward

i1 and 1st (F1) gear before traction control will engage. If
time of engagement for F1 is less than 1 second, it is
Potentio-
meter (V) looked at as not permanent; software will not respond to
2.5 signal as it is considered to be inconsequential. This
0 V1 V1 5
helps avoid erratic machine function.
V2 V2
V3 V3
Vmax Vmax Next, by pressing the [ (step forward)] button, the
80V2U62078 following screen is seen.
Initial set values
K-LEVER V1 0.25 V 80V2U62059
K-LEVER V2 1.0 V
K-LEVER V3 2.0 V This stands for Dual Stage for slip control. This parame-
ter is not used in USA production and should be disre-
K-LEVER i1 290 mA
garded. (It would have set a given hydraulic system
K-LEVER i2 400 mA pressure value to indicate that machine was excavating
K-LEVER i3 450 mA and MCU logic for traction control would take into
account this additional parameter.)
K-LEVER imax 470 mA

Note following screen is seen.
Type A and B are switched on the specification setting
monitor. (Refer to page 62-99)
In case of type A, screen changes as follows.

80V2U62060
V1 V2 Vmax i1 i2 imax
This stands for Inching slip control feature and is not
In case of type B, screen changes as follows. used. This parameter is not used in USA production and
should be disregarded. (If it were used, declutch (or
V1 V2 V3 i1 i2 i3 imax inching circuit) sensor would signal MCU to know brake
circuit pressure & deactivate traction control if the brake
circuit pressure was over a given value for a given time
frame (See "ti" below; ti is also not used).)
62-94
MODM
80V2U62061 80V2U62065
This is time inching. This is time frame in lsc above. This stands for Slip Control time; data is provided in
seconds of time. When the set time for starting slippage
Next, by pressing the [ (step forward)] button, the begins, traction control engages and makes adjust-
following screen is seen. ments accordingly.
8. Declutch
80V2U62062 Next, by pressing the [ (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
This is brake circuit pressure; at this pressure, the
declutch circuit will put the transmission to neutral posi-
tion, 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.

80V2U62064
This stands for Slip Control intensity; indicates acceler-

ated slipping velocity of traction control. The value is
indicated in km/h per 0.1 second. Each 1/10th of a sec-
ond the velocity is cut back by engine rpm reduction so
slippage will not occur, and this provides reduced tire
slippage.
62-95
MODM
9. Efficient loading system (ELS) 10. Engine power control
Next, by pressing the [ (step forward)] button, the Temperature

80V2U62067
80V2U62070
This is the voltage at the rotary sensor wire that returns
signal to MCU. This signal from the rotary sensor deter-
mines the boom height position. If the boom is high, the The screen should appear similar to what is shown.
unloader valve solenoid coil at the ELS control valve will
not be energized, and the ELS will not operate to unload This is the temperature at which hibernate mode will
the loading pump. 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 Next, by pressing the [ (step forward)] button, the
senses 2.5 V or less. following screen is seen.
Typical voltage for the rotary sensor is as shown in

graphic below (approximate values).
65V2E62024
Approximate voltage values

The screen should appear similar to what is shown.
Boom fully up=4.8 V
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
62-96
MODM
11. Lower kickout (for return to dig) 13. Calendar (Date and time)
80V2U62072 90ZV-262022
The screen should appear similar to what is shown; volt- The screen should appear similar to what is shown.
age 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)

80V2U62073
The screen should appear similar to what is shown; volt-

age 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 dam-

age caused by the mass of the boom, bucket, and link-
age moving up rapidly with the boom cylinders
extending and causing the pistons to hit the boom cylin-
der heads.
62-97
MODM
Parameter change Press the [ (step forward)] button to add "1" to a

numerical value. The numerical value will increase as
The parameter values can be changed when the both you press the [ (step forward)] button as follows.
conditions below are satisfied:
0 1 2 ..... 9 0
The engine is stopped (starter switch is ON).
The parking switch is ON. 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 specifica- 9 8 7..... 0 9
tion setting monitor. (Refer to page 92-46)
After changing parameter values, press and hold the
[ ] button for 2 second or more to finalize the input val-
Ride control setting 1 ues and return to the parameter setting screen.
Press the [ ] button to return to the parameter setting

screen without changing parameter values.
The date & time sequence reads as shown.

When the corresponding item is set to "INVALID", the
parameter screen is not displayed. (It is skipped to the
DATE YY / MM / DD
next screen.)
TIME hh : mm : ss
Calendar Y=year
M=month
D=day
90ZV-262022
h=hour
m=minute
Changing date and clock values: s=second
These values can be changed by doing the following. Example:
Press and hold the [ ] button for 2 seconds or more on DATE 06 / 07 / 12 = July 12, 2006
the parameter setting screen to display the parameter TIME 20 : 15 : 11 = 8:15:11 pm
change screen.
Note
The cursor flashes in a 1-second cycle (flashes on for Failure to enter the values correctly will make the clock
0.5 second). give the wrong time, and the date to read incorrectly in
all of the dependent functions, such as fault code mes-
Press the [ ] button to move the cursor. sages, etc.
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 [ ] but-
ton will move it to the left end in the upper line. The cur-
sor 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
62-98
MODM
Specification Setting Monitor 1. Specification setting display

(Refer to page 92-47 and 92-48) This monitor allows check of the specifications currently
set.
Specification setting monitor display
When attaching an optional unit, change the specifica-
From turning on key switch which would default to tion setting to make the corresponding function valid.
screen shown below.
It is necessary to log with the correct password for
changing the specification setting.
If no password is entered, only the initial specification

80V2U62002
setting monitor can be seen, and is shown the program
number that is designed for that particular machine
Pressing both the [ (step forward)] and [ (step model.
back)] buttons simultaneously, 5 times once after
another, arrive at the screen shown below.
80V2U62074
80V2U62074
When you are at this point, press the [ (step for-
ward)] button for over 2 seconds will take you to the fol-
lowing 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 CUSTOM-

ERS OR END USERS !
IT IS FOR TRAINED KAWASAKI SERVICE PERSON-

NEL ONLY ! SERIOUS DAMAGE TO MACHINE MAY
RESULT BY USING INAPPROPRIATE ENTRY VAL-
UES.
62-99
MODM
2. Password entry and changing settings Every time the [ (step back)] button is pressed, the
displayed content is changed "FR switch Wheel type
Note Kickout ..." in sequence.
To make changes to entry settings, engine must be
"OFF", and key switch in "ON" position with parking The following items can now be selected as "VALID" or
brake applied. Otherwise changes will not happen. "INVALID" by pressing and holding the [ ] button for 2
seconds or longer, and then selecting the [ (step for-
ward)] or the [ (step back)] button to choose
"VALID" or "INVALID" as required.
90ZV-262023
When finished, press and hold the [ ] button for 2 sec-
onds or longer to accept the change.
The password is a numerical password.
If you need to return without making a selection, press
Press the [ (step forward)] button to add "1" to a the [ ] button, and you will return to the previous
numerical value. screen without making a change of selection.
The numerical value will increase as you press the [ - Selection switch shift (shift lever or F/R switch)
(step forward)] button as follows; Valid/Invalid
0 1 2 3 4 5 ..... 9 0 1 2 3 - Shift hold

4 5 ..... etc. Valid/Invalid
Press the [ ] button to change the cursor position to - Ride control

continue password entry. When finished, press the [ ] Valid/Invalid
button for longer than 2 seconds to get to the following
screen. - Secondary steering
Valid/Invalid
- K-Lever (Stick steering)

A Type/B Type/Invalid
80V2U62075
- Hydraulic pressure increase

Every time the [ (step forward)] button is pressed Valid/Invalid
and held for 2 seconds, the displayed contents are
changed over "All setting reset Specification group 1 - Traction control
Specification group 2 All setting reset" in Valid/Invalid
sequence.
- Tachograph
Every time the [ (step back)] button is pressed and Valid/Invalid
held for 2 seconds, the displayed contents are changed
over "All setting reset Specification group 2 Speci- - Efficient loading system (ELS)
fication group 1 All setting reset" in sequence. Valid/Invalid
For the display sequence, refer to "Outline of MODM - Lower kickout

(Machine Operation Diagnostic Module) Operation" Valid/Invalid
page 92-40.
- Lift kickout (variable)
Specification group 1 Valid/Invalid
Every time the [ (step forward)] button is pressed, - Wheel type

the displayed content is changed "FR switch Shift A type (Big wheel)/B type (Small wheel)
hold Ride control ..." in sequence.
62-100
MODM
Specification group 2 - Engine oil pressure sensor (for communication and

monitor control)
Every time the [ (step forward)] button is pressed, Valid/Invalid
the displayed content is changed "Downshift button
Auto brake Engine speed ..." in sequence. - Brake pressure differential switch
Valid/Invalid
Every time the [ (step back)] button is pressed, the
displayed content is changed "Downshift button - Brake oil level
Brake oil level Brake oil differential sw ..." in Valid/Invalid
sequence.
Use the table on page 62-103 to do this.
The following items can now be selected as "VALID" or
"INVALID" by pressing and holding the [ ] button for 2 You may exit back to the default screen when finished
seconds or longer, and then selecting the [ (step for- by pressing the [ (step forward)] and [ (step
ward)] or the [ (step back)] button to choose back)] buttons simultaneously.
"VALID" or "INVALID" as required.
When finished, press and hold the [ ] button for 2 sec-

WARNING
onds or longer to accept the change. Changing the systems parameters to non factory set-
tings will render the monitor ineffective. This can lead
If you need to return without making a selection, press to warranty claims that will not be covered by the fac-
the [ ] button, and you will return to the previous tory warranty.
screen without making a change of selection. DO NOT VALIDATE OPTIONS OR SETTINGS THAT
DO NOT APPLY !
- 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 con-

trol)
Valid/Invalid
- Engine coolant temperature sensor (for monitor con-

trol)
Valid/Invalid
- Engine oil pressure switch (for monitor control)

Valid/Invalid
62-101
MODM
All setting reset Allows batch deletion or batch reset of information mon-
itor, replacement monitor or fault log monitor.
Specified
Item Comment
Parameter
Information monitor
Kick down (downshift button) SP1 Always valid
Selection switch shift When this is performed, the following items will be reset.
SP2 Optional
(shift lever or F/R switch)
Shift hold SP3 Always lnvalid
- Maximum engine coolant temperature
Autobrake SP4 Valid
Ride control SP5 Option - Maximum transmission oil temperature
Engine speed SP6 Sensor
Secondary steering SP7

Option - Maximum hydraulic oil temperature
(EU always valid)
K-Lever SP8 Option - Number of cycles
Engine curve SP9 Output
Hydraulic pressure increase
SP10 Option - Cycle time
(power up)
Traction control SP11 Valid - Trip meter (for hour meter)
Tachograph SP12 Always invalid
Efficient loading system (ELS) SP13 Valid
Replacement monitor
Lower kickout SP14 Always valid
Lift kickout SP15 Always valid
- Engine oil filter timer
Cooling fan SP16 A type
Torque converter oil tempera- - Fuel filter timer
SP17 Invalid
ture switch
Engine coolant temperature
switch
SP18 Invalid - Coolant filter timer
Engine coolant temperature
SP19 Sensor - Torque converter line filter timer
sensor
Engine oil pressure switch SP20 Always valid
Engine oil pressure sensor SP21 Sensor (INVALID) - Hydraulic oil return filter timer
Brake pressure differential
SP22 Invalid - Engine oil timer
switch
Brake oil level SP23 Invalid
Wheel type SP24 A or B type - Torque converter and transmission oil timer
- Axle gear oil timer
- Hydraulic oil timer
After timers are reset, each of them is automatically set

to the standard initial set value.
Fault log monitor
- The machine fault log is deleted.
- The engine fault log is deleted.
Note
This can be reset with engine running. It will retain reset
results.
62-102
MODM
All setting reset procedure (Start at screen

shown)
80V2U62075
Press and hold the [ ] button for 2 seconds or more to

display the all setting reset execution screen.
See example below.
80V2U62076
When executing the all setting reset function, press and

hold the [ ] button for 2 seconds or more. Then, the all
setting reset function is executed, and the specification
setting screen appears again.
Press the [ ] button to return to the specification setting

screen without executing the all setting reset function.
62-103
MODM
Default position of specification setting moni-

tor
OPTION EITHER
ITEM ZW550
VALID OR INVALID
Kick down
Valid/Invalid
(downshift button)
Selection switch shift
(shift lever or F/R Valid/Invalid x
switch)
Shift hold Valid/Invalid x
Autobrake Valid/Invalid
Ride control Valid/Invalid x
Engine speed Net/Sensor Sensor
Secondary steering Valid/Invalid x
K-Lever Valid/Invalid x
Engine curve Output/Net/Invalid Output
Hydraulic pressure
Valid/Invalid x
increase (power up)
Traction control Valid/Invalid
Tachograph Valid/Invalid x
Efficient loading sys-
Valid/Invalid
tem (ELS)
Lower kickout Valid/Invalid
Lift kickout Valid/Invalid
Cooling fan A type/B type/Invalid A type
Torque converter oil
Valid/Invalid x
temperature switch
Engine coolant tem-
Valid/Invalid x
perature switch
Engine coolant tem-
Net/Sensor Sensor
perature sensor
Engine oil pressure
Valid/Invalid
switch
Engine oil pressure
Valid/Invalid x
sensor
Brake pressure differ-
Invalid/Nc/No x
ential switch
Brake oil level Invalid/Nc/No x
Wheel type A or B type A type
=Valid x=Invalid
* Auto brake is always valid on ZW550 units. ** Pilot operated hydraulics for K-Lever on ZW550.

Items that are not shaded in table are addable options.

62-104
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
Detent 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.

Bucket leveler
Adjusting rod (detected object)
Connector
Proximity switch Bucket cylinder
85V2E62007
Proximity switch
Adjusting the clearance
Proximity switch +24V

LED
Switch Br 1
Coil for detent
main B 2 inside pilot
circuit L
3
valve
+24V
Detection part
Operation indicator lamp (LED)
1(Br)
Detected View Z
object
3(L) 2(B)
52 mm (0.1970.079 in) 85ZV62015
Adjust the clearance between the sensor and the

adjusting plate to 52 mm (0.1970.079 in). In this con-
dition, the operation indicator lamp (LED) is on, and the
circuit between the switches (2) (3) is on.
62-105
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 623
62-106
Lift kickout & lower kickout

Location
A
5
3
Detail A
6
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" posi- When the boom control lever is placed at "Float" posi-
tion and the boom reaches at the preset height, the lift tion and the boom reaches at the preset height, the
kickout automatically releases the detent and returns lower kickout automatically releases the detent and
the boom control lever to "Hold" position. The detent returns the boom control lever to "Hold" position. The
function and the units are the same way as those of the detent function and the units are the same way as those
bucket leveler. of the bucket leveler.
62-107
Sensor assy
4 4 2
2 3
5
1
A-A Detail of grease applying
1
A A
30
Position sensor detail
85V2E62009
1. Position sensor
2. Link
3. Plate
4. Shaft
5. Ball bearing
62-108
A B C
View A A
Position sensor detail
CCW
70T2U62008
Resistance 5 k 1 k
Electrical rotation 128 (Theoretical)
Mechanical rotation 180
Clockwise stop 90 from elect. center
Spring return To clockwise end of rotation
70T2U62009
62-109
Detent solenoid Preset height adjustment
Lever position: Lever position:

Lower kickout side Lift kickout side
Switch
Push rod Push rod

115V2E62019
Detent Detent
(Upper) (Lower)
solenoid solenoid
(for lift) (for lower)
Fixing Fixing Hold Hold
disc disc
Reset Reset
85V2E62017
65V2E62018
Two detent solenoids are installed in the pilot valve
boom side.
1. Lift kickout preset height
One is for the lift kickout and the other is for the lower
Raise the boom to the desired position and press
kickout.
the left side of the kickout control switch located on
the console box to set the boom height for the lift
Voltage DC 24 V
kickout.
Coil resistance 623
2. Lower kickout preset height
Lower the boom to the desired position and press

the right side of the kickout control switch located
on the console box to set the boom height for the
lower kickout.
62-110
Diode
Diode
Symbols Open circuit, failed in open position.
+24V
Switch
+ Solenoid
[Anode] [Cathode]
Surge voltage
(forward direction) Diode

Current flow
(backward direction)
Current flows while the diode is disconnected.
(The solenoid is energized, however the surge voltage
is not absorbed. This damages electrical parts.)
70ZV62051 70T2U62011
Normal A diode is an electronic part which makes the current

flow in one direction.
Current flow
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.
+24V
Switch
Solenoid
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.
Diode
Current flows while the diode is normal Some electrical parts, as solenoid valves, buzzers,
(The solenoid is energized.) 70ZV62052 relays, all equipped with electromagnetic coils may gen-
erate a surge voltage caused by counter electromotive
force when the power is turned off. This surge voltage
Short-circuit, failed in closed position.
may cause malfunction of equipment.
Diodes are provided to prevent such a malfunction.
+24V However, if a diode is damaged and short-circuited (or

Switch fails closed) in its inside, electronic parts may be
Solenoid harmed.
Therefore, if a malfunction occurs in electrical equip-

Diode ment, electrical connection diagrams should be referred
to first, to determine and repair the cause. If a diode is
Current flows through the diode with smaller resistance. provided in the electrical equipment, the diode should
The solenoid is not energized. be checked for damage.
95ZV62074
62-111
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
Coil
about 300 or smaller, the continuity is detected.
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 12V
Diode check mode
30A
ECM Battery
(1)
R1 BR F15 WR (2) (3) WP
B AC
R2 C 5A
(2)(3): Diode unit
Suppression diode
F14
F13
R1
5A
5A
Charge From
circuit alternator
I terminal
B Neutral
relay
115V2E62005
Forward check
Continuity is detected in the status shown in the figure.
Normal Continuity is not detected when tester terminals are con-
nected in opposite way.
Continuity is not detected in either way Disconnection
Abnormal
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 Judgement

Continuity (voltage value) Over level Normal
Over level Over level Open circuit
0 volt 0 volt Short-circuit
62-112
Resistance check mode
Analog type tester
R1>0 R2=
0 0
Forward check Backward check
Digital type tester
R1>0 R2=
R1
Forward check Backward check
Forward check Backward check Judgement

R (0<R<) Normal
Open circuit
0 0 Short-circuit
62-113
Diode
Surge voltage and surge suppres- Fig. 3

sion diodes
Fig. 1 Surge suppression
diode
Electromagnetic field forms

when switch closes. Coil
Coil
Current direction
Voltage
Battery
Current
Switch or
Current [A]
Voltage [V]
transistor
Time [sec] K70V2J62006
Load When the surge voltage was generated, it causes to

115ZVE62032
increase wear on the switch points.
Some electrical parts such as solenoid valves are During the coil is being activated by the transistor, when
equipped with a coil. the excruciating high voltage is loaded on the transistor,
the transistor may be broken.
When a coil is energized, an electromagnetic field is
formed. See fig. 1. In order to absorb this surge voltage, connect the diode
parallel to the coil in the reverse direction against the
Fig. 2 power supply.
When the switch opens, the When the switch is off, the same amount of electric cur-
field collapses across the coil rent, that was flown till now, flows through the diode.
windings.
Coil
Voltage This electric current is attenuated gradually and finally it
Battery
Current reaches zero. That means no surge voltage is gener-

ated in the circuit.
Current [A]
Voltage [V]
ON OFF This diode is called as flywheel diode.

Time [sec]
Surge voltage
Load
115ZVE62033
When the solenoid coil is de-energized, the field col-

lapses across the coil. The collapse of this electromag-
netic field across the solenoid coil generates an
unregulated voltage surge. See fig. 2.
This can damage transistors, contacts, and other elec-

tronic parts. (See connection diagram.)
62-114
Diode
72-1
115ZV-2 Function & Structure Operator Station Group

Operator Station Group
Cabin ....................................................................... 72-2

Operator Seat.......................................................... 72-10
Steering and Transmission Shift Lever.................... 72-11
Air Conditioner ........................................................ 72-14
Troubleshooting....................................................... 72-70
72-2
Function & Structure Operator Station Group
Cabin
Cabin
Mounting drawing
2
Floor board
Rear chassis 115V2E72001
The cabin equipped with the ROPS (Roll Over Protec-

tive Structure) is provided as standard.
1. Cabin
2. ROPS
72-3
Cabin
Outline drawing
AB A
7
6
8 B
4 B-B A-A
K115V2J72002
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
72-4
Cabin
Glass
70V2E72001
1. Front glass
2. Front side glass
3. Rear glass
72-5
Cabin
1. Part number KC3201121690 2. Part number KC3201121700
Clear glass Clear glass

(Outside) Laminate: 0.76 mm (Outside) Laminate: 0.76 mm
T=3.0 T=3.0
Green glass Green glass

(Inside) (Inside)
T=3.0 T=3.0
A-A A-A
(mm)
327.5
(mm)
0
953 R2
R3
A
A
1195
A
1149
R3
R53
96
R3
4- 299.5
R3
52.5
0
646.5 699
70V2E72002 70V2E72003
Note Note
This glass must comply with ECE REG43. This glass must comply with ECE REG43.
72-6
Cabin
3. Part number KC3201121500
(mm)
1262.5
R2 4
4 R2
848
T=6.0
0 R3
R3 0
1325.5
70V2E72004
Note
This glass must comply with ECE REG43.
72-7
Cabin
Wiper mount
Front wiper
714 (Along surface)
Wipin
g ang
le 56
2
ace) rf
long su
1
R750(A
2
1 3
97ZV72004
1. Wiper motor 4. Intermittent wiper relay

2. Wiper arm 5. Washer jet nozzle
3. Wiper blade
Rear wiper
97ZV72005
1. Wiper motor 3. Wiper blade

2. Wiper arm 4. Washer jet nozzle
72-8
Cabin
Wiper motor
Front
Cabin
(Automatic stop position)

12
159200 589
24V
100
3 4 5 6
80
(B
5 the
115
re
70
a
rh
60
ol
e)
.2
(3 10')
0
5.6
R8
Wipin
g angle
56 22
Ro
tati
ng
dire
cti on
(-1) AVS0.85 W
(-2) AVS0.85 L
(+) AVS0.85 R
(S) AVS0.85 Y
( L1~L3=3.7H
C1~C3=0.2F )
(+) AVS0.85 R
MOTOR
1
Circuit breaker
M
L3
L2 L1
C3
C2 C1
R R Y B L W
Washer motor 24 V
OFF
LOW
HIGH
SWITCH
Circuit diagram
2 7
97ZV72100
Wiper motor (front) specifications

1. Wiper motor assembly
2. Link assembly Nominal torque 23.5 N-m (2.4 kgf-m)
3. Washer Rated voltage DC 24 V
4. Nut Rotating speed Load: Low 464 min-1
5. Cap 1.0 N-m (0.1 kgf-m) High 687 min-1
6. Nut Low > 32 min-1
Rotating speed Load: =
7. Crank arm 4.0 N-m (0.4 kgf-m) High > 42 min-1
=
No-load starting voltage (Minimum) < 16 V
=
Automatic stopping voltage (Maximum) > 32 V
=
No-load current <2A
=
Locked rotor current < 15 A
=
72-9
Cabin
Rear
Wiping angle: 1063

Automatic stop
position
L(+)
LB (+1) Y(S)
Cabin
AVS0.85 LB
(+1)
AVS0.85 L
(+)
1 AVS0.85 WB
AVS0.85 Y
( )
MOTOR (S)
(Circuit breaker) WB
M
2 3 4 5 6
LB Y L
Cabin Tightening torque:
+1 S + Pantagraph arm 6.4~9.3 N-m (0.6~0.9 kgf-m)
OFF
24V
ON
SWITCH
Circuit diagram (motor stop position)
K97V2J72001
1. Wiper motor Wiper motor (rear) specifications

2. Washer
3. Packing Nominal torque 12 N-m (1.2 kgf-m)
4. Nut Rated voltage DC 24 V
5. Cap Rotating speed Load: Speed 385 min-1
6. Nut 0.6 N-m (0.6 kgf-m) Current 2 A or less
Rotating speed Speed 405 min-1
No load Current 1 A or less
Starting voltage 16 V or less
Locked rotor current 7 A or less
72-10
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.
2 Anti-Clockwise to lower seat.
1 3. Check ride indicator (5) shows green.

If red, readjust seat height.
Within the green band of the ride indicator there is 75

6 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.
95ZV OM EU SEAT
4
5 Up-stop height adjustment control (europe specifi-
cation)
85V2E72003
To adjust the up-stop height, rotate handwheel (6) clock-

wise to raise the seat unseated, rotate it counterclock-
1. Reclining adjustment lever
wise to lower the seat unseated.
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.
72-11
Steering and Transmission Shift Lever
Tilt quantity
56 56
Operator
stand 7
8 95ZVE72009
1. Steering wheel Handle tilt

2. Transmission shift lever 56 mm in each direction from the center
3. Turn signal indicator and head lamp high/low selec-
tor lever Handle slide
4. Handle tilt adjustment lever 85 mm upward and downward
5. Gas spring
6. Column shaft assembly Note
7. Lower column shaft - Install gas spring (5) with its rod side facing down-
8. Orbitrol ward as shown in the figure above.
- Install lower column shaft (7), together with the
Tilt case (1~6) can select the optimal position in the fol- Orbitrol, from the underside of the operator stand.
lowing range:
72-12
Tilt case
1
1
4 Lock 6
release
position
2 7
2
5
4
Operator
stand
9
Operator
270 (355 when slid)
stand
Slide quantity
Lock position
85
10 3
97ZV72017
1. Column shaft assembly : (6): 21.5 N-m (2.2 kgf-m)

2. Bracket : (7): 49 N-m (5.0 kgf-m)
3. Bracket : (8): 54 N-m (5.5 kgf-m)
4. Handle tilt adjustment lever : (10) (inside): 31.9 N-m (3.3 kgf-m)
5. Bolt : (10) (outside): 89.1 N-m (9.1 kgf-m)
6. Nut
(double-start thread, tapered in lever mounting
area)
7. Nut
8. Nut
9. Bushing
10. Nut
72-13
Column shaft
Grease
charged Adhesive
4 applied
3 1
8
8
10 9
2
11 7
6
5
Waterproof seal 13
11
11
8
12 B-B
A-A
97ZV72018
1. Column tube Shift lever

2. Column shaft
3. Column bushing Refer to "Electrical Group 62".
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)

72-14
Air Conditioner
Air Conditioner
Air conditioner components
4
1-1
1-2
5
1
7
9
2 10 12
11 14
6
8 13
97ZV72020
1. Air conditioner assembly Air conditioner specifications (system per-

1-1 Cooling unit assembly formance)
1-2 Blower assembly
2. Air distributor assembly
Cooling system performance
3. Recirculating air filter
4. Control panel
Cooling capacity 4.65 kw (15,881 BTU) 10 %
5. Condenser assembly
Air quantity 550 m3/h (720 yd3/h) 10 %
6. Compressor assembly
7. Receiver drier
8. Receiver drier bracket Power consumption 345 W (14.4 amps) 10 %
9. Joint
10. Drain hoses Heating system performance
11. Relay
12. Thermistor* (inside air sensor) Heat radiation quantity 5.2 kw (17,759 BTU) 10 %
13. Thermistor* (outside air sensor) Air quantity 380 m3/h (500 yd3/h) 10 %
14. Solar sensor (insolation sensor) Rated voltage DC 24 V
Power consumption 170 W (7.1 amps) 10 %
* or thermal resistor (Difference in temperature: 65C, water flow rate: 6 L/min)
72-15
Air Conditioner
Denso air conditioner structure

Cooling unit
37
14
57
51
38
13
25 2
50
49
24
9
24
23
11 6
5 8
15
3 17
16
12
97ZV72021
72-16
Air Conditioner
1. Cooling unit case (rear) 20. 39.

2. Cooling unit case (front) 21. 40.
3. 22. 41.
4. Evaporator core 23. Power integrated circuit 42.
5. Heater core assembly 43.
6. Expansion valve 24. Servo motor (A/M, air mixing) 44.
7. 25. Servo motor (mode) 45.
8. Tube 26. 46.
9. De-icing sensor 27. 47.
(thermal resistor) 28. 48.
10. 29. 49. Lever (face, front)
11. Door (upper) 30. 50. Control lever (face, front)
12. Door (lower) 31. 51. Door (S/A) (face, front)
13. Door (foot) 32. 52.
14. Damper (vent) 33. 53.
15. Pressure switch (triple) 34. 54.
16. Liquid tube 35. 55.
17. Suction tube 36. 56.
18. 37. Lever (face, door) 57. Thermo sensor (water temperature)
19. 38. Lever (foot, door)
72-17
Air Conditioner
Heater and accessories Air distributor (hood & defroster selection

box)
13
3
6
6 4 9
7
2
7
2
1
97ZV72024
11
17 10
1. Air damper case
2. Air damper case
3.
4.
5.
6. Control lever
7. Door
97ZV72023 8.
9. Control lever
1. Blower case
10.
2. Blower case
11.
3. Air damper case
12.
4. Air damper case
13. Servo motor actuator (AY, inside/outside air)
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
72-18
Air Conditioner
Air compressor (with magnetic clutch)
2-1
2 2-2
2-3
2-6
2-8
5~7
2-7
85V2U72001
1. Compressor 3.
2. Magnetic clutch assembly 4.
2-1 Magnetic stator coil 5. Plate washer
2-2 Magnetic clutch pulley 6. Plate washer
2-3 Clutch hub 7. Plate washer
2-6 Plate washer
2-7 Snap ring
2-8 Snap ring
Condenser unit
3
1
4
3 2
12
10 95V2U72001
1. Condenser core 7. Cover

2. Blower assembly 8.
3. Condenser bracket 9.
4. Condenser bracket 10. Wire harness
5. 11.
6. 12. Resistor
72-19
Air Conditioner
Control unit
Control
amplifier
Control panel
97ZV72027
Control panel
Temperature Vent mode

OFF switch Blower switches setting switches selector switch AUTO switch
Inside/outside air Liquid crystal display Air conditioner

selector switches (LCD) unit ON/OFF switch 97ZV72028
72-20
Air Conditioner
Function of cooling mechanism 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
Principle of cooling
agent. A down tube in the receiver drier is submerged
into the heavier liquid that is now at the bottom of the
Expansion
receiver drier. This tube will permit passage of only the
Indoor valve heavier liquid that is at the bottom of the receiver drier.
Expansion Condenser
Then the high-pressure liquid passes through the ther-
Evaporator
mal expansion valve that provides a restriction or throt-
Evaporation Releases
Condensation heat to the tles the flow of refrigerant. This restriction reduces the
outside. pressure of the liquid refrigerant thus reducing its boiling
Deprives heat
Compression Refrigerant point. The expansion valve also meters the amount of
of the adjacent
area.
refrigerant to the evaporator, by modulating the valve
from wide open to closed, which varies with the heat
Compressor
load. The expansion valve separates the high-pressure
Basic cooling cycle side from the low-pressure side.
97ZV72029
The refrigerant is now at the evaporator. Temperatures

in the evaporator are cold enough to cause the ambient
Function and operation of air conditioning sys- air to cool when blown through it. This causes conden-
tem sation to happen. The fan-charged air that rushes
through the evaporator is now going to shed its humid-
Very often, things are much simpler than they may ity. This humidity, or condensed water, is routed through
appear. This is also the case with an air conditioning some tubing to be discharged to the outside of the cab
system. Gas when compressed often heats as a result as waste water that falls to the ground. The refrigerant
of molecular compression, and when decompressed it is now on its way back to the compressor. It is still under
cools. Some gases are more prone to heat or cool to a pressure when compared to the atmospheric air pres-
greater degree when undergoing these changes than sure. However, because it is drawn along by the refrig-
are others. We use these natural laws to make an air erant compressor suction, we now say that is in the
conditioning system work. Another factor to take into suction side (low-pressure side) of the circuit.
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 tempera-

tures, imagine that you can very quickly make the refrig-
erant 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 con-
verted into a liquid at this point, while still in the con-
denser. This is why it is called the condenser, as it has
condensed the gas into a liquid. As a liquid that may still
72-21
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 --> liq-
uid --> gas ...", and carries heat from the low tempera-
ture side (inside the cab) to the high temperature side
(outside the cab) while changing its status.
There are many types of refrigerants. This air condi-

tioner 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 CH2FCF3

Molecular weight 102.03
Boiling point -26.19C (-15F)
Critical temperature 101.14C (214F)
4.1 MPa (41.45 kgf/cm2)
Critical pressure
(595 psi)
Critical density 511 kg/m3 (0.073 lbs)
Density of saturated liquid
1,206 kg/m3 (595 psi)
(at 25C/77F)
Specific volume of saturated vapor
0.0310 m3/kg
(at 25C or 77F)
197.54 KJ/kg (186 BTU)
Latent heat of evaporation (at 0C/32F)
(47.19 kcal/kg)
Combustibility Noncombustible
Ozone decomposition modulus 0
72-22
Air Conditioner
Refrigerant characteristics Generally, fluid (which is the generic name for com-
pressed / condensed non-gas liquid) has following prop-
erties.
100
(212)
1. When the temperature of gas at a certain pressure

Refrigerant temperature (C) (F)
80
(176)
decreases, the gas starts to condense and change
60
(140)
into liquid at a certain temperature. For each sub-
stance (liquid), this temperature is fixed at a given
40
(104)
35
pressure. This temperature determined by a given
(95)
20
pressure is called the "saturated temperature".
(68)
15
(59)
0
2. On the contrary when the temperature is deter-
mined, the pressure at which liquefication starts is
(
20
4) fixed. This pressure is called the "saturated pres-
(
30
22)
sure".
0 3.6 5 8 10 15 20 25 30 35 40 (kgf/cm )
2 The figure on the left shows the relationship
353 490 785 981 1,471 1,961 2,452 2,942 3,432 3,923 (kPa)
51 71 114 142 213 284 355 426 497 568 (psi) between the saturated temperature and the satu-
Gauge pressure (kgf/cm2G) rated pressure of refrigerant R134a.
Relationship between saturated pressure At the temperature and the pressure below at the
and saturated temperature of R134a 85V2U72002
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 25C (77F), the refrigerant should
change (be evaporated) from liquid into gas at a tem-
perature lower than 25C (77F). 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 con-

densed to liquid, the refrigerant is cooled down by out-
side air of about 35C (95F) so that it can condense.
Accordingly, as is seen from the figure, the refrigerant

can be liquefied at the pressure of 785 kPa (8.0 kgf/
cm2G) (114 psi) or more.
72-23
Air Conditioner
Cooling circuit The figure on the left shows the cooling circuit of the air
conditioner.
In this circuit diagram, the area which cools down the air
inside the cab is the evaporator. The cooling circuit uti-
lizes the fact that the refrigerant absorbs heat (latent
heat of evaporation) from the adjacent area when evap-
orated, and cools down the air inside the cab. The area
Inside cab where the refrigerant is evaporated is the evaporator.
Pressure bulb
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 refriger-
Evaporator Expansion valve
ant (wet evaporation refrigerant with low degree of dry-
Blower ness) is supplied into the evaporator.
Inside engine room

For example, in order to cool down the air to 15C
(59F), the refrigerant can absorb the latent heat of
evaporation from the air only when it is evaporated at a
Compressor Cooling fan temperature lower than 15C (59F). It can be seen from
the figure in the previous page that the pressure of the
Pressure switch
refrigerant inside the evaporator should be 353 kPa (3.6
kgf/cm2G) (51 psi) or less to realize it. And in order to
Receiver dryer keep sufficient cooling effect, the supplied refrigerant
quantity should be adjusted so that the refrigerant sup-
Condenser plied to the evaporator is completely evaporated inside
the evaporator into dry vapor or gas.
Structure of cooling circuit
Accordingly, the cooling circuit should be constructed to
85V2U72003
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 expan-
sion 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 com-
pressor and heat change (heat radiation) of the con-
denser, which acts to change the state of the gas to
liquid.
72-24
Air Conditioner
Electrical circuit
Control schematic drawing
Outside air
sensor Input signals Input signals
Set temperature, room temperature,
water temperature, air temperature Insolation sensor
after evaporator Outside air sensor
Insolation e = Inside air temperature - Set temperature Set temperature

sensor correction
Freeze sensor
Water temperature
sensor
Blower voltage/temperature control/blow-off servo motor position determination
Inside air
Blower
Water temperature (C)
Warm-up control
sensor 55
voltage
BLC
Temperature 25
control
servo HOT
Blower motor COOL

Blow-off
Temperature servo FACE
control servo B/I
FLOOR
Y value
Blow-off servo
Compressor ON-OFF
ON
3 4
Freeze sensor temperature (C)
95ZVE72018
72-25
Air Conditioner
Air conditioner functions of com-

ponents
Control panel
Name and function of each part on control
panel
(3) Temperature (4) Vent mode selector

(1) OFF switch Indicator lamps (2) Blower switches setting switches switch (5) AUTO switch
(6) Inside/outside air selector switches (7) Liquid crystal Indicator lamps (8) Air conditioner
display (LCD) unit ON/OFF switch
97ZV72036
- (1) OFF switch - (2) Blower switches
This switch stops the operation of the blower and the These switches change over the air flow quantity in
air conditioner. six steps.
When OFF switch (1) is pressed, the set tempera- The air flow quantity is displayed on the LCD unit.
ture and the air blow quantity displayed on LCD unit When the switch is pressed, the air flow quantity
(7) as well as the indicator lamps above AUTO increases.
switch (5) and air conditioner ON/OFF switch (8) When the switch is pressed, the air flow quantity
turned "off", and operation is stopped. decreases.
In the automatic mode, the air flow quantity is auto-
matically 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 "high"

72-26
Air Conditioner
- (3) Temperature setting switches
These switches set the temperature inside the cab in

the range from 18.0C (65F) to 32.0C (90F).
When the switch is pressed, the set temperature
increases.
When the switch is pressed, the set temperature
decreases.
Usually, set the temperature to 23~25.0C
(72~77F).
Display on the LCD unit and the function
Display on LCD unit Set temperature

18.0C (65F) Maximum cooling
18.5~31.5C Temperature inside cab is controlled so that
(65~95F) set temperature is realized.
32.0C (90F) 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 posi-
tions.
In the automatic mode, the vent mode is automati-
cally changed over.
Display on Vent positions

Vent mode Remarks
LCD unit (A) (B) (C) (D)
Face (blow-off to upper portion of

body mainly during cooling)
Face & foot
Foot
(blow-off to feet mainly during heating)
This mode is not

Foot & defroster selected in automatic
mode.
This mode is not
Defroster selected in automatic
mode.
- (5) AUTO switch
This switch automatically changes over the air blow When the automatic mode is changed over to the
quantity, the vent mode and the inside/outside air in manual mode, the indicator lamp above AUTO
accordance with the set temperature. switch (5) is extinguished. In the manual mode, the
When AUTO switch (5) is pressed, the indicator air blow quantity, the vent mode and the inside/out-
lamp above it lights. side air can be changed over by manipulating each
Usually, press this switch, set the temperature by switch.
using temperature setting switches (3), and use the
air conditioner in the automatic mode.
72-27
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 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.
Outside air entry
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 tempera-
ture 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 (cool-

ing 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 con-
ditioner is turned off and the indicator lamp is extin-
guished.
However, the air conditioner is turned on only while
the blower is operating (that is, while the air blow
quantity is displayed on the LCD unit.)
72-28
Air Conditioner
Operating method 2. Stopping the automatic operation
Normal use
1. Automatic operation (1) OFF switch
Set temperature (3) Temperature setting (5) AUTO switch

switches
97ZV72041
Air flow quantity (8) Air conditioner

ON/OFF switch Press OFF switch (1). Then, the set temperature and
the air flow quantity displayed on the LCD unit are extin-
97ZV72040
guished, the indicator lamps above AUTO switch (5)
and air conditioner ON/OFF switch (8) are extinguished,
(a) Set AUTO switch (5) to ON. Confirm that the set and the operation is stopped.
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/out-
side air to realize the set temperature.
Note
When the vent mode is set to or
in the automatic operation, if the engine water tem-
perature is low, the air flow quantity is restricted to
prevent blow-off of cold air.
72-29
Air Conditioner
3. Manual operation 4. Stopping the manual operation
(2) Blower switches (3) Temperature (4) Vent mode

setting switches selector switch
(1) OFF switch
(6) Inside/outside air selector switch (8) Air conditioner

ON/OFF switch
97ZV72042 97ZV72041
(a) Press blower switches (2), and adjust the air flow Press OFF switch (1). Then, the set temperature and
quantity. the air flow quantity displayed on the LCD unit are extin-
Confirm that the set temperature and the air flow guished, the indicator lamps above AUTO switch (5)
quantity are displayed on the LCD unit. and air conditioner ON/OFF switch (8) are extinguished,
and the operation is stopped.
(b) Set to ON air conditioner ON/OFF switch (8). Con-
firm that the indicator lamp above the switch lights.
(c) Adjust temperature setting switches (3), and set

arbitrary temperature.
(d) Press vent mode selector switch (4), and select

arbitrary vent mode.
(e) Press an either inside/outside air selector switch (6)

to select inside air circulation or outside air entry.
72-30
Air Conditioner
Other uses 2. Defroster operation
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 (3) Temperature

air selector switch setting switches
(6) Inside/outside (3) Temperature
air selector switch 97ZV72045
setting switches
97ZV72044
(a) Press blower switches (2), and adjust the air flow
quantity.
(a) Press blower switches (2), and adjust the air flow Confirm that the set temperature and the air flow
quantity. quantity are displayed on the LCD unit.
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.
(b) Press vent mode selector switch (4), and display
the vent mode on the LCD unit. (c) Set outside air introduction selector switch (6).
(c) Set to ON air conditioner ON/OFF switch (8). Con- (d) Press temperature setting switches (3), and display
firm that the indicator lamp above the switch lights. the set temperature "32.0" (maximum heating sta-
tus) on the LCD unit.
(d) Arbitrarily set blower switches (2), temperature set-
ting switches (3) and inside/outside air selector Adjust the louver at each vent position so that air flow
switches (6). reaches the windows.
Then, the air conditioner realizes the bi-level operation When defogging the windows or dehumidifying the air
in which cold air is blown to the head and hot air is inside the cab in rainy season, set air conditioner ON/
blown to the feet. OFF switch (8) to ON.
72-31
Air Conditioner
Other functions 3. Failure code deletion
Self-diagnosis function After completing the inspection and/or the repair,

delete the failure codes memorized in the com-
Each sensor and equipment used in the air conditioner puter.
can be diagnosed for failure. 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 sec-
(1) OFF switch onds or more.
<Display on the LCD unit and the failure mode>
Display Failure mode

E- No failure
E11 Wire breakage in inside air sensor
(6) Inside/outside E12 Short-circuit in inside air sensor
air selector (3) Temperature setting switches E13 Wire breakage in outside air sensor
switches Press and hold both the " " and " "
switches together E14 Short-circuit in outside air sensor
(for 3 seconds or more). 97ZV72035
E15 Wire breakage in water temperature sensor
E16 Short-circuit in water temperature sensor
1. Press the OFF switch to stop the operation. E18 Short-circuit in insolation sensor
(The set temperature and the air blow quantity dis- E21 Wire breakage in vent sensor
played on the LCD are extinguished.) E22 Short-circuit in vent sensor
E43 Abnormality in vent damper
2. When the both temperature setting switches " "
E44 Abnormality in air mixing damper
and " " (3) are pressed and held together for 3
E45 Abnormality in inside/outside air
seconds or more, the failure mode is displayed on
E51 Abnormality in refrigerant pressure
the LCD unit.
(a) If two or more failure are detected, the displayed Celsius-Fahrenheit selector function for the set tem-
contents can be scrolled through by pressing either perature display
one of the temperature levels (3) " " or " ".
While the blower is operating, press and hold both tem-
(b) Press OFF switch (1) again to finish the self diag- perature setting switches (3) " " and " " together
nosis function and return to the normal display. for 5 seconds or more to change over the unit of the dis-
played value between Celsius and Fahrenheit. How-
ever, the unit type (C or F) itself is not displayed.
Only the set value is displayed.
Value displayed on LCD unit

Celsius (C) 18.0~32.0
Fahrenheit (F) 65~90
72-32
Air Conditioner
Air conditioner unit Air mixing damper
[In the case of maximum cooling]

Air mixing damper A (completely opened)
Heater coil
Evaporator coil
Cold air
Co
ld
a ir
Air mixing damper B (completely closed)
[In the case of maximum heating]

Air mixing damper A (completely closed)
Blower motor
Co
ld
air
air
t
Inside/outside air selection damper
Air mixing damper A Inside Ho
air
Outside
air
Air mixing damper B (completely opened) 80ZVE72002
Fan
During maximum cooling, the air mixing damper B is
completely closed, and the air mixing damper A is com-
pletely opened. As a result, the air cooled by the evapo-
Blower motor rator does not go through the heater radiator but is
blown off.
Heater radiator Evaporator
Air mixing damper B During maximum heating, the air mixing damper A is
completely closed, and the air mixing damper B is com-
pletely opened. As a result, all the air which has gone
through the evaporator goes through the heater radia-
80ZVE72001 tor, then the warmed air is blown off.
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.
72-33
Air Conditioner
Evaporator The evaporator is an important heat exchanger which

evaporates liquid refrigerant set to low temperature and
low pressure by an expansion valve, utilizes its latent
heat, and absorbs heat from air (target) inside the cab.
Accordingly, heat should be smoothly transmitted
Evaporator between the target and the refrigerant in the evaporator.
(5)
(7)
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
(4) between the refrigerant and the air.
(2)
By cooling, the moisture contained in the air condenses,
(8) (1)
changes into water drops, and adheres to the outside of
the evaporator. If these water drops are frozen, the cool-
(6) ing effect deteriorates. To prevent this, attention should
be paid also to proper drainage of condensed water.
The refrigerant quantity supplied to the evaporator is

(3) 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
Refrigerant flow inside evaporator ( ) evaporator should be minimal.
From expansion valve(1) to (8)
Compressor Accordingly, reduction of pressure drop is an element to
enhance the performance of the evaporator.
97ZV72048
Troubleshooting the evaporator
Item Symptom Cause Action

Both high pressure and low pressure are low,
- Joint portion of supply area - Tightening
Gas leak and air bubbles can be seen through sight
- Cracks in evaporator main body - Repair/replacement
glass.
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
- Blockage in filter
Freezing Air quantity is small, and low pressure is low. (Evaporator is not preforming - Cleaning/replacement
inadequately.)
72-34
Air Conditioner
Expansion valve (box type) Expansion valve operation
(Evaporator) Diaphragm
Evaporator
Spring
Temperature
sensing rod
Diaphragm
Temperature sensing rod
Needle valve (To compressor)

(From receiver) Needle valve
Structural drawing of box type expansion valve From receiver To compressor

(High pressure) (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
1. By injecting the liquid refrigerant at high tempera- to the refrigerant gas chamber.
ture and high pressure which has gone through the
receiver from a small hole, the expansion valve The gas pressure changes in accordance with the
expands dramatically the liquid refrigerant into mist detected temperature, the temperature sensing rod
refrigerant at low temperature and low pressure. directly connected to the diaphragm is moved, then the
needle valve opening is adjusted.
2. Promptly in accordance with the vaporized status of
the refrigerant inside the evaporator, the expansion - When the temperature at the exit of the evaporator is
valve adjusts the refrigerant quantity. low or when cooling load is small, following occurs.
In order to ensure that the evaporator offers its full
performance, the liquid refrigerant should be kept in The gas pressure inside the diaphragm chamber
a state in which it deprives heat of the adjacent becomes low, the volume decreases, the temperature
area and its evaporation is always completed at the sensing rod moves to the right, and the needle valve is
exit of the evaporator. closed.
To realize this, the expansion valve automatically
adjusts the refrigerant quantity in accordance with - When the temperature at the exit of the evaporator is
fluctuation of the temperature inside the cab (cool- high or when cooling load is great, following occurs.
ing load) and fluctuation of the rotation speed of the
compressor. The gas pressure inside the diaphragm chamber
The expansion valve consists of a needle valve, a becomes high, the volume increases, the temperature
diaphragm and a temperature sensing rod. sensing rod moves to the left, the needle valve is
The temperature sensing rod detects the tempera- opened, and more quantity of refrigerant is supplied to
ture of the refrigerant which has gone through the the evaporator.
evaporator, and transfers the detected temperature
to the refrigerant gas chamber located in the upper
portion of the diaphragm chamber.
72-35
Air Conditioner
Troubleshooting the expansion valve

Blocked expansion Both high pressure and low pressure are low,
valve or defective and air bubbles cannot be seen through sight - Expansion valve - Cleaning/adjustment or replacement
adjustment (too closed) glass.
Defective adjustment Low pressure is too high, and compressor
- Expansion valve - Adjustment or replacement
(too open) head is cold.
Cooling is disabled during operation. Frosting
Freezing caused by is not detected in evaporator. Both high pres- - Replace receiver tank, evacuate air,
- Expansion valve
moisture sure and low pressure are low, and air bubbles then charge gas again.
cannot be seen through sight glass.
72-36
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 radia-
tor, the air receives heat from the heater radiator fins
and is warmed.
The hot water inside the heater radiator is forcedly cir-

culated by the engine water pump.
Troubleshooting the heater radiator

- Joint portion of supply area
Water leak Water leaks from heater core. - Repair/replacement
- Cracks in heater core main body
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
72-37
Air Conditioner
Servo motor
3 2 1
5 4
1
2
3
6
4
5 M
7
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 deter-
mined 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 posi-
tion 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

Motor is locked - Motor
- Servo motor does not rotate. - Repair/replacement
(disabled). - Control unit
- Indicator lamps of temperature setting
switches do not light in accordance with - Fixed plate
Contact is contacting
preset pattern. - Moving contact - Repair/replacement
poorly.
- Servo motor does not stop in accordance - Control unit
with preset pattern.
72-38
Air Conditioner
Blower motor assembly Blower motor assembly specifications
Voltage DC 24 V
Fan Blower motor
Number of rotations of motor 3,100 min-1
Power consumption 225 W (9.4 amps) 10 %
Fan outer diameter 150 (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

- Blower motor
Blower motor operation is defective. Air is not blown at all. - Repair/replacement
- Control unit
BLC (blower linear control)
85V2U72004
97ZV72054
This resistor changes over the air quantity of the blower

motor.
Troubleshooting the blower linear control

- BLC
Wire in BLC is broken. Air quantity does not change. - Replacement
- Control unit
- Blower motor
Blower motor operation is defective. Air is not blown at all. - Repair/replacement
- Control unit
72-39
Air Conditioner
De-icing sensor (Thermistor (or thermal resis- Evaporator

tor))
Appearance of thermistor
8,000
7,000
6,000
Thermistor
Resistance ()
5,000
4,000 Heater radiator 97ZV72056
3,000
2,000
The thermistor mounted on the blowoff port side of the
1,000 evaporator detects the temperature of the air cooled by
0
10 5 0 5 10 15 20 25 30
the evaporator, and transmits it as a signal to the control
(14) (23) (32) (41) (50) (59) (68) (77) (86) amplifier.
Temperature (C) (F)
Characteristics curve between temperature
and resistance of thermistor 85V2U72005 If the air at the vent is 3C (37F) or less, the control
amplifier turns off the compressor clutch relay. If the air
at the blowoff port becomes 4C (39F) or more, the
The thermistor, a kind of semi-conductor, offers the
control amplifier turns on the compressor clutch relay
characteristics as shown in the curve on the above.
again to restart cooling.
When the temperature becomes high, its resistance
Because the air temperature at the vent is detected and
becomes small. When the temperature becomes low, its
the compressor clutch relay is turned on and off accord-
resistance becomes large.
ingly, freezing of the evaporator is prevented.
Troubleshooting the thermistor

Cable in thermistor is broken. Compressor clutch does not work.
- Thermistor - Replacement
Thermistor is short-circuited. Air not blowing.
*Note
For temperature reference between C and F please
see references below.
Temp C Temp F
-10C 14F
0C 32F
10C 50F
20C 68F
25C 77F
30C 86F
72-40
Air Conditioner
Water temperature sensor Foot/defroster selection box
Air conditioner unit
Foot
Def
97ZV72057 97ZV72059
This sensor detects the temperature of the engine cool- This selection box changes over the vent positions
ing water flowing into the heater core, and feeds it back between the foot side and the defroster side.
to the control panel.
When the vent mode selector switch (MODE) on the
This sensor is installed on the rear side of the heater control panel is pressed, the servo motor in this selec-
core, and can be taken out when being pulled out. tion box changes over the vent selection damper to the
foot side or the defroster side by way of a link and lever.
Temperature Resistance value
-30C (-22F) 91.4 k
25C (77F) 5 k
100C (212F) 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

0C (32F) 1.645 k
25C (77F) 5 k
72-41
Air Conditioner
Compressor and magnetic clutch Compressor specifications

Compressor
Piston
Discharge valve
1 Discharge valve
6
74
3
10
5 Suction valve
Suction valve
Diagonal plate
8
Suction/compression action 97ZV72061
Model 10S150
2 9 Cylinder diameter 32 (1.26")
11
Stroke 20.8 mm (0.82")
97ZV72060
Number of cylinders 10
Cylinder capacity 167.3 cm3 (10.21"3)
Maximum allowable number of rotations 6,000 min-1
1. Compressor 7. Coil
2. Magnetic clutch 8. Bearing Lubricating oil ND-OIL8
3. Rotor 9. Shaft Lubricating oil quantity 180 cm3 (11"3) [6 oz]
4. Stator 10. Dust proof cover
5. Hub 11. Pressure relief valve
6. Pulley
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 temper-
ature 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 cylin-
ders) 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 com-

pression stroke, the other one is in the vacuum stroke.
The compressor is lubricated by the compressor oil con-

tained 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 sei-
zure, 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.
72-42
Air Conditioner
Magnetic clutch Magnet clutch specifications
Model L50T
S
Voltage DC 24 V
Pulled Power consumption 40 W (1.67 amps)
force
Stator Drive belt V-ribbed belt (six ribs)
Switch Air gap 0.50.15 mm (0.020" 0.006")
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 com-
pressor.
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.
72-43
Air Conditioner
Troubleshooting the compressor and magnetic

clutch

- Compressor temperature is abnormally high.
- High pressure is abnormally low, and low
pressure is abnormally high.
Suction or exhaust valve is - Air bubbles cannot be seen through sight - Suction or exhaust valve - Repair/replacement
damaged. * glass.
- Abnormal sounds are made while clutch is
turned on.
Clutch draw voltage is low. - Stator coil - Replacement
- Wiring on main body - Repair
Power is not supplied to
- Control amplifier - Replacement
stator coil.
- Pressure switch - Replacement
- Compressor does not rotate.
Gap between hub and rotor (Air in cab does not become cool enough.) - Magnetic clutch - Replacement
is large.
Compressor main body is
defective - Shaft, piston - Repair/replacement
(seized, etc.).
Clutch bearing is damaged. - Clutch bearing - Replacement
Contact or slippage caused
- Abnormal sounds are made while clutch is
by too small gap between - Magnetic clutch - Replacement
turned off.
hub and rotor.
V belt is slack. - V belt - Adjustment/replacement
Compressor main body is - Internal compressor trou-
- Abnormal sounds are made while clutch is - Repair/replacement
defective. ble
turned on.
V belt is slack. - V belt - Adjustment/replacement
* This can be the result of "liquid charging". Do not liquid charge as a compressor cannot compress liquid; this will damage it.
72-44
Air Conditioner
Condenser unit Condenser fan motor
The condenser fan motor used to cool down the con-

denser is mounted on the condenser together with a fan
Condenser
shroud.
Blower assembly Condenser specifications

Resistor
Voltage DC 24 V
Power consumption 80 W (3.4 amps) x 10 %
Cover
Air quantity 1,75010 m3/Hr (61,800"3/Hr)
Number of rotations of motor 2,200 min-1 (rpm)
Fan motor
95V2U72002
Each condenser unit consists of a condenser, a con-

denser 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 (70C, 1,618 kPa (16.5 kgf/cm2)) (158F (235
psi)) sent from the compressor, and change it into liquid
refrigerant during passing tubes.
72-45
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
Resistance 4.0
Troubleshooting the condenser unit

Heat radiation quantity is
- Blockage or crushed fins - Clean or replace condenser
insufficient due to blockage*. Both high pressure and low pressure are
abnormally high, and air does not become
Rotation of condenser fan cool enough. - Fan motor - Repair or replace motor
motor is defective.
High pressure is abnormally high, low pres-
sure is abnormally low, and air does not
Blockage / condenser airflow - Internal to condenser fins - Clean or replace condenser
become cool enough.
Air bubbles can be seen through sight glass.
Both high pressure and low pressure are
- Leaks at joints - Tightening
Gas leak abnormally low, and air bubbles can be seen
- Cracks in main body - Repair or replacement
through sight glass.
* It is important to check the fan blades also as these can become bent or packed with dirt, making them ineffective.
72-46
Air Conditioner
Receiver dryer Desiccant
If moisture is present inside the cooling circuit, the com-

pressor valve and oil may deteriorate, metal parts within
the circuit may corrode, or moisture may be frozen
Refrigerant inlet inside expansion valve which may clog the circuit. To
Refrigerant outlet prevent such failure, synthetic zeolite (drying agent) is
positioned inside the air conditioner and acts as a desic-
cant 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
Desiccant Strainer
be replaced.
Desiccant specifications
Capacity 550 cm3

Receiver tube Desiccating agent Synthetic zeolite
Desiccating agent capacity 290 g
Receiver tank
IMPORTANT
If parts of the cooling circuit are removed and left for
a long time for repair or another reason, the desiccant
97ZV72065 absorbs moisture contained in the air and loses its
absorption performance, and the receiver dryer
should be replaced. To prevent this, after parts are
The receiver dryer consists of a receiver tank, desic-
removed, all openings should be plugged.
cant, 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 fluc-
tuation 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 cir-
cuit.
In addition, the receiver tank stores a reserve of refriger-

ant 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.
72-47
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 consid-

erably clogged (in this case, the high pressure
increases and the low pressure decreases), the entire
receiver dryer should be replaced.
Troubleshooting the receiver tank

- At first, air in cab will cool down, but after a
Icing - Desiccating agent in receiver - Replacement of receiver dryer
short time no longer will cool properly.
- High pressure is excessively high, low pres-
Blockage in strainers sure is excessively low, and air does not - Blockage in strainers - Replacement of receiver dryer
become cool enough*.
*A means to test this is to check the temperature between the inlet and outlet of receiver dryer. If it drops more than it should the dryer is
plugging and should be replaced.
72-48
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 The pressure switch detects the pressure on the high
on the top of the receiver dryer. Only through this sight pressure side of the cooling circuit, and stops the com-
glass, the refrigerant quantity inside the circuit can be pressor when detecting any abnormality so that damage
visually checked. of the equipment in the cooling circuit can be prevented.
There are three types of pressure switches, high pres-

WARNING sure type, medium pressure type and low pressure
Possible freezing of eye tissue. type, which function as shown in the table below.
Always wear protective eyewear when doing a visual
inspection.
72-49
Air Conditioner
Switching pressure Switch operation Causes of abnormal

Switch Function
kPa (kgf/cm2) (psi) confirmation method pressure
Pressure switch coupler

2,550 3,136 A
When pressure between Heat radiation of condenser
compressor and expansion (26) (32) is insufficient due to clogging
High valve becomes abnormally (370) (455) in condenser or defective
pressure high, this switch shuts down ON C D rotation of condenser fan*.
switch power supplied to compressor
magnetic clutch to protect *A damaged fan blade would
OFF B
circuit. produce a similar symptom.
Check conductivity
between A and B.
When detecting fluctuation of

pressure between compressor 1,519
and expansion valve, this (15.5)
switch gives a signal to control (220)
Medium amplifier about whether to ON Check conductivity between C and D
pressure rotate condenser fan motor at in pressure switch coupler shown
switch low speed or high speed. above.
While this switch is ON, fan OFF
motor rotates at high speed. 1,225
While this switch is OFF, fan (12.5)
motor rotates at low speed. (178)
When pressure between

compressor and expansion 226
valve becomes abnormally low (2.3)
due to refrigerant leak, this (33)
Low switch shuts down power ON Check conductivity between A and B
Refrigerant leak from a part
pressure supplied to compressor in pressure switch coupler shown
of circuit.
switch magnetic clutch to prevent above.
seizure of compressor caused OFF
by insufficient compressor oil 196
which decreased together with (2.0)
refrigerant. (28)
Troubleshooting the pressure switch

- Condenser fan motor does not change its speed - Medium pressure
Insufficient cooling - Replacement
(to high speed). switch
- Even when abnormal high pressure (3,136 kPa (32 kgf/cm2)
(455 psi)) occurs, compressor does not turn off. - High or low pres-
Gas leak - Replacement
- Even when gas (refrigerant) has run short, compressor does sure switch*
not turn off.
*If abnormally high pressure occurs while the high pressure switch is non-functioning, the equipment in the cooling circuit may be damaged.
The pressure relief valve releases the refrigerant to the atmosphere in order to prevent equipment or personnel damage.
72-50
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

0 compressor service valve releases the refrigerant to the
atmosphere when abnormal high pressure occurs.
28.1 35.0 42.4

Pressure
(kgf/cm2 ) IMPORTANT
2,756 3,430 4,158 (kPa)
400 500 600 (psi) When the refrigerant quantity inside the cooling cir-
cuit is correct, the pressure switch always remains
Characteristics drawing of ON even if the compressor is stopped because the
relief valve operation refrigerant pressure is approximately 588 kPa (6.0
kgf/cm2) (85 psi) as far as the outside air temperature
97ZV72069a
is around 25C (77F).
When the outside air temperature becomes 0C
(32F) 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.
Pressure relief valve 97ZV72070

72-51
Air Conditioner
Relay A Relay B
97ZV72072 97ZV72099
Relay A specifications Relay B specifications
Rated voltage DC 24 V Rated voltage DC 24 V

Rated current 16 A Rated current 11 A
Rated coil current 0.1 A Rated coil current 0.075 A
Troubleshooting the relay

- Blower motor does not rotate at all. - Blower motor main
- Blower motor remains rotating. relay
- Blower motor does not rotate at high speed. - Blower motor Hi
- Blower motor remains rotating at high speed. relay
- Blower motor does not rotate at medium speed Me2. - Blower motor Me2
- Blower motor speed does not change from Me2 to Me1. relay
- Blower motor does not rotate at medium speed Me1. - Blower motor Me1
Coil wire is broken. - Blower motor speed does not change from Me1 to low speed. relay
- Replacement
Contact is melted down.
- Both condenser fans do not rotate.
- Condenser fan relay
- Both condenser fans remain rotating.
- When condenser fan is at high pressure, it does not rotate at
high speed. - Condenser fan relay
- When condenser fan is at low pressure, it remains rotating at 1
high speed.
- Compressor magnetic clutch does not turn on. - Compressor clutch
- Compressor magnetic clutch remains ON. relay
72-52
Air Conditioner
Refrigerant hose
WARNING
Burst hazard
These hoses operate at high pressure for HVAC sys-
Outer layer tems and must not be replaced with substandard
hoses.
Reinforcing layer
Use only OEM replacement hoses or hoses of the
same rating as OEM replacement hoses.
Mouth ring
Inner layer
Intermediate layer
97ZV72073
White line and "R134a" indication
97ZV72074
As shown in the figure on the above, the refrigerant

hose consists of the outer layer, the reinforcing layer,
the intermediate layer and the inner layer, and the
mouth ring is crimped.
Region Material
Outer layer Ethylene propylene rubber
Reinforcing layer Polyester
Intermediate layer Chlorinated butyl rubber
Inner layer Nylon
The mouth ring of this hose is changed and the symbol

"R134a" is indicated on this hose as shown in the figure
on the right.
IMPORTANT
Never use any other hose or any other refrigerant.
Otherwise, refrigerant may leak.
72-53
Air Conditioner
Charge of refrigerant
WARNING
WARNING Serious accidents may occur during storage and
transportation of a service can.
Serious accidents may occur in the refrigerant charg- Observe the following contents.
ing work. - A service can accommodates high pressure gas in
Observe the following contents. the saturated liquid status. If the temperature rises,
- Only trained or experienced specialists having suf- the pressure may increase drastically and the can
ficient knowledge on the contents of the work may burst. Keep the temperature of the service
should be allowed to perform the refrigerant charg- can at 40C (104F) or less.
ing work. Make sure to keep the can away from hot objects
- If the refrigerant comes into contact with your eyes, or fire.
you may lose your eyesight. Make sure to wear - During storage, make sure to avoid direct sunlight,
protective goggles. and store the can in a dark and cool place.
- The refrigerant in the liquid status is at low temper- - Inside the closed cab (including trunk), the air tem-
ature (approximately -30C (-22F)). If it splashes perature may rise considerably due to solar heat,
on your skin, you may suffer from frostbite. Pay etc., and may become dangerously temperature
close attention when handling it. even in winter if the closed cab is exposed to direct
- If the refrigerant (Refrigerant R134a) touches a hot sunlight. Never put the can inside the cab.
object (approximately +400C or more), it decom- - If the service can suffer from flaws, dents and
poses and generates harmful substances. deformations, its strength deteriorates. Never hit or
Never release the refrigerant in a room where ven- drop it. And never throw or drop a package of cans
tilation is bad and there is a hot object or a fire while loading or unloading it.
(such as in the presence of a stove). - Keep the can away from the reach of children.
- In order to protect the environment, do not release
the gaseous refrigerant to the atmosphere.
IMPORTANT
CAUTION - It is prohibited by law to reuse service cans. Never
reuse them.
Serious accidents may occur during the refrigerant - Pay close attention so that air and dusts do not
charging work. enter into the cooling circuit.
Observe the following contents. - Never charge the refrigerant excessively.
- When warming a service can to charge the refrig- - The air conditioner is so designed as to be used
erant, make sure to open the low pressure valves with Refrigerant R134a. Never charge any other
of the service can and the gauge manifold, then refrigerant such as Freon R12.
warm it with hot water of 40C (104F) or less (tem- - If the compressor oil (ND-OIL 8) adheres to the
perature at which you feel warm when putting your painting face or the resin area, the painting may
hand into it). peel off or the resin may be damaged. If so, wipe it
Never warm the can with boiling water or overheat off soon.
it with open fire. If the can is treated in such a way, - Tighten the piping at the specified torque.
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.
72-54
Air Conditioner
Work procedure Charging procedure
The refrigerant charging process is mainly divided into 1. Charge the system with the required amount of gas
"refrigerant evacuation procedure" and "gas charging by weight, and check for leaks by letting the HVAC
procedure" as shown below. 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
Refrigerant evacuation procedure step (3).
3. Turn on the engine, run at 1,200~1,500 rpm.
The "refrigerant evacuation process"* eliminates mois- 4. Turn on the HVAC air condition system, making
ture present inside the cooling circuit. If the moisture sure that the heat is off and A/C is set with fan on
remains inside the circuit, it may cause varied problems high.
even if its quantity is extremely small: The moisture may 5. Let the HVAC system run on coldest setting until all
freeze inside the expansion valve during operation, and parts are cold saturated; this should take about 30
may block the circuit or generate oxidation. To prevent minutes or more.
such problems, the refrigerant containing air inside the 6. Check the temperature that is coming from the
cooling circuit should be evacuated, and the moisture vents of the HVAC system inside the cab. Check
inside the circuit should be boiled and evaporated so the performance in the operating pressure and tem-
that all moisture is eliminated before pure refrigerant is perature chart.
recharged into the circuit. 7. Either remove or install more refrigerant depending
upon the findings.
*May be referred to as "air evacuation procedure" since it contains air
which also contains water that can cause system damage as noted.
Observe the work procedure and cautions shown below,
and charge the refrigerant correctly.
Gas charging procedure
The system should operate within about 5% of the
The "gas charging procedure" charges the refrigerant parameters. Be sure that the condenser is clear, evapo-
as gas into the circuit while in a vacuum state. The gas rator is clean and the fans are all working as they should
charging process not only affects the cooling ability of with good airflow in the system.
the air conditioner but also affects the system compo-
nent life.* Note
If the inside of the cab become cold during the charging
If the refrigerant is charged too quickly or in a liquid process, the compressor magnetic clutch turns off and
state, pressure inside the circuit may become extremely system charging is disabled.
high and the cooling ability may deteriorate. If the refrig-
erant charging volume is too low, the lubricating oil for When charging, completely open the cab doors.
the compressor may not circulate smoothly and com-
pressor pistons may seize and lock up the compressor. This will keep the system from turning off and on.
Because the gas charging process involves high pres-

sure gas, it is extremely dangerous if it is not done cor-
rectly.
Observe the work procedure shown below and the cau-

tions, and charge the refrigerant correctly.
*Note
Liquid charging destroys a compressor. Never permit
entry of liquid refrigerant.
72-55
Air Conditioner
Charging procedure chart
Start evacuation.
20~30 min -750 mmHg (-30" Hg) or less

Refrigerant If too little vacuum, repair leaking
evacuation Stop evacuation.
connection*
process *It is possible that system may need pressurized
Leave system untouched for 5 min. and tested for leaks.
Check pressure. Stop when gage indicates excessive pressure

(air entry)
When gage indicates a normal value
Charge refrigerant gas. Charge gaseous refrigerant until gauge pressure

reaches 98 kPa (1 kgf/cm2) (14 psi). Check for leaks.
Check for gas leak.

Gas Note
charging A full charge should be about 20.1 lbs (90050 g) of
process
refrigerant.
Charge refrigerant.
As a general guideline, with engine off and HVAC

system static, the pressure in the system should be
Check for gas leak. about 85 psi (588 kPa) (6.0 kgf/cm2) with the pres-
sure has equalized between the low and high pres-
sure side.
Performance test
95ZVE72042
72-56
Air Conditioner
Refrigerant charging tools Charging hose and quick connectors

Recovery and recycling unit
Gauge manifold*
Low pressure
charging hose High pressure
(blue) charging hose
95ZV72024
(red)
Quick connector
(Lo)
It is against Federal Regulations* in the United States to
release refrigerant to atmosphere. A recovery and recy-
cling unit must be used to capture the refrigerant so as
not to release it into the atmosphere.
Center charging hose
(green or yellow)
*Refer to section 609 of the clean air act at www.epa.gov.
Quick connector
(Hi)
It is used for the following;
1. Recover the refrigerant. 97ZV72077

2. Filter the refrigerant.
3. Measure the refrigerant weight.
These different colored hoses are used to evacuate the
4. Remove trapped non compressible gases (air).
air and charge the gas. (The colors may be different
5. Measure the refrigerant to install in system by
depending on the manufacturer.)
weight.
6. Measure the pressure of the refrigerant in system.
Red hose
7. Measure ambient temperature.
Connects the high pressure valve of the gauge manifold
8. View bubbles in system if there are any.
and the high pressure charging valve (with "H" mark on
its cap) of compressor outlet hose.
Read and understand the Operation Manual for the
recovery and recycling machine.
Blue hose
Connects the low pressure valve of the gauge manifold
IMPORTANT and the low pressure charging valve (with "L" mark on
Only use a vacuum pump if the system is already its cap) of the compressor inlet hose.
open to atmosphere and refrigerant has completely
left the system. Green or yellow hose
Connects the center valve of the gauge manifold and
the vacuum pump (or the service can valve).
*Gauge manifold may be used with vacuum pump or recovery unit.

72-57
Air Conditioner
Leak detector Gauge manifold
Many recovery and recycling units are equipped with a

gauge manifold, which is very similar to the gauge man-
ifolds 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

recling unit.
85V2U72007
Low pressure High pressure
gauge 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 High pressure
valve
Low pressure
charging hose Center valve High pressure
mounting nipple Center charging charging hose
hose mounting mounting nipple
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 vac-
uum.
3. Boiling action, perhaps due to pressure changes.
72-58
Air Conditioner
Cautions on handling of quick connector and Precautions

charging valve
When discharging the refrigerant, use a quick connec- Quick connector

tor.
1. Connecting the quick connector.
Screwdriver, etc.
Sleeve "Click" sound (OK)
Valve pin
(A)
Spring
Charging valve Charging valve
97ZV72082
97ZV72080
IMPORTANT
Slide the sleeve upward, push the quick connector If you push the valve pin with a considerable force
against the charging valve, press and hold securely [294 kPa (3 kgf/cm2) (43 psi)] with a screwdriver, etc.,
part (A) until a click is heard, then slide the sleeve the spring may come off and the refrigerant may leak.
downward. Never do this.
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
(A)
(B)
97ZV72081
While pressing and holding the part (A) of the quick

connector, slide sleeve upward to disconnect quick
connector.
72-59
Air Conditioner
Refrigerant charging procedure Valve setting

Lo Hi
Air evacuation work
Closed Closed
High pressure valve
WARNING
If hoses are connected incorrectly, serious accidents Low pressure valve
may occur.
Observe the following.
(red)
- Never confuse connection of hose to the high pres-
(blue)
sure side and the low pressure side of the gauge
(green)
manifold.
(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
With system "OFF";

(a) Close both the high pressure (Hi) valve and the low
pressure (Lo) valve of the gauge manifold.
95ZV72024
(b) Connect the charging hose.

It is against Federal Regulations* in the United States to
release refrigerant to atmosphere. A recovery and recy- Red hose
cling unit must be used to capture the refrigerant so as To be connected between the high pressure (Hi)
not to release it into the atmosphere. valve of the gauge manifold and the high pressure
charging valve.
*Refer to section 609 of the clean air act at www.epa.gov.
Blue hose
1. Connecting the gauge manifold To be connected between the low pressure (Lo)
valve of the gauge manifold and the low pressure
CAUTION charging valve of the compressor.
Close both low and high pressure valve, as seen in Yellow or green hose
"a" below. 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 con-
nected, a vacuum condition cannot take place.
72-60
Air Conditioner
2a. Evacuating the system with a vacuum pump 2b. Evacuating the system with a recycling and recove-
ry unit.
When pulling a vacuum with a vacuum pump on a sys-
tem that has been open due to replacing major compo-
nents.
After air evacuation Valve setting

Valve setting
Lo Hi for 30 minutes Lo Hi
OpenedOpened Closed Closed
High pressure valve
Low pressure valve

95ZV72024
(red)
(blue)
Each manufacture of recycling and recovery units pro-
(green) vide operating instructions for their units. Read, under-
stand and closely follow operating instructions as
provided.
(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 evac-

uate until the degree of vacuum becomes -750 mm
Hg (-30" Hg) for about 20~30 minutes.
(c) After finishing evacuation, close both the high pres-

sure 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.
72-61
Air Conditioner
3. Checking for leaks after vacuum has been drawn Refrigerant charging process
This section describes a static charging procedure with

Valve setting Leave for 10 minutes or more
as per EPA regulations
the engine in "OFF" and compressor not turning.
Lo Hi
Pointer of low
Closed Closed pressure gauge Do not run engine until high and low pressures are
moves toward "0".
Low pressure gauge equal so that no damage is done to the compressor.
0
0 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
Moves atmosphere. Use of a recovery and recycle unit is best.
toward "0". Carefully follow instructions with recovery unit.
Tighten connection areas
of piping.
97ZV72085
Valve setting
Lo Hi
After a vacuum has been pulled on system; Closed Closed
Leave the circuit for 5 minutes or more with H and L

valves of gauge manifold closed. Then, make sure that Open the
service can-
the needle of each gauge does not move. ister valve.
Red
Blue (low) (high)
If the needle of the gauge moves toward "0", a leak has
occurred somewhere in the circuit. Tighten the connec-
tion areas of the piping, evacuate the system again, Service
Charging hose canister
then make sure that there is no leaks. R134a
(green or yellow) 97ZV72086
IMPORTANT
Make sure to tighten the connection areas of the pip-
IMPORTANT
ing at a specified tightening torque. Never purge or vent refrigerant to atmosphere. (EPA)
For the tightening torque, refer to the volume "Mainte-
nance Standard".
72-62
Air Conditioner
1. Charging the refrigerant from the high pressure

Valve setting After 1~1.5 service Valve setting side with the engine in the "OFF position.
Lo Hi cans are charged Lo Hi
OpenedOpened Closed Closed
(a) After evacuation, disconnect the charging hose
(green or yellow) of gauge manifold from vacuum
pump, and connect it to the service canister.
High pressure valve
(b) Purging air from lines

Low pressure
valve Open the service canister valve very slightly with
low and high pressure manifold valves closed.
(red) 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
(blue)
lines, as air is discharged by the refrigerant pres-
(green) (Hi)
sure. EPA says that release of this tiny bit of air that
is very small is ok.
(Lo)
Charging valve
on high pressure (c) WITH ENGINE "OFF"; Open tank canister valve
side 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 ser-
Compressor
(stopped) vice cans. If using scale, add one to one and a half
Service can valve lbs.)
(opened charge
R134a closed)
95ZVE72052 (d) After charging, close the low and high pressure
valves of the gauge manifold and the service can
valve.
WARNING
If the refrigerant were changed from the high pres- 2. Check for gas leak with a leak detector
sure side, the refrigerant would flow in reverse direc-
tion and the can and the hose may be burst if you Check for gas leak in the circuit using a leak tester,
start the engine and operate the compressor. Never etc. If a leak is detected, repair leak as required. If
start the engine in this condition. located at connections, tighten the connection area.
IMPORTANT
IMPORTANT
Make sure to tighten the connection areas of the pip-
If you charge refrigerant with refrigerant canister ing at a specified tightening torque.
placed upside down liquid will exit canister, refrig- For the tightening torque, refer to the volume "Mainte-
erantis sucked into the compressor in a liquid state. nance Standard". Do not overtighten or it will worsen.
This will damage the compressor. Charge only with
refrigerant gas.
72-63
Air Conditioner
3. Charging the refrigerant - low pressure side - e/g (c) Start the engine, and increase the number of rota-
"ON". tions to approximately 1,500 min-1(rpm).
Charge the refrigerant (d) On the control panel, set the fan speed to high and
Valve setting until air bubbles seen Valve setting set the air flow volume to maximum cold, and set
through the sight glass
Lo Hi disappear. Lo Hi the vent port temperature switches to the coldest
Opened Closed Closed Closed
status.
(e) Open the low pressure valve of the gauge manifold

High pressure valve
and service canister valve to charge the refrigerant.
When air bubbles seen through the sight glass of
Low pressure the receiver dryer disappear, charge the refrigerant
valve further more by 150~250 g.
(red)
IMPORTANT
When replacing service canister while charging
refrigerant, connect the line as described earlier so
(blue) (green) (Hi)
as to not have air in the line.
(Lo)
Charging valve (f) After charging, close the low pressure valve of the
on high pressure gage manifold and the service can valve. Then,
side stop the engine.
Compressor Refrigerant quantity to be charged (guideline)

(On-load)
Service can valve
90050 g (2.00.1 lb)
(opened charge
R134a closed) Refrigerant
Sight glass situation
95ZVE72052 quantity
Gas bubbles are few.
(When the number of rpms of the
Proper engine is gradually increased from the
idle status to 1,500 min-1, gas bubbles
Sight glass disappear.)
Gas bubbles are not seen in the flow at

all. System is over-pressurized.
Too much (In this case, both the high pressure
Receiver joint and the low pressure are high, and the
cooling ability is deteriorated.)
Many gas bubbles are seen in the flow.

Receiver dryer Insufficient
(Gas bubbles visibly seen constantly.)
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.
72-64
Air Conditioner
4. Guidelines to determine quantities of refrigerant 5. Disconnecting the gauge manifold

charge
Use the following table to determine the refrigerant

charge quantity.
Item Criteria
(A)
Doors Completely open
Temperature control switches Maximum cooling
Blower speed High
Inside/outside air selection Inside air
(B)
Number of rotations of engine 1,500 min-1

Air conditioner switch ON
1,862 kPa (19 kgf/cm2) (270 psi)
Pressure on high pressure side 97ZV72081
or less
After inspecting the refrigerant charge, disconnect

IMPORTANT the charging hose from the high and low pressure
- If outside air temperature is high (40C/104F or charging valves using the following procedure.
more) or if the pressure on the high pressure side
is 1,862 kPa (19 kgf/cm2) (270 psi) or more when (a) While pressing and holding part (A) of the quick
the judgement condition above is set, perform the connector, slide sleeve upward and disconnect the
following so that the pressure becomes 1,862 kPa quick connector.
(19 kgf/cm2) (270 psi) or less, then check the
refrigerant quantity. (b) Attach a cap to each of the high and low pressure
- Close the doors completely, and set the charging valves.
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 refriger-
ant quantity is extremely low, lubricant in the com-
pressor 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 cir-
cuit may become abnormally high (which is dan-
gerous). Never do this.
72-65
Air Conditioner
Troubleshooting using the gauge manifold Condition

Normal status After warming up the engine, check the pressure under
the following condition.
- Doors
<Low pressure side> <High pressure side>
Completely open
215~275 kPa 1,470~1,765 kPa
(2.2~2.8 kgf/cm2) (15~18 kgf/cm2) - Inside/outside air selection
(31~40 psi) (213~255 psi)
Inside air
- Number of rotations of engine

1,500 min-1
- Temperature at suction port of air conditioner

30~35C (86~95F)
- Blower speed
High
- Temperature control switches

Maximum cooling
97ZV72091
Pressure values indicated by gauges in the normal status
A/C suction port temperature Pressure Pressure value by gauge

High pressure side 1,000~1,215 kPa (10.2~12.4 kgf/cm 2) (145~176 psi)
20~25C (68~77F)
Low pressure side 127~167 kPa (1.3~1.7 kgf/cm 2) (18~24 psi)
25~30C (77~86F)
30~35C (86~95F)
35~40C (95~104F)
72-66
Air Conditioner
When the refrigerant charge quantity is insuffi- When the refrigerant does not circulate (due to
cient clogging in the cooling circuit)
<Low pressure side> <High pressure side> <Low pressure side> <High pressure side>
49~98 kPa 686~981 kPa Negative value 490~588 kPa
(0.5~1.0 kgf/cm2) (7~10 kgf/cm2) (5~6 kgf/cm2)
(7~14 psi) (100~144 psi) (71~85 psi)
97ZV72092 97ZV72093
Symptom Cause Inspection/action point Symptom Cause Inspection/action point

- Pressure is low on - Refrigerant - Find and repair - If cooling circuit is Clogging in cool- - Inspect receiver
both low and high quantity is leaks. completely blocked, ing circuit dryer, expansion
pressure sides. insufficient. needle on low pres- valve, etc. (Temper-
- Repair leak. Add sure side indicates a ature is different
- Gas bubbles go - Gas is refrigerant. vacuum immedi- between IN and
through sight glass leaking. ately. OUT of failing part.)
continuously. - If pressure indicated
by gage is around - If cooling circuit is - After finishing work,
- Temperature of "0", detect and partially blocked, evacuate system
blown air is not cold. repair leaks, vac- needle on low pres- and recharge.
uum system and sure side slowly
recharge. indicates a vacuum.
72-67
Air Conditioner
When the moisture has entered into the cooling When the compression in compressor is defec-
circuit. tive.

392~588 kPa 686~981 kPa
Abnormal status 686~981 kPa
(4~6 kgf/cm2) (7~10 kgf/cm2)
Vacuum (7~10 kgf/cm2)
(57~85 psi) (100~144 psi)
(100~144 psi)
Normal status
215~275 kPa 1,470~1,765 kPa
(2.2~2.8 kgf/cm2) (15~18 kgf/cm2)
(31~40 psi) (213~255 psi)
97ZV72095
Symptom Cause Inspection/action point

- Pressure on low Compressor is - Review 2nd symp-
97ZV72094 pressure side is defective. tom.
unusually high, and
pressure on high - If pressure in com-
Symptom Cause Inspection/action point pressure side is pressor is low, com-
unusually low. pressor will not build
- Air conditioner oper- Expansion valve - Inspect expansion much heat due to
ates normally for a is frozen due to valve, replace if - Shortly after air con- lack of pressure.
while after startup, entry of mois- needed. ditioner turns off,
but pressure on low ture. pressure becomes - Replace compres-
pressure side indi- - Replace receiver equal between high sor.
cates a vacuum dryer. pressure side and
value later. low pressure side. - After finishing work,
- After finishing work, evacuate system
evacuate system and recharge.
completely and
recharge.
72-68
Air Conditioner
When there is too much refrigerant or cooling When air has entered into the cooling circuit
in the condenser is insufficient
<Low pressure side> <High pressure side> <Low pressure side> <High pressure side>
245~343 kPa 1,961~2,452 kPa 245~294 kPa 1,961~2,452 kPa
(2.5~3.5 kgf/cm2) (20~25 kgf/cm2) (2.5~3.0 kgf/cm2) (20~25 kgf/cm2)
(35~50 psi) (284~355 psi) (35~43 psi) (284~355 psi)
97ZV72096 97ZV72097
Symptom Cause Inspection/action point Symptom Cause Inspection/action point

- Pressure is high on - Refrigerant - Check and correct - Pressure is high on Air has entered - Refrigerant is bad.
both low pressure quantity is refrigerant charge both low pressure system.
side and high pres- too much. pressure. side and high pres-
sure side. sure side.
- Plugged or - Inspect and repair
- Even when engine bent con- condenser fins. - Low pressure pip- - Evacuate system
rpms (min-1) are denser fins. ing is not cold. completely.
reduced, gas bub- - Repair or replace
bles cannot be seen - Bad fan fan or fan motor - Gas bubbles go - Replace refrigerant.
at all in sight glass. motor or fan through sight glass.
blade. - Inspect and repair
- Air in cab does not evaporator fins.
become cool - Heat trans-
enough. fer does not
occur in
evaporator
has plugged
fins
72-69
Air Conditioner
When the expansion valve is opened too much

294~392 kPa 1,961~2,452 kPa
(3.0~4.0 kgf/cm2) (20~25 kgf/cm2)
(43~57 psi) (284~355 psi)
97ZV72098
Symptom Cause Inspection/action point

- Pressure is high on Expansion valve - Temperature sens-
both low pressure is defective. ing rod may be
side and high pres- sticking.
sure side.
- Inspect expansion
- Condensation forms valve. Check temp
on low pressure in and out of valve
side pipes. to determine if it is
operating correctly.
Thermal expansion valve
To and from evaporator Diaphram
Spring
Temperature sensing rod
Needle valve Compressor return

From receiver dryer
97ZV72049
72-70
Troubleshooting
Troubleshooting
Air conditioner Error code table
Fault diagnosis procedure Display Failure mode

E- No failure
E11 Wire breakage in inside air sensor
Hearing check E12 Short-circuit in inside air sensor
E13 Wire breakage in outside air sensor
E14 Short-circuit in outside air sensor
Error code check
E15 Wire breakage in water temperature sensor
E16 Short-circuit in water temperature sensor
Phenomenon check E18 Short-circuit in insolation sensor
E21 Wire breakage in vent sensor
E22 Short-circuit in vent sensor
Basic check
E43 Abnormality in vent damper
In accordance with fault phenomenon E44 Abnormality in air mixing damper
E45 Abnormality in inside/outside air
E51 Abnormality in refrigerant pressure
1) Control mechanism
2) V-belt
3) Sight glass
4) Piping connection
Refrigerant cycle Electrical system

check check
- Pressure check
- Gas leak check
Repair/check
End
80V2E01012
72-71
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.
<Trouble shooting charts> 72-72
Clogged inner air filter Clean the filter.

Clogged outer air filter Clean the filter.
Troubleshooting
Existence of obstacle at vicinity of suction port Remove the obstacle.
Normal rotation Deformed or damaged blower Replace the blower with a new one.
Frosting in evaporator Stop the air compressor, to melt the ice.
Examine the cause before taking the corrective measure. See A-1 .
Blower motor Adhesion of dust to surface of evaporator Clean the surface of evaporator.
rotation
Decreased supply voltage Check the battery charging system.

Battery terminal contact failure Correct the contact failure.
Slow rotation
Blower motor rotation failure Replace the blower motor with a new one.
Air flow rate
BLC failure Replace the BLC with a new one.
failure
Blower is rotated only
when the fan switch is Operation of BLC over-voltage protective function Examine the cause of over-voltage before taking the corrective measure.
selected to High-speed Examine the cause before taking the corrective measure,and then replace
position. Blown fuse the fuse with that of the same capacity. See B-1 .
Blower motor
rotation Blower main relay failure Replace the blower main relay with a new one.
failure Blower motor failure Replace the blower motor with a new one.
Rotation failure Interference of blower with case Correct the interference.
for all modes Blower switch failure Replace the panel with a new one.
Body earth failure Earth the body securely.
Without
Wiring failure, disconnected connector Check the wiring.
diagnostic
display Operation of BLC protective function due Replace the motor with a new one.
to locked motor
Normal pressure Mixing of outside air Close the window and door.
Adjust the inside/outside air changeover damper.
Disengaged A/M link Re-set the link.
Compressor
normal rotation
Too high pressure at low-pressure side(approx. 294kPa[3kgf/cm2] or over) See C-2 .
Too low pressure at high-pressure side(Pressure is not increased to approx. 981kPa[10kgf/cm2] or over) See C-3 .
Pressure error
Cooling failure
Too low pressure at low-pressure side(Pressure is decreased to approx. 49kPa[0.5kgf/cm2] or less See C-4 .
Normal air High pressure both at high-pressure side and low-pressure side See C-5 .
flow rate Low pressure both at high-pressure side and low-pressure side Insufficient refrigerant.
Broken or slipped belt Replace the V-belt with a new one.

Compressor
Compressor failure(locking) Replace the compressor with a new one.
normal rotation
failure Magnet clutch failure Repair the magnet switch, or replace it with a new one. See D-1 .
Clutch engagement failure due to Check the wiring. See D-2 .
electrical system failure
Wiring failure, disconnection, disengaged connector Check the wiring.
With diagnostic display:
E44 (A/M servo motor Servomotor failure Replace the servo motor with a new one.
error) Blocked foreign matter Remove the foreign matter.
Operation of high-pressure cut

function See C-1 .
With diagnostic display:
E51 (refrigerant high/
Operation of low-pressure
lower pressure error) See C-3 .
function
80V2E01013
Magnet clutch circuit failure Check the clutch circuit. Replace the clutch relay with a new one.
Voltage applied to Thermister(frosting sensor) wiring failure Check the short-circuit. Correction
magnet clutch
Thermister(frosting sensor) characteristic failure Check for characteristic. Replace the thermister(frosting sensor) with a new one.
Adjustment failure of gap between the thermister(frosting sensor) and evaporator Adjust the gap (12 5 mm) (0.5 0.2 in).
A-1
12 5 mm
(0.5 0.2 in)
Voltage not applied
to magnet clutch Magnet clutch failure Replace the magnet clutch
with a new one. Thermister
(frosting sensor)
Evaporator
Locked blower motor Replace the blower motor with a new one.
B-1 Erroneous wiring Perform the checking, referring to the wiring diagram.
Sort-circuit wiring Check the wiring.
Unusually high outside air temperature

Insufficiently cooled condenser Clogging of dust or mud, etc. in fin. Clean(Washing with water) the fin.
C-1
Over-filled refrigerant Discharge the refrigerant to proper level.
Mixing of air during refrigerating cycle Fully discharge the refrigerant, and execute the
evacuation, and fill the refrigerant again to
proper level.

Compressor failure Broken head gasket
C-2 Broken suction valve Replace the compressor with a new one.
Foreign matter caught by suction valve
Excessively opened expansion valve Valve failure Replace the valve with a new one.
Contact failure in Correction
pressure needle valve
85V2U72008
Troubleshooting
72-73
72-74
Troubleshooting
Unusually low outside air temperature
Limited refrigerant Limited amount of refrigerant filled Fill the refrigerant to proper level.
Gas leakage Perform the leak test and repair the location of
failure before filling the refrigerant.
C-3
Compressor failure Swash plate shoe seizure
Locked piston Replace the compressor with a new one.
Suction/discharge valve failure
Expansion valve failure Clogged valve(mixing of foreign matter) Replace the valve with a new one.
Relieved gas from pressure needle valve Replace the valve with a new one.
Clogging(mixing of moisture content) due to frozen valve Execute the evacuation fully after replacing the
valve and receiver with a new one respectively.
Unusually low outside air temperature

Limited refrigerant Limited amount of refrigerant filled Fill the refrigerant to proper level.
Gas leakage Perform the leak test and repair the location of
failure before filling the refrigerant.
Clogging during refrigerating cycle Clogged receiver & drier Replacement

C-4 Clogging due to foreign matter in the course of piping Replacement
Expansion valve failure Clogged valve(mixing of foreign matter) Replace the valve with a new one.
Relieved gas from pressure needle valve Replace the valve with a new one.
Temporary clogging(mixing of moisture content) Execute the evacuation fully after replacing the
due to frozen valve valve and receiver with a new one respectively.
Frosted evaporator to A-1
Insufficiently cooled condenser Clogging of dust or mud, etc. in fin. Clean(washing with water) the fin.
C-5
80V2E01015
Disconnected stator coil Replacement
Excessive air gap between rotor and stator Repair or replacement
Slipped clutch Slippage due to broken key or key insertion failure Replace the key with a new one.
Stained clutch surface due to oil Remove the oil.
D-1
Rare-short in coil Replacement
Battery voltage drop Re-charging
Foreign matter caught between rotor and stator Disassembling/repair
Air conditioner switch failure Replace the control panel with a new one.
Blower switch failure Replace the control panel with a new one.
Compressor clutch relay failure Replacement
D-2
Thermo-sensor failure Replacement
High/low-pressure switch failure Replacement
High-pressure error Excessively high pressure [2452 kPa(25kgf/cm2)or over] C-1
2
Excessively low pressure [981 kPa(10kgf/cm )or lower] C-4
80V2E01016
Troubleshooting
72-75
72-76
Insufficient Same as "Cooling failure"
wind force
Troubleshooting
Heating failure
Low water temperature
Normal wind
force
The air is mixed in hot-water circuit. Discharge the air.

Clogged or bent piping Repair or replacement
Normal water Excessively low outside air temperature
temperature
Limited engine cooling water Fill the coolant to proper level.
Broken heater core Replace the heater core with a

new one.
Note: Do not fail to check that the pump pressure is normal, and that the heater hose is not connected with
IN side and OUT side reversed.
The temperature
controller LED is Disengaged temperature controller link Re-set the link.
operated properly. Foreign matter caught Remove the foreign matter.
The temperature
Wiring failure, disconnection, disconnected connector Check the wiring.
controller LED is not
operated properly. Servo motor failure Replacement
Leakage of water in
Clogged drain hole Cleaning
operator's cab
85V2U72009
Without diagnostic display
Disengaged link Re-set the link.
(blow-off servo motor normal)
Blow-off changeover Wiring failure, disconnection, disconnected connector Check the wiring.
failure
With diagnostic display: E43
Servo motor failure Replacement
(blow-off servo motor abnormal)
Foreign matter caught Remove the foreign matter.
Without diagnostic display

Disengaged link Re-set the link.
(inside air/outside air servo motor normal)
Outside air/inside air Wiring failure, disconnection, disconnected connector Re-check the wiring
changeover failure
Servo motor failure Replacement
(inside air/outside air servo motor abnormal)
Foreign matter caught Remove the foreign matter.

Disconnected harness, disengaged connector Re-check the wiring.
(disconnected inside air sensor)
Disconnected inside air sensor Replacement
Room temperature With diagnostic display: E12

Short-circuit harness Check the wiring.
higher or lower than (short-circuit inside air sensor)
setting temperature
Short-circuit inside air sensor Replacement
Without diagnostic display Perform the checking in

Cooling failure, heating failure accordance with the paragraph
(without inside air sensor error)
"Cooling failure/heating failure".
80V2E01018
Troubleshooting
72-77
72-78
MEMO
73-1
115ZV-2 Check & Adjustment Operator Station Group
Check & Adjustment

Operator Station Group
Air Conditioner ........................................................ 73-2

73-2
Check & Adjustment Operator Station Group
Air Conditioner
Air Conditioner
Adjustment of lubricating oil

quantity when components of air WARNING
conditioner are replaced In order to protect the environment, do not release
refrigerant to atmosphere when removing compo-
nents from air conditioner system. It not illegal to do
so.
IMPORTANT
- When replacing components of the air conditioner,
if the lubricant oil quantity is too small, the com-
pressor may seize. And if the lubricating oil quan-
tity 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).
Fig. 1
97ZV73002 - 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 Tightening torque

Pipe size or bolt size
area N-m (kgf-cm) (lb-ft)
8 pipe 14.7 (150) (7)
Nut type
1/2 pipe 24.5 (250) (18)
(Fig. 2)
Fig. 2
97ZV73003 5/8 pipe 34.3 (350) (25)
M6 bolt in receiver (4T) 6.9 (70) (5)

Block joint
(Fig. 3) Any M6 bolt other than
11.8 (120) (9)
above (6T)
Fig. 3 97ZV73004
73-3
Air Conditioner
When the compressor is replaced Torque values
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)
Oil quantity Example

remaining (B)
inside circuit Suppose that the oil quantity (A) removed from the com-
A A pressor to be replaced is 100 cm3. See figure 1.
Fig. 1 Oil quantity remaining inside circuit (B)

97ZV73005
= 180 cm3 - (100 + 20) = 60 cm3
Remove 60 cm3 from the new compressor to avoid

To avoid overloading the circuit;
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 systems 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.
73-4
Air Conditioner
When the evaporator is replaced When the condenser is replaced
Quantity of lubricating oil lost by replacement of con-

denser is approximately 40 cm3 (1.35 oz).
1
When replacing the condenser core, add 40 cm3 (1.35
oz) of compressor oil (ND-OIL 8) to a new condenser.
: (1): 25 N-m (2.5 kgf-m) (18 lb-ft)

: (2): 15 N-m (1.5 kgf-m) (11 lb-ft)
When the receiver dryer is replaced

Evaporator
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.
: (1): 7 N-m (0.7 kgf-m) (5 lb-ft)

: (2): 15 N-m (1.5 kgf-m) (11 lb-ft)
97ZV73006
Quantity of lubricating oil lost by replacement of evapo-

rator 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)

73-5
Air Conditioner
Adjustment of air gap (between 1. Remove the front cover of the magnetic clutch.
hub and rotor) in compressor 2. Measure dimension A between rotor end face and
magnetic clutch 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 Reference plane Standard (normal dimension) of air gap (A - B)
0.500.15 mm (0.0200.006 in)
Air gap
0.500.15 mm (0.0200.006 in)
A (OFF status) If the obtained value does not agree with the crite-
Position while magnetic ria, loosen the head bolt, remove the hub, and
clutch is ON
adjust the air gap by adjusting the thickness of the
B (ON status) washer plate between the hub and the shaft.
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 perform-

ing this work.
73-6
Air Conditioner
Compressor V-belt adjustment
Bracket
Bracket Air conditioner

compressor Plate
V-belt
Adjusting nut
Bracket mounting
nut
Bolt
115V2E73001
Belt adjustment procedure Belt adjustment value
1. Loosen four bracket mounting nut.
: Bracket mounting nut:

53.0 N-m (5.4 kgf-m) (39 lb-ft) A
2. Loosen the adjusting nut.

Turn the adjusting nut clockwise to adjust the V-
belt.
Turn the adjusting nut counter clockwise to loosen
the V-belt.
3. After the adjustment, tighten the bracket mounting

nut securely. 85V2E73002
Adjust the V-belt tension so that the belt tension at A

part is 35388 N (369 kgf) by using tension gauge.
Note
The V-belt tension should be 559108 N (5711 kgf)
when the belt is replaced with new one.
73-7
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
Note
Cleaning When replacing the receiver dryer, do not release the
Once every 2 weeks or when required. refrigerant into the atmosphere.
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 fil-
ter.
Replacement
Once each year or when required.
When air flow volume is so small as to affect air move-

ment 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 move-

ment even after the filter has been cleaned, or when the
air filter has been cleaned 6 times, replace it.
73-8
MEMO
80-1
115ZV-2 Function & Structure Supplement

Supplement
Foreword ................................................................. 80-2

Quick Coupler .......................................................... 80-3
Power boost circuit .................................................. 80-7
Short Boom (OPT)................................................... 80-15
Limited Slip Differential (LSD) ................................. 80-17
80-2 93216-00520
93216-00520 August 2009
August 2009
Foreword
The purpose of this supplemental manual is to provide information about the following features:
- Quick Coupler for the easier installation of attachment

- Power Boost Switch to increase the hydraulic oil pressure to assist heavy loading work
- Short Boom (option) to increase the unit strength of the bucket
- Limited Slip Differential to increase tractive effort.
Refer to the 115ZV-2 Shop Manual, Function and Structure (Manual No. 93216-00460) for the other information.
01-2 80-3
Function & Structure Supplement 115ZV-2 Function & Structure Supplement
Quick Coupler Quick Coupler
Quick Coupler
Hydraulic line and electrical circuit
2,13
Main switch
3 1
C 10 C
11
B
B 12
6 4 6
K115V2E01004
1. Solenoid valve assembly 8. Adapter

2. High pressure hose 9. Plug
3. High pressure hose 10. Cable assy
4. High pressure hose 11. Cable assy
5. Oil pipe 12. Cable assy
6. Elbow adapter 13. Spiral tube
7. Elbow adapter
80-4 01-3
7
9
T
2
B
7
P
A
8
8
5
Details of A
B-B K115V2E01005
Main switch Fuse box

R5 R5 R5
RL RG LR LW YR YW
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
W R Y B L G Br O WR
WR R5
RL RG LR LW YR YW YW YR LW
W R Y B L G Br O R5 R5 LR RG RL
R1.25 R Br R L Lg0.5 R5 R5 BW W
G BW G1.25 WR R5 WR G W
10
C-C
Power connector for option
Lock cylinder
Lock when cylinder extends. Main switch WR
Release when cylinder shortens.
Energize SOL A B 7 10 O
1 4
W W W
Solenoid valve De-energized 2
R
5
R R R
B A 3
G 6 G G
Left Right Energize SOL B
A B
SOL A SOL B
12 11
P T
G G
W W
Floor board
To tank
From control valve
(bucket cylinder bottom
circuit)
Yellow tape
B (Release)
+ +
Hydraulic circuit
+ + Electrical circuit
A (Fix) K115V2E01006
01-4 80-5
115ZV-2 Function & Structure Supplement 115ZV-2 Function & Structure Supplement
Solenoid valve
T
SOLENOID a SOLENOID b
A B
SOL. a SOL. b
P
2 1 6
T3
7 5 8 3 4 9
T2
T1
A B
a b
P T
Hydraulic symbol
K92V2E01004
1. Casing :
2. Spool T1: 6.4 0.5 N-m (0.65 0.05 kgf-m)
3. Washer T2: 44.1 4.9 N-m (4.50 0.50 kgf-m)
4. Spacer (Width across flats: 17 mm)
5. Spring T3: 7.8 0.5 N-m (0.80 0.05 kgf-m)
6. Screw
7. Solenoid
8. O-ring
9. O-ring
80-6 01-5
Solenoid valve specifications
P, A, B port 31.5 MPa (320 kgf/cm2)

Maximum hydraulic oil pressure
T port 15.7 MPa (160 kgf/cm2)
Maximum oil flow amount 70 L/min
Rated voltage DV 24 V
Rated current 1.1 A
80-7 80-7
Power
Power boost
boost circuit
circuit Power boost circuit
Power boost circuit
DOWN UP
B2
A2
6
19 23.5 0.5 MPa
b2 (240 5 kgf/cm2) a2
TS
DUMP RAISE
G1/4
1.3
B1 TS
G1/4
A1
23.5 0.5 MPa

b1 (240 5 kgf/cm2) a1
Relief valve
From pump line
P
TS
(b1) 1 2 (a1)
DUMP RAISE
Solenoid valve
(b2) 3 4 (a2)
DOWN UP
P T
16
A P TB 95
From
reducing To tank
valve From To tank
reducing
valve K115V2E01001
80-8 01-7
Power boost circuit Power boost circuit
Power boost
switch
K115V2E01002
During heavy loading work, when the power boost

switch is pressed, the solenoid valve is energized and
the pilot pressure from the reducing valve acts on the
relief valve piston of multiple control valve (3).
It increases the relief set pressure from the normal pre-
set value 20.6 MPa (210 kgf/cm2) to 22.7 MPa (230 kgf/
cm2) for 5 seconds. The 5 seconds time limit is con-
trolled by the MCU.
While increasing the main pressure, the lifting force and

the digging force are increased.
01-8 80-9
Multiple control valve main relief valve (MRV) (2 stage relief)

The main relief valve is installed between the pump port
and the cylinder port.
If the pressure is above the preset value as the cylinder
comes to the stroke end, etc., the oil fed from the pump
is discharged into the tank through this main relief valve
to prevent the pump and pipes from being damaged.
Multiple
control
Relief valve valve
K115V2E01007
PL
P
7 9 6 8 5 4 3 2 1
11 10 135ZV42064
1. Plunger
2. Spring seat
3. Filter
4. Seat
5. Poppet
6. Piston
7. Adapter plug
8. Spring
9. Lock nut (High pressure side)
10. Lock nut (Low pressure side)
11. Adapter plug
80-10 01-9
Multiple control valve main relief valve Multiple control valve main relief valve
(MRV) operation (MRV) adjusting set pressure
8 Low pressure setting

T
Loosen lock nut (10), and screw in adapter plug (11) to
increase the set pressure.
P Loosen adapter plug (11) to decrease the set pressure.
High pressure setting

increase the set pressure.
T Loosen adapter plug (7) to decrease the set pressure.
5 4 3 2 1 135ZV42065
Note
When setting pressures, low side pressure must be
When the oil pressure is lower than the set point
adjusted before adjusting high side pressure.
When adjusting low side pressures, high side must be
- The pressure of the pump port acts on poppet (5) via
rechecked and reset.
the orifice in the center of plunger (1), the orifice in
spring seat (2) and filter (3). Poppet (5) is pressed
onto seat (4) by spring (8). IMPORTANT
At the completion of check and adjustment of main
relief valve pressure, be sure to tighten the lock nut.
- When the pressure of the pump port exceeds the
force of spring (8), poppet (5) opens and the oil in
the chamber on the left side of plunger (1) escapes
into the tank port. As a result, the pressure in the
chamber on the left side drops drastically, plunger
(1) moves to the left, and the pressurized oil in the
pump port escapes into the tank port.
When the pressure intensifying switch is depressed
- When the pressure intensifying switch is depressed,

piston (6) is shifted to the right by the pressure from
the pressure intensifying solenoid valve via the port
PL of adapter plug (7), and spring (8) is compressed
by the dimension A. By this motion, the pressure of
the relief (high pressure side) setting increases.
80-11 80-11
Function & Structure Supplement Function & Structure Supplement
Measuring loading circuit overload relief Adjusting overload relief pressure

pressure
1. Attach the pressure gauge to the gauge port.

Lock nut
(250 kgf/cm2) (3,560 psi), so the pressure is above
the overload relief pressure.
Adjusting screw
T
PL P Overload relief valve

95ZV43005
T
adjusting screw.
11 10
Main relief valve sure, or turn counterclockwise the adjusting screw to
K115V2E01003
Note IMPORTANT
raise the main relief valve pressure. At the completion of check and adjustment of over-
load relief valve pressure, be sure to reset the main
Bucket cylinder bottom side

tion.

1. Bucket cylinder rod side
1. Keep the boom horizontal.
2. Move the bucket control lever to the dump position,

hold and then measure and record the pressure.
80-12 01-11
Hydraulic line
Solenoid valve
Relief valve
Combination valve mount
K115V2E01009
01-12 80-13
Electrical cable
To control box
Ground
Power boost switch

Floor harness
Solenoid valve
Cable assy (1)
Cable assy (2)
K115V2E01010
80-14 01-13
Electrical connection diagram
Switch
Floor harness
B G
MCU
B
277
Cable assy (1) G 000 GB
B C24
C
B 278
Y GB
A
2 1
Y
2 1
Solenoid valve
B Y Y B
Cable assy (2)
Ground
K115V2E01011
01-14 80-15
Short Boom (OPT) Short Boom (OPT)
Short Boom (OPT)
Bucket cylinder
Short boom
K115V2E01008
80-16 01-15
Short Boom (OPT) Short Boom (OPT)
Bucket cylinder
12,13,14
6 7,8 11 15 24 3 1 2 23 5 16,17 4 20 18,19 21 6
25,26 9,10
K115V2E01012
1. Cylinder tube 16. O-ring

2. Piston rod 17. Back-up ring
3. Piston 18. U-packing
4. Rod cover 19. Back-up ring
5. Bushing 20. Buffer ring
6. Bushing 21. Dust seal
7. Piston nut 22. Dust seal
8. Stop ring 23. Set screw
9. Bolt 24. Wear ring
10. Washer 25. Plug
11. Wear ring 26. O-ring
12. Back ring
13. Slipper ring
14. Back-up ring
15. O-ring
:Piston nut (7): 8,820 N-m (900 kgf-m) (6,510 lb-ft)

:Bolt (9): 1,270 N-m (130 kgf-m) (940 lb-ft)
Bucket cylinder specifications

mm (in)
225 x 120 x 719
(8.86 x 4.72 x 28.31)
100 x 120
Piston rod
(3.93 x 4.72)
Pin hole (inner diameter x width)
100 x 120
Cylinder
(3.93 x 4.72)
01-16 80-17
Limited Slip Differential (LSD) Limited Slip Differential (LSD)
Limited Slip Differential (LSD)
LSD gear structure
Note
Differential assembly 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
Differential cage
Side gear
5
Without lining
1
2
2
3
4
Limited Slip Differential
1
2
3
3
2
95V2U22004
1. Differential cage
2. Clutch assembly
3. Side gear
4. Pin
5. Bolt
80-18 01-17
2 1 23 24
3 28
29
26
33
35
32
4
31
30
27
5
6
34
7
22
8
9
10
17
21
25
15
38
11
12
13
14 37 16 18 19
20
K115V2E01013
1. Nut 11. Taper roller bearing 21. Roller bearing 31. Friction disc
2. Flange yoke 12. Adjusting nut 22. O-ring 32. Separation disc
3. Oil seal 13. Plate 23. O-ring 33. Pin
4. Plug 14. Wear ring 24. O-ring 34. Spring pin
5. Housing 15. Side gear 25. Snap ring 35. Spring
6. Shim 16. Differential pinion 26. O-ring 36.
7. Taper roller bearing 17. Pin 27. O-ring 37. Clutch assembly
8. Spacer 18. Wear ring 28. Gear 38. Pin
9. Spiral gear set 19. Spider 29. Piston assembly
10. Carrier assembly 20. Housing 30. Oil seal
01-18 80-19
115ZV-2 Function & Structure Supplement Function & Structure Supplement
2 1
29
36
K115V2U22002
Front differential gear (S/N 9101~)
2 1
29
36
K115V2U22003
1. Nut
2. Flange yoke
3. Oil seal
29. Piston assembly
36. Oil seal (Double lip) (S/N 9051~)
80-20 01-19
1 22
3
2 31
23
28 5
4 24
8
21
6
20
10
27
25
11 26
7 13
12
18
30
17
19
14
32
29
16 15 K115V2E01014
1. Nut 9. Spiral gear set 17. Side gear 25. O-ring

2. Flange yoke 10. Carrier assembly 18. Spider 26. Pin
3. Oil seal 11. Adjusting nut 19. Housing assy 27. Snap ring
4. Trunnion 12. Lock plate 20. Roller bearing 28. Bolt
5. Housing 13. Straight pin 21. O-ring 29. Bolt
6. Taper roller bearing 14. Wear ring 22. O-ring 30. Bolt
7. Taper roller bearing 15. Wear ring 23. O-ring 31. Oil seal (Double lip)
8. Sleeve 16. Differential pinion 24. Shim (S/N 9051~)
32. Clutch assembly
01-20 80-21
LSD function LSD operation
LSD performance
Differential
ge
pinion LSD Differential point 0.6 atin g ran
(bias ratio 1.75) Oper
LSD clutch LSD
assembly
ge
Torque
A
Differential ran
cage he
s i nt
pin
ir es
et
On
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1

Axle shaft
Friction ratio between right and left tires
Torque is transferred to the

right and left tires evenly until
the friction ratio between the
right and left tires comes to
Side gear moves
0.6:1. The result is that the
to the left and
LSD adds tractive effort.
pushes LSD
clutch. 0.6 1
Side gear
A - Detail
95V2E22014 K115V2E01015
LSD (Limited-Slip Differential) is installed between the The following shows operation for the left tire.
side gear and the differential cage, and increases trac-
tive effort. If the surface traction of the right and left tires A rotating driving force is transmitted from the differen-
differ from each other during operation, LSD clutch tial cage via spider (cross shaft) to the differential pinion
engages and prevents traction loss. and the side gear.
The performance of LSD is shown by using the bias When the ground surface resistance for the left tire less-
ratio. The bias ratio is the ratio between the driving force ens, the tapered interface between the differential pin-
of the right and left tires while the differential pinion is ion and the left side gear induces a side force. It pushes
turned. When the bias ratio is larger, it is easier to gain the left side gear to the left resulting in frictional engage-
traction on the ground surface with less resistance. ment with the differential cage, thus impeding free left
side gear rotation and gaining traction.
80-22
Function & Structure Supplement
MEMO
Maintenance Log
Date Machine hours Service performed

Notes

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93216-00460

Measurement for Performance Check .................................................................................................................. 03-1

Function & Structure Chassis Group ..................................................................................................................... 12-1

Check & Adjustment Chassis Group ..................................................................................................................... 13-1

Function & Structure Power Group ........................................................................................................................ 22-1

Check & Adjustment Power Group ........................................................................................................................ 23-1

Function & Structure Hydraulic Group ................................................................................................................... 42-1

Orbitrol .......................................................................................................................................................... 42-52

Orbitrol structure ..................................................................................................................................... 42-52

Orbitrol specifications .............................................................................................................................. 42-53

Orbitrol operation .................................................................................................................................... 42-54

Orbitrol feed-back mechanism operation ................................................................................................ 42-56

Reducing Valve (for Orbitrol) ......................................................................................................................... 42-73

Check & Adjustment Hydraulic Group ................................................................................................................... 43-1

Function & Structure Brake Group ........................................................................................................................ 52-1

Check & Adjustment Brake Group ......................................................................................................................... 53-1

Function & Structure Electrical Group ................................................................................................................... 62-1

Function & Structure Operator Station Group ....................................................................................................... 72-1

Function & Structure Supplement ...........................................................................................................................80-1

How to Use Manual ................................................. 00-2

How to Use Manual

Safety precautions - Do not start to work in an enclosed area if adequate

- Be sure to release the internal pressure before you

- Be sure to apply the articulation stopper before start-

- While supporting the bottom of the chassis using a

- When the boom or bucket is raised or when a unit is

Symbol Item Description

Shows the condition or procedure that will be useful

Shows the weight of a part or unit. The weight

Tightening Shows the tightening torque of a section that should

Shows the type of coating or adhesive and the coat-

Shows the oil or water drain port and the drain

E/G ........... Engine RH ............Right hand side 3rd ............3rd speed

Layout of main components

1. Engine assembly 9. Air cleaner 16. Efficient loading system (ELS)

Inspection and maintenance table IMPORTANT

: First time replacement or cleaning only

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

Clean Crankcase Breather Tube

Adjust Belt Tension

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

Replace Coolant Every 2 years or 3000 hours

: First time replacement or cleaning only