93216-00226

115ZV
September 2014

SHOP MANUAL
SHOP MANUAL

WHEEL LOADER

Function & Structure

General Information
115ZV
General Information
Standard Measurement Values for
Performance Check
Function & Structure
Check & Adjustment
93216-00226

Powered by CUMMINS QSK19-C ENGINE

Serial No. 11C4-0101~

©2014 KCM Corporation. All rights reserved. Printed in Japan (K)
11C4-9001~
( ヨーロッパ・輸出一般用 )
 93216-00226
September 2014

Foreword
To ensure good machine performance, reduce failures or problems, and prolong the service life of each component,
it is necessary to operate the machine as is directed in the Operator and Maintenance Manual.

To effectively diagnose and repair the machine, it is important to follow the guidelines laid out in this Shop Manual.

General Information
Function and structure

For the engine, refer to the engine Shop Manual provided by the engine manufacturer.

The purpose of this manual is to provide information on the product and the correct maintenance and repair 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.

Machine Specification
Market Serial numbers Remarks
Asia and Africa 11C4-0101 and up
Powered by CUMMINS QSK19-C Engine
Europe 11C4-9001 and up
Safety Symbols
An accident may occur if you disregard safety rules.
In this manual, several expressions are used according to levels of danger for inspection and repair work as shown
below. Read the work procedures and cautions described in this manual, and take preventive measures against
possible problems before starting service work.

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

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

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

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

We cannot predict all possible accidents or incidents that may occur during service work. Therefore, an accident that
is not specifically mentioned in this manual may occur. To protect yourself from all accidents, be careful when doing
service work.
CONTENTS
00 General Information ......................................................................................................................................... 00-1
How to Use Manual ........................................................................................................................................... 00-2
Safety precautions ...................................................................................................................................... 00-2
Symbols ...................................................................................................................................................... 00-3
Outline ............................................................................................................................................................... 00-4
Layout of main components ........................................................................................................................ 00-4
Inspection and maintenance table .............................................................................................................. 00-5
Recommended lubricants ........................................................................................................................... 00-8
Coolant ..................................................................................................................................................... 00-10
Lubrication chart ........................................................................................................................................00-11
Weight of main components ..................................................................................................................... 00-12
Bolt tightening torque ................................................................................................................................ 00-13
Hose band tightening torque ..................................................................................................................... 00-17
Liquid gasket and screw lock agent .......................................................................................................... 00-18
03 Measurement for Performance Check ............................................................................................................. 03-1
Cautions on Safety ............................................................................................................................................ 03-2
Standard Measurement Values for Performance Check ................................................................................... 03-3
12 Function & Structure Chassis Group ................................................................................................................ 12-1
Front Chassis .................................................................................................................................................... 12-2
Loading linkage ........................................................................................................................................... 12-2
Loading linkage pin ..................................................................................................................................... 12-4
Rear Chassis .................................................................................................................................................... 12-5
Fuel tank ..................................................................................................................................................... 12-5
Floor board mount ....................................................................................................................................... 12-7
Center Pin ......................................................................................................................................................... 12-8
Upper center pin ......................................................................................................................................... 12-8
Lower center pin ......................................................................................................................................... 12-8
Dust seal ..................................................................................................................................................... 12-9
13 Check & Adjustment Chassis Group ................................................................................................................ 13-1
Linkage Pin ....................................................................................................................................................... 13-2
Liner ............................................................................................................................................................ 13-2
Center Pin ......................................................................................................................................................... 13-6
Adjusting shim ............................................................................................................................................. 13-6
Installing bearing cover ............................................................................................................................... 13-6
Installing bearing outer ring ......................................................................................................................... 13-6
22 Function & Structure Power Group .................................................................................................................. 22-1
Power Line ........................................................................................................................................................ 22-2
Engine / Transmission ....................................................................................................................................... 22-3
Engine / transmission mount ....................................................................................................................... 22-3
Radiator ............................................................................................................................................................. 22-4
Radiator mount ............................................................................................................................................ 22-5
Propeller Shaft .................................................................................................................................................. 22-6
First propeller shaft assembly ..................................................................................................................... 22-7
Second propeller shaft assembly ................................................................................................................ 22-8
Third propeller shaft assembly .................................................................................................................. 22-10
Axle Assembly ................................................................................................................................................. 22-11
Axle Support .................................................................................................................................................... 22-14
Differential Gear .............................................................................................................................................. 22-20
Function of differential gear ....................................................................................................................... 22-24
Operation of differential gear ..................................................................................................................... 22-24
23 Check & Adjustment Power Group ................................................................................................................... 23-1
Engine ............................................................................................................................................................... 23-2
Measuring engine speed ............................................................................................................................. 23-2
Measuring engine oil pressure .................................................................................................................... 23-2
Propeller Shaft .................................................................................................................................................. 23-3
Propeller shaft phase .................................................................................................................................. 23-3
Second propeller shaft alignment ................................................................................................................ 23-3
Tightening torque ........................................................................................................................................ 23-4
Axle ................................................................................................................................................................... 23-5
Axle nut tightening procedure ..................................................................................................................... 23-5
32 Function & Structure Torque Converter and Transmission Group ................................................................... 32-1
Torque Converter .............................................................................................................................................. 32-2
Torque converter structure .......................................................................................................................... 32-3
Power flow path ........................................................................................................................................... 32-3
Torque multiplication ................................................................................................................................... 32-3
Torque Converter Gear Pump ........................................................................................................................... 32-4
Gear pump specifications ............................................................................................................................ 32-4
 Transmission ..................................................................................................................................................... 32-5
Clutch combination ..................................................................................................................................... 32-6
Planetary gear ............................................................................................................................................. 32-6
Shift lever position ....................................................................................................................................... 32-6
Power up switch operation .......................................................................................................................... 32-6
Gear train and number of teeth ................................................................................................................... 32-7
Clutch Pack ..................................................................................................................................................... 32-10
Power Flow Path in the Transmission ..............................................................................................................32-11
Forward ......................................................................................................................................................32-11
Reverse ..................................................................................................................................................... 32-14
Hydraulic System Diagram ............................................................................................................................. 32-16
Hydraulic Circuit Diagram ............................................................................................................................... 32-17
T/C and T/M Oil Circulation ............................................................................................................................. 32-18
Oil flow in the torque converter line ........................................................................................................... 32-19
Oil flow to the clutch .................................................................................................................................. 32-19
Modulator Valve Unit ....................................................................................................................................... 32-20
Interior schematic (not exact representation) ............................................................................................ 32-22
Modulation Mechanism ................................................................................................................................... 32-23
Modulator valve function ........................................................................................................................... 32-23
Modulator valve operation ......................................................................................................................... 32-25
Clutch Solenoid Valve ..................................................................................................................................... 32-26
33 Check & Adjustment Torque Converter and Transmission Group ................................................................... 33-1
Clutch Oil Pressure and Time Lag .................................................................................................................... 33-2
Measuring clutch oil pressure ..................................................................................................................... 33-2
Measuring clutch time lag ........................................................................................................................... 33-4
42 Function & Structure Hydraulic Group ............................................................................................................. 42-1
Flushing Hydraulic Circuit ................................................................................................................................. 42-2
Purpose of flushing ..................................................................................................................................... 42-2
Cautions on Hydraulic Parts Replacement ....................................................................................................... 42-3
Hydraulic Circuit Symbols ................................................................................................................................. 42-4
Hydraulic lines ............................................................................................................................................. 42-4
Pumps & motors .......................................................................................................................................... 42-4
Cylinders ..................................................................................................................................................... 42-4
Operation methods ...................................................................................................................................... 42-5
Pressure control valve ................................................................................................................................. 42-5
Flow control valve ....................................................................................................................................... 42-5
Directional control valve .............................................................................................................................. 42-6
Check valve ................................................................................................................................................. 42-6
Miscellaneous hydraulic symbols ................................................................................................................ 42-7
Hydraulic System Operation ............................................................................................................................. 42-8
Hydraulic system operation outline ............................................................................................................. 42-8
Layout of Hydraulic Units ................................................................................................................................ 42-10
Hydraulic Tank ................................................................................................................................................. 42-11
Hydraulic tank specifications ..................................................................................................................... 42-11
Hydraulic oil level check ............................................................................................................................ 42-11
Hydraulic tank (S/N 0101~0200, 9001~) ................................................................................................... 42-12
Hydraulic tank (S/N 0201~) ....................................................................................................................... 42-14
Hydraulic Pump ............................................................................................................................................... 42-16
Loading and pilot and brake pump ............................................................................................................ 42-17
Pump specifications .................................................................................................................................. 42-17
Steering pump ........................................................................................................................................... 42-18
Steering pump specifications .................................................................................................................... 42-18
Hydraulic pump principle ........................................................................................................................... 42-19
Hydraulic pump wear plate ........................................................................................................................ 42-20
Hydraulic pump bushing lubrication .......................................................................................................... 42-20
Hydraulic Cylinder ........................................................................................................................................... 42-21
Boom cylinder ........................................................................................................................................... 42-21
Bucket cylinder .......................................................................................................................................... 42-21
Steering cylinder ....................................................................................................................................... 42-22
Hydraulic cylinder specifications ............................................................................................................... 42-22
Loading System .............................................................................................................................................. 42-23
Reducing Valve (for Pilot Pressure) ................................................................................................................ 42-24
Pilot Valve (S/N 0101~0140, 9001~9020) ....................................................................................................... 42-25
Pilot valve operation .................................................................................................................................. 42-27
Pilot valve detent magnet solenoid ........................................................................................................... 42-29
Detent adjustment procedure .................................................................................................................... 42-29
Pilot valve (S/N 0141~0172, 9021~) ............................................................................................................... 42-30
Pilot valve operation .................................................................................................................................. 42-32
Pre-detent and detent magnet solenoid .................................................................................................... 42-34
Pilot valve (S/N 0173~0176) ........................................................................................................................... 42-35
Pilot valve (S/N 0177~) ................................................................................................................................... 42-40
Multiple Control Valve (KML35A/2T103) ......................................................................................................... 42-45
Multiple control valve specifications .......................................................................................................... 42-46
Multiple control valve main relief valve ..................................................................................................... 42-47
Multiple control valve overload relief valve ............................................................................................... 42-49
Multiple control valve bucket spool ........................................................................................................... 42-52
Multiple control valve boom spool ............................................................................................................. 42-54
Adapter (Orifice) .............................................................................................................................................. 42-57
Vibration Damper (OPT) ................................................................................................................................. 42-58
Vibration damper operation ....................................................................................................................... 42-59
Vibration damper hydraulic line ................................................................................................................. 42-68
Steering System .............................................................................................................................................. 42-69

Orbitrol® .......................................................................................................................................................... 42-70

Orbitrol® structure ..................................................................................................................................... 42-70

Orbitrol® specifications .............................................................................................................................. 42-71

Orbitrol® operation .................................................................................................................................... 42-72

Orbitrol® feed-back mechanism operation ................................................................................................ 42-74

Steering speed and flow rate control ........................................................................................................ 42-75
Hydraulic pump oil amount and steering force .......................................................................................... 42-75
Orbit rotor operation principle ................................................................................................................... 42-76
Steering Valve (KVS32-A4.0/21) ..................................................................................................................... 42-77
Steering valve operation ........................................................................................................................... 42-79
Steering spool variable throttle ................................................................................................................. 42-81
Steering valve flow control spool .............................................................................................................. 42-82
Steering valve main relief valve ................................................................................................................ 42-83
Steering valve overload relief valve .......................................................................................................... 42-85
Steering pilot circuit and its operation ....................................................................................................... 42-87
 Stop Valve ....................................................................................................................................................... 42-89
Stop valve function .................................................................................................................................... 42-91
Stop valve operation ................................................................................................................................. 42-92

Reducing Valve (for Orbitrol®) ......................................................................................................................... 42-93

Steering Line Filter .......................................................................................................................................... 42-94
Fan Motor System ........................................................................................................................................... 42-95
Fan Motor Line (S/N 0101~0120, 9001~9010) ............................................................................................... 42-96
Fan Motor (GM30C) .................................................................................................................................. 42-98
Valve Assembly (for Fan Motor) ................................................................................................................ 42-99
Relief Valve (Two-step Relief) ................................................................................................................. 42-100
Solenoid Valve (for Fan Speed Control) .................................................................................................. 42-103
Fan Motor Line (S/N 0121~, 9011~) .............................................................................................................. 42-104
Fan Motor (GM30W) ............................................................................................................................... 42-106
Fan motor (FM30) (S/N 0168~) ............................................................................................................... 42-108
Thermo Sensing Valve ............................................................................................................................ 42-110
Fan Motor Relief Valve Assembly ........................................................................................................... 42-112
Emergency Steering ...................................................................................................................................... 42-114
Emergency steering operation ................................................................................................................ 42-115
Emergency steering hydraulic line .......................................................................................................... 42-115
Emergency steering oil flow .................................................................................................................... 42-116
Emergency steering pump ...................................................................................................................... 42-118
43 Check & Adjustment Hydraulic Group .............................................................................................................. 43-1
Loading/Steering Circuit Relief Valve ................................................................................................................ 43-2
Loading circuit relief valve setting pressures .............................................................................................. 43-2
Steering circuit relief valve setting pressures .............................................................................................. 43-7
Hydraulic Cylinder ........................................................................................................................................... 43-11
Cylinder natural drift .................................................................................................................................. 43-11
Stop Valve ....................................................................................................................................................... 43-13
Stop valve adjustment procedure .............................................................................................................. 43-13
Fan Motor Revolution ...................................................................................................................................... 43-14
Fan maximum revolution measurement (S/N 0101~0120, 9001~9010) ................................................... 43-14
Fan maximum revolution measurement (S/N 0121~, 9011~) ................................................................... 43-16
52 Function & Structure Brake Group ................................................................................................................... 52-1
Brake System Outline ....................................................................................................................................... 52-2
Service brake .............................................................................................................................................. 52-2
Parking brake .............................................................................................................................................. 52-2
Auto brake .................................................................................................................................................. 52-2
Adjustment of axle internal pressure ........................................................................................................... 52-2
Brake Units Layout ............................................................................................................................................ 52-3
Unloader Valve .................................................................................................................................................. 52-4
Unloader valve operation ............................................................................................................................ 52-6
Reducing valve ................................................................................................................................................. 52-7
Valve Unit (Main Brake Manifold Block) ............................................................................................................ 52-8
Brake Accumulator Line .................................................................................................................................... 52-9
Accumulator .............................................................................................................................................. 52-10
In-Line Filter ...............................................................................................................................................52-11
Brake Valve ..................................................................................................................................................... 52-12
Brake main valve (left pedal) .................................................................................................................... 52-12
Brake pilot valve (right pedal) ................................................................................................................... 52-13
Brake valve performance chart ................................................................................................................. 52-14
Brake valve outline .................................................................................................................................... 52-15
Stop Lamp Pressure Switch ............................................................................................................................ 52-18
Pressure switch (for stop lamp) ................................................................................................................ 52-18
Pressure switch (for Declutch) .................................................................................................................. 52-19
Service Brake .................................................................................................................................................. 52-20
Service brake operation ............................................................................................................................ 52-20
Service brake friction plate ........................................................................................................................ 52-21
Service brake steel plate ........................................................................................................................... 52-22
Service brake piston ................................................................................................................................. 52-23
Service brake pedal stroke adjusting mechanism ..................................................................................... 52-24
Parking Brake ................................................................................................................................................. 52-28
Parking brake operation ............................................................................................................................ 52-30
Parking brake solenoid valve .................................................................................................................... 52-31
Parking Brake Manual Release ...................................................................................................................... 52-32
Parking Brake Spring Chamber ...................................................................................................................... 52-34
Brake Circuit Check Valve ............................................................................................................................... 52-35
 Auto Brake ...................................................................................................................................................... 52-36
Auto brake operation set value ................................................................................................................. 52-36
Auto brake circuit ...................................................................................................................................... 52-36
Solenoid valve (for auto brake circuit) ....................................................................................................... 52-37
Shuttle Valve ................................................................................................................................................... 52-38
53 Check & Adjustment Brake Group ................................................................................................................... 53-1
Brake Circuit Oil Pressure ................................................................................................................................. 53-2
Unloader valve setting pressure .................................................................................................................. 53-2
Brake valve oil pressure .............................................................................................................................. 53-6
Service Brake .................................................................................................................................................... 53-8
Service brake performance check ............................................................................................................... 53-8
Service brake friction plate wear measurement .......................................................................................... 53-9
Parking Brake .................................................................................................................................................. 53-12
Parking brake performance check ............................................................................................................ 53-12
Parking brake clearance adjustment ......................................................................................................... 53-14
62 Function & Structure Electrical Group .............................................................................................................. 62-1
How to Use Electrical Wiring Diagram .............................................................................................................. 62-2
Utilisation des schémas des câblages électriques (FRANÇAIS) ...................................................................... 62-3
Verwendung des elektrischen Schaltplans (DEUTSCH) ................................................................................... 62-4
Modalità di utilizzo dello schema dei collegamenti elettrici (ITALIANO) ............................................................ 62-5
Cómo utilizar un Diagrama de Alambrado Eléctrico (ESPAÑOL) ..................................................................... 62-6
Como Utilizar o Diagrama de Ligações Eléctricas (PORTUGUÊS) .................................................................. 62-7
Electrical Cable Color Codes ............................................................................................................................ 62-8
Electrical Circuit Symbols .................................................................................................................................. 62-9
Sensor Mount .................................................................................................................................................. 62-10
Fuse ................................................................................................................................................................ 62-11
Fuse box ................................................................................................................................................... 62-12
Fusible link ................................................................................................................................................ 62-13
Engine Start Circuit ......................................................................................................................................... 62-14
Engine start circuit diagram (S/N 0101~0153, 9001~) .............................................................................. 62-14
Engine start circuit diagram (S/N 0154~) .................................................................................................. 62-15
Neutral starter ........................................................................................................................................... 62-16
Starter switch ............................................................................................................................................ 62-17
Battery relay .............................................................................................................................................. 62-18
Alternator I terminal wire ........................................................................................................................... 62-18
Diode unit .................................................................................................................................................. 62-19
Neutral relay .............................................................................................................................................. 62-19
Magnet switch ........................................................................................................................................... 62-20
Voltage relay ............................................................................................................................................. 62-20
Power Generating/Charging Circuit ................................................................................................................ 62-22
Alternator .................................................................................................................................................. 62-22
ECM (Engine Controller) ................................................................................................................................. 62-23
Function of ECM ....................................................................................................................................... 62-23
Connection diagram .................................................................................................................................. 62-23
Monitor lamp test ...................................................................................................................................... 62-24
Failure diagnosis ....................................................................................................................................... 62-25
Quantum fault code information ................................................................................................................ 62-30
Power mode change ................................................................................................................................. 62-37
Accelerator pedal ...................................................................................................................................... 62-38
Accelerator pedal ...................................................................................................................................... 62-40
Transmission Control Circuit (S/N 0101~0153, 9001~) .................................................................................. 62-42
Controller .................................................................................................................................................. 62-42
Controller connection diagram .................................................................................................................. 62-44
Controller function ..................................................................................................................................... 62-45
Monitor controller ...................................................................................................................................... 62-62
Transmission Control Circuit (S/N 0154~) ...................................................................................................... 62-63
Machine control unit (MCU) ...................................................................................................................... 62-63
Machine control unit (MCU) connection diagram (S/N 0154~0222) ......................................................... 62-65
Machine control unit (MCU) connection diagram (S/N 0223~) ................................................................. 62-66
Monitor Circuit ................................................................................................................................................. 62-68
Monitor controller (S/N 0101~0153, 9001~) .............................................................................................. 62-71
Monitoring sensor and switch ................................................................................................................... 62-73
 Instrument Panel and Switch .......................................................................................................................... 62-74
Instrument panel ....................................................................................................................................... 62-74
Instrument panel rear surface ................................................................................................................... 62-76
Gauge circuit ............................................................................................................................................. 62-78
Fuel gauge circuit ...................................................................................................................................... 62-80
Tachometer circuit ..................................................................................................................................... 62-81
Electrical Detent Circuit ................................................................................................................................... 62-82
Bucket leveler ............................................................................................................................................ 62-82
Boom kick-out (option) .............................................................................................................................. 62-83
Detent solenoid ......................................................................................................................................... 62-84
Diode ............................................................................................................................................................... 62-85
Diode check method ................................................................................................................................. 62-86
Caution for diode check method ............................................................................................................... 62-86
Surge voltage and surge suppression diodes ........................................................................................... 62-88
Diagnostic System (S/N 0101~0153, 9001~) .................................................................................................. 62-89
Transmission controller ............................................................................................................................. 62-89
Monitor controller ...................................................................................................................................... 62-93
Diagnostic failure history indication and deletion ...................................................................................... 62-96
Diagnostic switch ...................................................................................................................................... 62-98
MODM (S/N 0154~) ........................................................................................................................................ 62-99
MODM function ......................................................................................................................................... 62-99
Monitor Changeover .................................................................................................................................. 62-99
MODM: Input/output monitor - Input/output signal correspondence table ............................................... 62-106
63 Check & Adjustment Electrical Group .............................................................................................................. 63-1
Cautions Regarding Electric Circuit Check ....................................................................................................... 63-2
Disconnecting or reinstalling connector ...................................................................................................... 63-2
How to attach the probes of the circuit tester .............................................................................................. 63-4
Electrical Transmission Control System Troubleshooting Flowchart (S/N 0101~0153, 9001~) ........................ 63-5
Standard troubleshooting flowchart ............................................................................................................. 63-5
Transmission Controller Abnormal Operation Judgment (S/N 0101~0153, 9001~) .......................................... 63-6
Transmission controller check ..................................................................................................................... 63-6
Transmission controller LED indicator ........................................................................................................ 63-8
 Electrical Circuit Check (S/N 0101~0153, 9001~) .......................................................................................... 63-10
Shift lever input electrical circuit check ..................................................................................................... 63-10
Inching (Declutch) input electrical circuit check ........................................................................................ 63-12
QUAD switch input electrical circuit check ................................................................................................ 63-14
Machine speed sensor input electrical circuit check ................................................................................. 63-15
Clutch solenoid valve output electrical circuit check ................................................................................. 63-16
Modulator valve output electrical circuit check .......................................................................................... 63-18
Neutral relay electrical circuit check .......................................................................................................... 63-20
Parking brake electrical circuit check ........................................................................................................ 63-21
Auto brake electrical circuit check ............................................................................................................. 63-23
Gauge circuit electrical circuit check ......................................................................................................... 63-25
Fuel level gauge electrical circuit check .................................................................................................... 63-27
Bucket positioner electrical circuit check .................................................................................................. 63-29
72 Function & Structure Operator Station Group .................................................................................................. 72-1
Cabin ................................................................................................................................................................. 72-2
Glass ........................................................................................................................................................... 72-4
Wiper mount ................................................................................................................................................ 72-7
Wiper motor ................................................................................................................................................ 72-8
Operator Seat ................................................................................................................................................. 72-10
Steering and Transmission Shift Lever ............................................................................................................72-11
Tilt case ..................................................................................................................................................... 72-12
Column shaft ............................................................................................................................................. 72-13
Shift lever .................................................................................................................................................. 72-13
Air Conditioner ................................................................................................................................................ 72-14
Air conditioner components ...................................................................................................................... 72-14
Air conditioner structure ............................................................................................................................ 72-15
Cooling mechanism .................................................................................................................................. 72-20
Cooling circuit ........................................................................................................................................... 72-22
Electrical circuit ......................................................................................................................................... 72-23
Air conditioner functions of components ................................................................................................... 72-24
Charge of refrigerant ................................................................................................................................. 72-51
Air conditioner troubleshooting ................................................................................................................. 72-66
73 Check & Adjustment Operator Station Group .................................................................................................. 73-1
Air Conditioner .................................................................................................................................................. 73-2
Adjustment of lubricating oil quantity when components of air conditioner are replaced ............................ 73-2
Adjustment of air gap (between hub and rotor) in compressor magnetic clutch ......................................... 73-5
Parts to be replaced periodically ................................................................................................................. 73-6
92 Cross-section drawing & Diagrams .................................................................................................................. 92-1
Axle Assembly ................................................................................................................................................... 92-2
Torque Converter and Transmission ................................................................................................................. 92-4
Loading/Steering Hydraulic Line (S/N 0101~0120) ........................................................................................... 92-5
Loading/Steering Hydraulic Circuit (S/N 0121~) ................................................................................................ 92-6
Loading/Steering Hydraulic Circuit (S/N 9001~9010) ........................................................................................ 92-7
Loading/Steering Hydraulic Circuit (S/N 9011~) ................................................................................................ 92-8
Brake Circuit ...................................................................................................................................................... 92-9
Electrical Wiring Diagram (1/2) (S/N 0101~0120) ........................................................................................... 92-10
Electrical Wiring Diagram (2/2) (S/N 0101~0120) ........................................................................................... 92-11
Electrical Wiring Diagram (1/2) (S/N 0121~0124) ........................................................................................... 92-12
Electrical Wiring Diagram (2/2) (S/N 0121~0124) ........................................................................................... 92-13
Electrical Wiring Diagram (1/2) (S/N 0125~0153) ........................................................................................... 92-14
Electrical Wiring Diagram (2/2) (S/N 0125~0153) ........................................................................................... 92-15
Electrical Wiring Diagram (1/3) (S/N 0154~0222) ........................................................................................... 92-16
Electrical Wiring Diagram (2/3) (S/N 0154~0222) ........................................................................................... 92-17
Electrical Wiring Diagram (3/3) (S/N 0154~0222) ........................................................................................... 92-18
Electrical Wiring Diagram (1/3) (S/N 0223~) ................................................................................................... 92-19
Electrical Wiring Diagram (2/3) (S/N 0223~) ................................................................................................... 92-20
Electrical Wiring Diagram (3/3) (S/N 0223~) ................................................................................................... 92-21
Electrical Wiring Diagram (1/2) (S/N 9001~9010) ........................................................................................... 92-22
Electrical Wiring Diagram (2/2) (S/N 9001~9010) ........................................................................................... 92-23
Electrical Wiring Diagram (1/2) (S/N 9011~) ................................................................................................... 92-24
Electrical Wiring Diagram (2/2) (S/N 9011~) ................................................................................................... 92-25
Electrical Wiring Diagram Abbreviation Chart (S/N 0101~0153, 9001~) ........................................................ 92-26
Electrical Wiring Diagram Abbreviation Chart (S/N 0154~0222) ..................................................................... 92-27
Electrical Wiring Diagram Abbreviation Chart (S/N 0223~) ............................................................................. 92-28
Electrical Wiring Diagram (CAB) ..................................................................................................................... 92-29
Electrical Connection Diagram (S/N 0101~0120) ........................................................................................... 92-31
Electrical Connection Diagram (S/N 0121~0124) ........................................................................................... 92-32
Electrical Connection Diagram (S/N 0125~0153) ........................................................................................... 92-33
Electrical Connection Diagram (S/N 0154~0222) ........................................................................................... 92-34
Electrical Connection Diagram (1/2) (S/N 0223~) ........................................................................................... 92-35
Electrical Connection Diagram (2/2) (S/N 0223~) ........................................................................................... 92-36
Electrical Connection Diagram (S/N 9001~9010) ........................................................................................... 92-37
Electrical Connection Diagram (S/N 9011~) ................................................................................................... 92-38
Electrical Circuit Diagram (Cabin Air Conditioner) .......................................................................................... 92-39
Electrical Wiring Diagram (Cabin Air Conditioner) .......................................................................................... 92-40
Equipment Operation Table (Cabin Air Conditioner) ....................................................................................... 92-41
Electrical Equipment Layout ........................................................................................................................... 92-42
MEMO
 115ZV EX 00-1
00 General Information

00 General Information

How to Use Manual ................................................. 00-2

Outline ..................................................................... 00-4
115ZV EX 00-2
00 General Information
How to Use Manual

How to Use Manual

Safety precautions
- Contact tire manufacturer's local dealer for tire ser-
vicing and changing.
The most important point in providing repair service is
safety. To ensure safety, observe the general cautions - Always store the tools in good condition, and use
described below. them properly.

- This manual is intended for properly trained and - Keep the work area clean. Clean up spills immedi-
equipped service technicians. ately.

- Any work on the machine must be performed by the - Avoid the use of flammable solvents and cleaners.
trained personnel only.
- When working outdoors keep work areas, ladders,
- Carefully read this manual to thoroughly understand steps, decks and work platforms clear of snow, ice,
the operation method before you operate or repair and mud.
the machine.
- Use safe work platforms to reach higher areas of the
- Be sure to wear appropriate clothes and protectors, machine.
such as safety boots, hard hat and goggles.

- Place the machine on level and solid ground, and

place chocks against the wheels to prevent move-
ment.

- Remove the cable from the battery before starting

the service work, and attach a "DO NOT OPERATE!"
tag to the steering wheel.

- Be sure to release the internal pressure before you

remove a pipe, such as the hydraulic oil, air, or
engine coolant pipe.

- Be sure to apply the articulation stopper before 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.

- Do not start to work in an enclosed area if adequate

ventilation is not provided.

- To remove a heavy unit (20 kg (40 lbs) or more), be

sure to use a crane or other lifting tool.

- Just after stopping operation, be careful not to

directly touch a hot component. You may get
burned.
 115ZV EX 00-3
00 General Information
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 92-26.

E/G ........... Engine B ............Battery 1st ............1st speed

T/C ........... Torque converter R ............Rear or Reverse 2nd ............2nd speed
T/M ........... Transmission RH ............Right hand side 3rd ............3rd speed
SOL ........... Solenoid valve LH ............Left hand side 4th ............4th speed
SW ........... Switch H ............High DD ............Dynamic damper
F ........... Front or Forward L ............Low M/C ............Machine
QUAD......... Quick up and down shift GND ............Ground min-1 ............RPM
A/M ........... Auto/Manual OPT ............Option
Assy ............Assembly
115ZV EX 00-4
00 General Information
Outline

Outline

Layout of main components

12

8 3 9 1 10
23
17 5 20 7 6 15 11

22 21 19 18 2 14 16 13

115ZVE00001

1. Engine assembly 9. Air cleaner 17. Front axle assembly

(Cummins QSK19-C) 10. Muffler 18. Rear axle assembly
2. Torque converter assy 11. Radiator 19. 1st propeller shaft
3. Transmission 12. Hydraulic oil cooler 20. 2nd propeller shaft
4. Hydraulic pump (air-to-oil type) 21. 3rd propeller shaft
5. Multiple (loader) control valve 13. T/C oil cooler 22. Parking brake
6. Steering valve (lower tank of radiator) 23. Fan motor
7. Pilot valve 14. T/C oil cooler (installed on E/G)
(for loading) (right side) 15. Charge air cooler
8. Transmission control valve 16. Fuel cooler
 115ZV EX 00-5
00 General Information
Outline

Inspection and maintenance table

: 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

Check Warning Lamps

Check Exhaust Gas

Drain Water and Sediment from Fuel Filter

Check Fuel Level

Check Drive Belt

Check Air Intake System

Check Cooling Fan

Drain Water and Sediment from Fuel Tank

Replace Engine Oil and Oil Filter Cartridge

Check Crankcase Breather

Adjust Belt Tension

Engine Replace Fuel Filter Cartridge

Replace DCA4 Coolant Filter Cartridge

Check Engine Compression Pressure

Check Injection Pressure

Check and Adjust Injection Timing

Clean Fuel Tank

Check and Adjust Valve Lash Clearance

Check Vibration Damper

Clean Crankcase Breather Tube

Replace Ether Cylinder

Clean or Replace Air Cleaner Element

Clean Radiator / Air Cooler / Fuel Cooler Fins

Clean or Replace Air Cleaner Element After six cleanings or once a year

Replace Coolant Every 2 years or 3000 hours

Check Transmission Oil Level

Transmission
& Replace Transmission Oil Filter Cartridge
Torque
Replace Transmission Oil
Converter
Clean or Replace Transmission Breather
115ZV EX 00-6
00 General Information
Outline

: First time replacement or cleaning only

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

Check Tire for Damage, Air and Tread Depth

Check Tire Air Pressure

Greasing (Axle support)

Check Differential Gear Oil

Check Planetary Gear Oil

Axle system Greasing (Pillow block bearing unit)

Check Tightness of Wheel Bolts

Greasing (Differential seals)

Greasing (1st, 2nd and 3rd Propeller Shafts)

Replace Differential Gear Oil

Replace Planetary Gear Oil

Check Steering Wheel Operation

Steering
Greasing (Steering Cylinder)
system
Clean Filter for Orbitrol®

Check Service Brake Operation

Check Parking Brake Operation

Greasing (Parking brake adjuster and shaft)

Brake
Adjust Parking Brake Lining
system
Check Service Brake Disk Wear

Check Brake Accumulators

Clean Filter for Brake Line

Check Hydraulic Oil Level

Greasing

Replace Hydraulic Oil Return Filter

Replace Hydraulic Oil, Clean Filter

Loading
system Replace Filter in the Hydraulic Tank Cap (S/N 0101~0200,
9001~)
Replace Filter in the Hydraulic Tank Breather Valve (S/N 0201~)

Replace Bucket Teeth (option)

Replace Cutting Edge (option)

Adjust and Check Rear View Mirrors

ROPS (Roll Over Protective Structure)
(option for other than Europe)
Greasing (Center Pin)
Chassis
Check Vibration Damper Accumulator (option)

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

Check Windshield Washer Fluid

 115ZV EX 00-7
00 General Information
Outline

: First time replacement or cleaning only

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

Check Monitor Panel Operation

Check Horn Operation

Check Back-up Alarm Operation

Electrical
system
Check Wiring Harnesses

Check Battery Electrolyte Level

Check or Replace Fuses

Check and Adjust Air Conditioner Belt

Clean Air Conditioner and Heater Filter Element (option)

Check Air Conditioner Refrigerant

Air
Conditioner
Replace Air Conditioner Filter Elements (option)

Clean Air Conditioner Condenser (option)

Replace Air Conditioner Receiver Dryer (option) Every 3 years or 6000 hours

Others Walk-Around Inspection

115ZV EX 00-8
00 General Information
Outline

Recommended lubricants

Ambient Temperature Change

Refill capacity -22ºF -4 14 32 50 68 86 104
Kind of Oil Interval
(Approximate) -30ºC -20 -10 0 10 20 30 40
(Hours)
SAE10W
Engine oil SAE10W-30
Engine 65 liter (17.2 gal) 250
(CH4 or CG4) SAE15W-40

Engine oil (CD) SAE10W

Transmission 85 liter (22.5 gal) 1,000
or ATF ATF

ISO VG32
1
Hydraulic tank 225 liter (59.4 gal) Hydraulic oil ISO VG46
2,000

Front:
Differential & 180 liter (47.6 gal) Engine oil SAE40 or SAE50
Engine oil (CD) 2,000
Planetary Rear:
180 liter (47.6 gal)
ASTM D975 No.1
Fuel tank 670 liter (177 gal) Diesel fuel daily
ASTM D975 No.2

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

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

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

Hydraulic System Use industrial-type hydraulic oils which are certified by suppliers having anti-wear, anti-foam,
anti-rust and anti-oxidation additive properties for heavy duty use. Use of the wrong viscosity
of oil can cause improper operation of hydraulic functions or premature pump failure.
*2. In a case that fire-resistant fluid is to be used in the hydraulic circuit, some hydraulic
equipment must be replaced. Contact your Kawasaki dealer for service.
Be sure to use ISO VG32 when the temperature is below -15ºC. When replacing the
hydraulic oil ISO VG46 with ISO VG32, the brakes must be bled to fully circulate the new
oil, or brake problems could occur. Contact your Kawasaki dealer for service.

Differential & 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.
 115ZV EX 00-9
00 General Information
Outline

Diesel Fuel Requirements for diesel fuel

Specifications
Grade No.1-D Grade No.2-D
Flash Point ºC. min. 38 52
Water and Sediment % vol. max 0.05 0.05
Distillation Temperature ºC 90% vol. recovered max. 288 338
2
Kinematic Viscosity mm /s at 40ºC min. 1.3 1.9
max. 2.4 4.1
Ash % mass max. 0.01 0.01
Sulfer % mass max. 0.50 0.50
Cetane Number min. 40 40
Carbon residue on 10% distillation residue % mass max. 0.15 0.35
115ZV EX 00-10
00 General Information
Outline

Coolant
IMPORTANT
Coolant specification
Do not mix different brands of antifreeze because
they each contain special additives.
The machine is originally filled with Long Life Coolant Careless mixing often diminishes the effect of these
(non-Amin type ethylene glycol) which need not be additives and causes packing damage or water leak-
replaced for the first two years or 3,000 hours. age.

Do not use Amin type Long Life Coolant in cooling sys-

tem. It may cause a corrosion against radiator or heater
core.

If standard antifreeze (not Long Life Coolant) is used for

the replacement, it should be replaced every six
months.

Recommended mixture of antifreeze

Expected Minimum -35ºC -30ºC -25ºC -20ºC -15ºC

Ambient Temperature (-31ºF) (-22ºF) (-13ºF) (-4ºF) (5ºF)
(liter) 58.6 63.4 69.5 75.7 81.7
Pure Water
(gal) (15.5) (16.7) (18.4) (20.0) (21.6)
(liter) 63.4 58.6 52.5 46.3 40.3
Antifreeze
(gal) (16.7) (15.5) (13.8) (12.2) (10.6)
Mixture Ratio (%) 53 48 43 38 33

- Keep the antifreeze mixture ratio between 33% and

53% in all seasons, presuming the minimum ambient
temperature 5ºC lower than a minimum ambient
temperature in the working area.

If the mixture ratio is less than 33%, it reduces anti-

rust and anti-corrosion to the engine.

Please note the antifreeze with a few mixture ratio

may cause to corrode the engine. It may work as a
corrosion accelerator.

- Too much antifreeze in the coolant mixture may

cause engine overheating.

Keep 33% antifreeze mixture (same as the mixture

for a minimum ambient temperature of -15 ºC) if the
engine overheats in a high ambient temperature.

- When adding coolant, do not add water only.

Add the antifreeze with the same mixture ratio as

filled first.

- Do not use hard water or water with high levels of

calcium and magnesium ions as the coolant water.
 115ZV EX 00-11
00 General Information
Outline

Lubrication chart

DIFF & GEAR HYD. OIL DIFF & GEAR

BOX TANK BOX

GO HO GO EVERY 2000Hr
DIFF TRANSMISSION DIFF
G TO G EVERY 1000Hr
PILLOW UNIT ENGINE OIL PAN
GO G GO EO EVERY 250Hr
CENTER PIN (UPPER) AXLE SUPPORT
G G EVERY 50Hr
BUCKET LINK SYSTEM
G G TO HO EO EVERY DAY

G G
G CENTER PIN STEERING CYL.
(LOWER)
PARKING G G
BRAKE
PROPELLER PROPELLER
SHAFT SHAFT

115ZVE00002

G HO
Grease point Multipurpose grease Hydraulic oil

GO TO
Check and add if necessary Gear oil Engine oil

EO
Oil replacement Engine oil
115ZV EX 00-12
00 General Information
Outline

Weight of main components

Item Approx. Approx.

weight weight Remarks
Unit name Part name (kg) (lb)
Bucket 4,985 10,990 RVT bucket
Boom 3,210 7,080 Standard
“Z” -Lever 435/pc 960/pc
Link (Bucket to Lever) 90/pc 200/pc
Screen board 200 445
Roof 65 143
Engine room
Radiator guard 250 555
Hydraulic tank 360 795 Excluding oil
Chassis Fuel tank 330 730 Excluding fuel
Floor board 160 355
Right side 80 180 With handrail
Deck
Left side 105 230 With handrail
Front chassis 3,700 8,160
Rear chassis 4,000 8,820
Counter weight 1,530 3,375
Cab 270 595
ROPS 840 1,855
Engine 1,900 4,190 Excluding water and oil
Radiator 730 1,610 Excluding water and oil
Torque converter 350 775 Excluding oil
Transmission 1,100 2,425 Excluding oil
First propeller shaft 14 35
Power line Second propeller shaft 180 400
Third propeller shaft 27 60
Front axle assembly 2,780 6,130 Excluding tires and oil
Rear axle assembly 2,940 6,485 Excluding tires and oil (Including axle support)
Front 565 1,245
Differential
Rear 560 1,235
Multiple control valve 95 210
Pilot valve 9.5 21
Steering valve 50 110
40 90 Main & pilot
Hydraulic system Gear pump
40 90 Switch
Boom cylinder 510/pc 1,125/pc Excluding oil
Bucket cylinder 245/pc 540/pc Excluding oil
Steering cylinder 80/pc 180/pc Excluding oil
Tire 1,530/pc 3,375/pc With rim (35/65-33-24PR); No Hydro Inflation
Other
Battery 60/pc 135/pc
 115ZV EX 00-13
00 General Information
Outline

Bolt tightening torque

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

(N-m)
Bolt size Bolt strength
Type Nominal Nominal
Pitch 8.8 (8T) 10.9 (11T)
dimension dia.
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.
115ZV EX 00-14
00 General Information
Outline

(kgf-m)
Bolt size Bolt strength
Type Nominal Nominal
Pitch 8.8 (8T) 10.9 (11T)
dimension dia.
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

Note: Tighten the bolts according to the above list, unless otherwise specified.
 115ZV EX 00-15
00 General Information
Outline

(lb-ft)
Bolt size Bolt strength
Type Nominal Nominal
Pitch 8.8 (8T) 10.9 (11T)
dimension dia.
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

Note: Tighten the bolts according to the above list, unless otherwise specified.
115ZV EX 00-16
00 General Information
Outline

Flanged hexagon bolt

1. Bolt type: Metric thread

2. Bolt strength: 8.8 (8T)

3. Thread pitch: Coarse pitch thread (C)

(N-m)
Bolt size Bolt strength
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)
Bolt size Bolt strength
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)
Bolt size Bolt strength
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
 115ZV EX 00-17
00 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
115ZV EX 00-18
00 General Information
Outline

Liquid gasket and screw lock Cautions regarding reassembly

agent To reassemble a screw

Completely remove the hardened lock agent from the

To reassemble the disassembled parts, be sure to use
screw and the threaded hole before reassembling the
the specified liquid gasket or screw lock agent or the
screw.
equivalent according to the following lists:

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 cleans
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 to 250°C) using a soldering iron
or gas torch.

Caution

If there is a seal near the screw or shaft to be removed,

carefully use the heating method for removal, to avoid
damage to the seal.

If heat has been used to remove the bolt a new bolt

should be used during reassembly.
 115ZV EX 00-19
00 General Information
Outline

Screw lock agent application procedure How to wind a seal tape

Through-hole

Apply screw lock agent one or two lines on the male

threads.

Seal tape

Screw lock agent

Leave 1~2 screw

65ZV00004a

As the screw is tightened by turning clockwise, seal

65ZV00002 tape must be wound up clockwise direction as shown
above. If not, the tape will be loosened or removed while
tightening the screw, resulting in oil leakage.
Blind hole
To avoid a piece of seal tape left in the circuit, leave 1 or
Apply screw lock agent all-round on the female threads 2 screws from the end of the thread and start threading
at 1/3 of the female thread length from the bottom. it clockwise.

Slightly stretch the tape when cutting it out, and press to

fit the tape onto the screw thread.

H
About 1/3H

65ZV00003
115ZV EX 00-20
00 General Information
Outline

Cautions regarding welding repair service

If welding is needed to repair the chassis, observe the
following precautions to protect the hydraulic cylinders,
hydraulic units, gear sets, and electrical units from pos-
sible damage.

Cautions

1. Turn the starter switch OFF. 5. To ground the welder, check that the electric current
will not flow through the cylinders.
2. Remove the battery terminals both positive and Cylinder head covers for some models have a low
negative sides from the battery. conductive metal that will cause spark if the welding
current flows through it. The spark may damage
3. Disconnect the connectors for SCU (transmission the cylinder rod or other parts.
controller), ECM (engine controller), air conditioner
and tachometer converter as per Cummins Engine 6. Calibrate throttle pedal to ECM.
Co.
(a) Turn the starter switch to "ON".
4. Ground the welder near the section to be welded. (b) Fully depress and release the throttle pedal
three times.
(c) Turn the starter switch to "OFF".

Example 1

Section to be welded

Do not ground this section.

Electric current may flow
through the cylinders.
Ground this section.
(correct grounding)

35C00002

Example 2

Do not ground this section.

Electric current may flow Section to be welded Ground this section.
through the cylinders. (correct grounding)

35C00006
 115ZV EX 00-21
00 General Information
Outline

7. The weld spattered on the hydraulic cylinders and

on the plated sections of pins will damage the cylin-
ders and pins. There are other parts that may be
damaged by the spatter; hydraulic units, har-
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

35C00005

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.
115ZV EX 00-22
00 General Information

MEMO
 115ZV EX 03-1
03 Measurement for Performance Check

03 Measurement for Performance Check

Cautions on Safety ................................................................03-2

Standard Measurement Values for Performance Check .......03-3
115ZV EX 03-2
03 Measurement for Performance Check
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 side cover.
- Apply the parking brake.
- Block the tires with chocks to prevent the tires from
moving.
- Determine the signals between the service man.
- Prohibit any person from walking into dangerous
areas.
- Near articulation areas of the machine
- Under the machine
- Around the engine
- In front of or behind the machine

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

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

WARNING
Entering the articulation area of the machine body
while the engine is running may cause severe 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.
 115ZV EX 03-3
03 Measurement for Performance Check
Standard Measurement Values for Performance Check

Standard Measurement Values for Performance Check

For Asia and Africa (S/N 0101~)

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

Item Standard measurement val-

ues for performance check Remarks
System Measurement item
Normal Power
Minimum no-load speed, Low Idle (LI) 775 ± 50
Maximum no-load speed, High Idle (HI) 2,350 ± 50
Maximum speed in torque converter stall mode 2,130 ± 100
Engine

Engine speed
(min-1) (rpm) Maximum speed in multiple control valve relief mode 2,140 ± 100

Maximum speed in torque converter stall plus multiple

1,520 +150
- 100 1,650 +150
- 100
control valve relief mode

1st speed 2.2~2.3 (22~23) (313~327)

Low idle
Clutch pressure Except 1st speed 2.5~2.6 (25~26) (356~370)
Transmission

Engine speed
MPa (kgf/cm2) (psi) 1st speed 2.5~2.6 (25~26) (356~370)
High idle
Except 1st speed 2.6~2.9 (27~30) (384~427)

Clutch time lag NeutralForward 1st speed

0.3 ± 0.1 Before wheels move
(sec) (engine speed: 1,500 min-1 (rpm))

Cylinder drift Boom cylinder 3 (1/8) or less

(when boom and
bucket are horizontal
and with no load)
(mm/min) (in/min) Bucket cylinder 4 (5/32) or less
Hydraulic line

Idling (LI) 23 ± 3.0

Boom rising time
-1
(no load) Engine speed 1,500 min (rpm) 10.5 ± 1.0
(sec)
Maximum (HI) 8.4± 0.5
Idling (LI) 5.0 ± 0.5
Full steering time -1
Engine speed 1,500 min (rpm) 3.9 ± 0.3
(sec)
Maximum (HI) 3.9 ± 0.3
115ZV EX 03-4
03 Measurement for Performance Check
Standard Measurement Values for Performance Check

20.6 ± 0.5 (210 ± 5)

Loading line main relief pressure (HI)
(2,986 ± 71)
Run engine at lowest
23.5 ± 0.5 (240 ± 5)
Loading line overload relief pressure (LI) possible speed while
(3,413 ± 71)
setting
20.6 ± 0.5 (210 ± 5)
Steering line main relief pressure (HI)
(2,986 ± 71)
Relief valve setting Run engine at lowest
24.5 +1.0 +10
0 (250 0 )
pressure Steering line overload relief pressure (LI) possible speed while
(3,555 +1420 )
MPa (kgf/cm2) (psi) setting
Hydraulic line

Low press.: 9.5 (97) (1,380)

S/N 0101~0120 High press.: 19.0 (194)
Fan motor line relief pressure (HI) (2,760)
(Reference values) Low press.: 9.5 (97) (1,380)
S/N 0121~ High press.: 18.1 (185)
(2,625)
Pilot line reducing pressure (LI) 3.5 (36) (512)
Engine water temp. < 94ºC (200ºF) 1,120 Low press. 9.5 MPa
S/N 0101~0120 High press. 19.0
Fan maximum revo- Engine water temp. > 94ºC (200ºF) 1,600
MPa
lution
min-1 (rpm) Engine water temp. < 80ºC (176ºF) 1,120 Low press. 9.5 MPa
S/N 0121~ High press. 18.1
Engine water temp. > 93ºC (200ºF) 1,600
MPa

Shift lever position 2nd speed reverse Slowly increase the engine
Performance of ser- speed, and check that the
vice brake machine does not move at
Engine speed Maximum (HI) the maximum engine speed.

Shift lever position 3rd speed reverse Before brake check,

be sure to discon-
Performance of park-
 nect the cable con-
ing brake
nector of parking
Engine speed Maximum (HI) brake solenoid valve.

11.8 ± 0.5 (120 ± 5)

Off (Cut-out)
Unloader valve (1,706 ± 71)
setting pressure
(LI) 6.9 ± 1.0 (70 ± 10)
On (Cut-in)
(995 ± 142)
Brake

Brake line setting

Low-pressure alarm switch setting pressure 3.9 ± 0.3 (40 ± 3)
pressure
(For brake accumulator circuit) (569 ± 43)
MPa (kgf/cm2) (psi)

Brake line reducing pressure 12.3 (125) (1,778)

Auto brake reducing pressure 3.5 (36) (512)

The time from the low-pressure

Accumulator charge
Engine speed (LI) alarm is turned off till the unloading 16
time (sec)
valve cuts off pressure
Repeat stepping on
Run engine 1 minute high idle, then stop the engine.
the brake pedal as
Number of brake (Turn key switch “ON” with engine off.)
at least 11 times follows:
pedal applications Step on the brake pedal and release, and check the num-
On: 5 seconds
ber of times until the low-pressure alarm is turned on.
Off: 5 seconds
1/5 slope
Declutch engagement Engine: Maximum speed/ Inching pedal: Quick release
15 (6) or less (approx. 11º),
(cm) (in) (Distance the loader rolls back before moving forward.)
unladen, 1st speed
 115ZV EX 03-5
03 Measurement for Performance Check
Standard Measurement Values for Performance Check

For Europe (S/N 9001~)

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

Item Standard measurement val-

ues for performance check Remarks
System Measurement item
Normal Power
Minimum no-load speed, Low Idle (LI) 775 ± 50
Maximum no-load speed, High Idle (HI) 2,250 ± 50
Maximum speed in torque converter stall mode 2,130 ± 100
Engine

Engine speed
(min-1) (rpm) Maximum speed in multiple control valve relief mode 2,140 ± 100

Maximum speed in torque converter stall plus multiple

1,520 +150
- 100 1,650 +150
- 100
control valve relief mode

1st speed 2.2~2.3 (22~23) (313~327)

Low idle
Clutch pressure Except 1st speed 2.5~2.6 (25~26) (356~370)
Transmission

Engine speed
MPa (kgf/cm2) (psi) 1st speed 2.5~2.6 (25~26) (356~370)
High idle
Except 1st speed 2.6~2.9 (27~30) (384~427)

Clutch time lag NeutralForward 1st speed

0.3 ± 0.1 Before wheels move
(sec) (engine speed: 1,500 min-1 (rpm))

Cylinder drift Boom cylinder 3 (1/8) or less

(when boom and
bucket are horizontal
and with no load)
(mm/min) (in/min) Bucket cylinder 4 (5/32) or less
Hydraulic line

Idling (LI) 23 ± 3.0

Boom rising time
-1
(no load) Engine speed 1,500 min (rpm) 10.5 ± 1.0
(sec)
Maximum (HI) 8.4± 0.5
Idling (LI) 5.0 ± 0.5
Full steering time -1
Engine speed 1,500 min (rpm) 3.9 ± 0.3
(sec)
Maximum (HI) 3.9 ± 0.3
115ZV EX 03-6
03 Measurement for Performance Check
Standard Measurement Values for Performance Check

20.6 ± 0.5 (210 ± 5)

Loading line main relief pressure (HI)
(2,986 ± 71)
Run engine at lowest
23.5 ± 0.5 (240 ± 5)
Loading line overload relief pressure (LI) possible speed while
(3,413 ± 71)
setting
20.6 ± 0.5 (210 ± 5)
Steering line main relief pressure (HI)
(2,986 ± 71)
Relief valve setting Run engine at lowest
24.5 +1.0 +10
0 (250 0 )
pressure Steering line overload relief pressure (LI) possible speed while
(3,555 +1420 )
MPa (kgf/cm2) (psi) setting
Hydraulic line

Low press.: 9.5 (97) (1,380)

S/N 9001~9010 High press.: 19.0 (194)
Fan motor line relief pressure (HI) (2,760)
(Reference values) Low press.: 9.5 (97) (1,380)
S/N 9011~ High press.: 18.1 (185)
(2,625)
Pilot line reducing pressure (LI) 3.5 (36) (512)
Engine water temp. < 94ºC (200ºF) 1,120 Low press. 9.5 MPa
S/N 9001~9010 High press. 19.0
Fan maximum revo- Engine water temp. > 94ºC (200ºF) 1,600
MPa
lution
min-1 (rpm) Engine water temp. < 80ºC (176ºF) 1,120 Low press. 9.5 MPa
S/N 9011~ High press. 18.1
Engine water temp. > 93ºC (200ºF) 1,600
MPa

Shift lever position 2nd speed reverse Slowly increase the engine
Performance of ser- speed, and check that the
vice brake machine does not move at
Engine speed Maximum (HI) the maximum engine speed.

Shift lever position 3rd speed reverse Before brake check,

be sure to discon-
Performance of park-
 nect the cable con-
ing brake
nector of parking
Engine speed Maximum (HI) brake solenoid valve.

11.8 ± 0.5 (120 ± 5)

Off (Cut-out)
Unloader valve (1,706 ± 71)
setting pressure
(LI) 6.9 ± 1.0 (70 ± 10)
On (Cut-in)
(995 ± 142)
Brake

Brake line setting

Low-pressure alarm switch setting pressure 3.9 ± 0.3 (40 ± 3)
pressure
(For brake accumulator circuit) (569 ± 43)
MPa (kgf/cm2) (psi)

Brake line reducing pressure 12.3 (125) (1,778)

Auto brake reducing pressure 3.5 (36) (512)

The time from the low-pressure

Accumulator charge
Engine speed (LI) alarm is turned off till the unloading 16
time (sec)
valve cuts off pressure
Repeat stepping on
Run engine 1 minute high idle, then stop the engine.
the brake pedal as
Number of brake (Turn key switch “ON” with engine off.)
at least 11 times follows:
pedal applications Step on the brake pedal and release, and check the num-
On: 5 seconds
ber of times until the low-pressure alarm is turned on.
Off: 5 seconds
1/5 slope
Declutch engagement Engine: Maximum speed/ Inching pedal: Quick release
15 (6) or less (approx. 11º),
(cm) (in) (Distance the loader rolls back before moving forward.)
unladen, 1st speed
 115ZV EX 12-1
12 Function & Structure Chassis Group

12 Function & Structure

Chassis Group

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

Rear Chassis.........................................................................12-5
Center Pin .............................................................................12-8
115ZV EX 12-2
12 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)
 115ZV EX 12-3
12 Function & Structure Chassis Group
Front Chassis

Even contact both sides

5,040 mm
(16.5 ft)
43º 50º

300 mm (Hinge pin height at

11.8 (in) bucket on ground)
Typical bucket dump stopper clearance
(Contact attachment supplier for details on non-standard
attachments)
Typical bucket roll-back stopper adjustment To increase clearance increase height of lever stopper surface (9).
(Contact attachment supplier for details on non- To reduce clearance decrease height of lever stopper surface (9).
standard attachments)
K115ZV12001
115ZV EX 12-4
12 Function & Structure Chassis Group
Front Chassis

Loading linkage pin

mm (in)
1. Bucket - Boom 2. Boom - Lever 3. Boom - Boom cylinder

4. Front chassis - Boom 5. Bucket - Rod 6. Lever - Rod

7. Lever - Bucket cylinder 8. Bucket cylinder - 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
 115ZV EX 12-5
12 Function & Structure Chassis Group
Rear Chassis

Rear Chassis

Fuel tank
(S/N 0101~0211, 9001~)
B 2

10

(S/N 0101~0125)
4 (S/N 9001~9020)

: 3
Torque when installing fuel level
sensor (2): (S/N 0126~) 9
14.7 N-m (1.5 kgf-m) (10.8 lb-ft) 2 4 (S/N 9021~)

10
1

3/4

1/2

6
1/4
A 8
1/8

A
E

8
5

1. Fuel tank
7
2. Fuel level sensor
3. Fuel tank filler assembly
4. Filter
5. Drain cock
6. Inspection hole cover
7. Gasket (Rubber seal type) A-A
8. Suction pipe
9. Pipe (for vacuum prevention)
B-B (FM)
10. Fuel return pipe K115ZVE12001
115ZV EX 12-6
12 Function & Structure Chassis Group
Rear Chassis

(S/N 0212~)

2
9

: 3
Torque when installing fuel level
sensor (2):
2 4
14.7 N-m (1.5 kgf-m) (10.8 lb-ft)

9
1

3/4

1/2

6
1/4
A 8
1/8
A
E

8
5

1. Fuel tank 7
2. Fuel level sensor
3. Fuel tank filler assembly
4. Filter
5. Magnet plug (S/N 0251~)
6. Inspection hole cover
7. Gasket (Rubber seal type) A-A
8. Suction pipe
9. Fuel return pipe
115ZVE12001
 115ZV EX 12-7
12 Function & Structure Chassis Group
Rear Chassis

Floor board mount Viscous mount

Floor board

1 2
1
2

115ZV12008
5

1. Floor board
2. Viscous mount
6

7
The floor board is installed on the rear chassis by the 8 9
rubber cushion. The instrument panel, control box,
operator’s seat and the air conditioner unit are on the
floor board.
70ZV12007

1. Stud
2. Cushion rubber
3. Case
4. Cap
5. Damping plate
6. Plain washer
7. Head bolt
8. Silicon oil
9. Plug
Inspection hole
(S/N 0108~, The floor board is supported by a viscous mount in four
9004~)
K115ZVE12002
positions so that vibrations, impacts and sounds gener-
ated in the chassis are not transmitted to the inside of
cabin.
Note
The access hole for floor servicing is provided on S/N
9004~ (Europe) and S/N 0108~ (other area).
115ZV EX 12-8
12 Function & Structure Chassis Group
Center Pin

Center Pin

Upper center pin Lower center pin

1
4 9, 10 3
1 6
7

5
Front 2
chassis 3
6
Front
7 chassis

5 4 Rear
11 Rear chassis chassis
Lower
2 8, 10
Upper 115ZV12011
115ZV12010

Upper Lower

1. Center pin 1. Center pin

2. Plate 2. Bearing retainer
3. Bearing cover 3. Bearing assembly
4. Washer 4. Dust seal
5. Shim 5. Bushing
6. Bearing assembly 6. Bolt
7. Dust seal 7. Plate
8. Bolt
9. Bolt
10. Washer
11. Bushing
 115ZV EX 12-9
12 Function & Structure Chassis Group
Center Pin

Dust seal

Center
pin

Dust seal position

90ZV12007

When installing the dust seal, check that the lip faces
toward the outside. If the lip faces toward the outside,
the dust will not be drawn through the seal.
115ZV EX 12-10
12 Function & Structure Chassis Group

MEMO
 115ZV EX 13-1
13 Check & Adjustment Chassis Group

13 Check & Adjustment

Chassis Group

Linkage Pin ...........................................................................13-2

Center Pin .............................................................................13-6
115ZV EX 13-2
13 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 hang a "DO NOT toed shoes.
OPERATE!" tag on the steering wheel.
- Block the tires with chocks to prevent the tires from
moving.

Liner

5 6

2 8

1 3 7

115ZV12005

Adjustment
1 2 3 4 5 6 7 8
portion
Liner hole dia. 110 91 91 121 101 121 Adjustment 71
mm (in) (4.33) (3.58) (3.58) (4.76) (3.98) (4.76) unnecessary (2.80)
 115ZV EX 13-3
13 Check & Adjustment Chassis Group
Linkage Pin

Adjustment

* *

95ZV12005

Adjust the clearance (*) to 1.0 mm (0.04 in) or less for

#1 (split type) and #2 (Refer to the following pages).
Adjust the clearance (*) to 1.2 mm (0.05 in) or less for
#3 ~ #7 between the bosses using liners.

For the steering cylinder, be sure to adjust the clearance

on the rear chassis side first and then on the front chas-
sis side while checking that the cylinder is not inclined.
115ZV EX 13-4
13 Check & Adjustment Chassis Group
Linkage Pin

Bucket hinge pin section (#1)

Bucket
Boom
Bushing A Bushing B

Hinge pin

Dust seal Bolt

Seal retainer assy

Shim Shim
(as required)

K115ZV13001

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 ring assy so that the clearance between the
R142

boom boss and the seal ring (* marked) is less than

1 mm.
5

Tighten the bolt for the seal retainer assy.

R5

Shim : 765 N-m (78 kgf-m) (564 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.)
 115ZV EX 13-5
13 Check & Adjustment Chassis Group
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 1
mm.

Shim thickness

1.0, 0.5 mm (0.039, 0.020 in)

(2 kinds of shim thickness)

Shim 115V2E13003 3. Align the pin holes in the bucket and the link. Then
insert the pin.
115ZV EX 13-6
13 Check & Adjustment Chassis Group
Center Pin

Center Pin

Adjusting shim Installing bearing cover

1
4 9, 10 3
Grease nipple

Front
5
Front Grease pipe
chassis
6

7
[Upper] [Lower]

115ZV13002

11 Rear Install the grease nipples for both the upper and lower
2 8, 10 chassis
center pins as shown in the figure.
Upper 115ZV12010

The clearance between the front chassis and bearing

cover (3) is 0.75 ± 0.5 mm (0.03 ± 0.02 in) before shim Installing bearing outer ring
adjustment.

Add shims (5) so that the clearance is 0.1 ± 0.05 mm

(0.004 ± 0.002 in). Tighten bolt (9).

: Bolt (8): 662 N-m (67.5 kgf-m) (488 lb-ft)

(with lubricating oil)
: Bolt (9): 441 N-m (45.0 kgf-m) (326 lb-ft) Front Rear

3
Center line
Split of outer
bearing

95ZV13003

Install bearing outer ring (3) so that the split is perpen-

dicular to the front–rear line of the machine.
 115ZV EX 22-1
22 Function & Structure Power Group

22 Function & Structure

Power Group

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

Engine / Transmission...........................................................22-3
Radiator.................................................................................22-4
Propeller Shaft.......................................................................22-6
Axle Assembly.....................................................................22-11
Axle Support........................................................................22-14
Differential Gear ..................................................................22-20
115ZV EX 22-2
22 Function & Structure Power Group
Power Line

Power Line

3 5 17 2 12 1 15 13 4

11

8 6 10 7 9 16 14

115ZV22001

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, air charge cooler, fuel cooler and an external
15. Air charge cooler air type hydraulic oil cooler. The parking brake is
16. Fuel cooler installed on the second propeller shaft.
17. Precleaner
 115ZV EX 22-3
22 Function & Structure Power Group
Engine / Transmission

Engine / Transmission

Engine / transmission mount

D&E

C B

Engine

1
1
2
1

3 T/C case

E/G flywheel 4
housing

A-Detail B-Detail C-Detail D-Detail E-Detail

115ZV22002

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.
115ZV EX 22-4
22 Function & Structure Power Group
Radiator

Radiator

Thermo-sensing valve
(S/N 0121~, 9011~)
Charge air
cooler OUT Coolant IN
Charge air 4
Hydraulic oil
cooler IN
cooler IN

B
3
B

A
D D C
A
C
2
5

Coolant OUT

Hydraulic oil T/C oil T/C oil

cooler OUT cooler OUT cooler IN
Fuel cooler Fuel cooler
OUT IN

(S/N 0121~, 9011~)

K115ZV22001

1. Radiator assembly 5. Hydraulic oil cooler The torque converter oil cooler is in the radiator lower
2. Radiator duct 6. T/C oil cooler tank.
3. Stay (Bracket) 7. Fuel cooler
4. Charge air cooler When the coolant is hot, the thermostat opens and the
coolant flows to the radiator.
The radiator incorporates the engine coolant, cooling
fin, air charged cooler, and an external air type hydraulic When the coolant is cold enough, the thermostat is
oil cooler. For the engine coolant, air charge cooler, fuel completely closed and no coolant flows to the radiator.
cooler and hydraulic oil, the air-cooling system is used.
For the torque converter oil, the water cooling system is The fuel cooler and air charge cooler are required to
used. meet engine emission regulations.
 115ZV EX 22-5
22 Function & Structure Power Group
Radiator

Radiator mount

A-Detail B-Detail C-Detail

D-Detail
K115ZVE22004

1. Strip seal

Capacity in radiator:
Cooling water 64.6 L (17 gal)
Hydraulic oil 15 L (4 gal)
Torque converter oil 3.9 L (1 gal)
Fuel 2.1 L (0.6 gal)

Dry weight 730 kg (1,610 lbs)

115ZV EX 22-6
22 Function & Structure Power Group
Propeller Shaft

Propeller Shaft
5 2 1

6 3 115ZV22004

1. 1st propeller shaft The engine power is transmitted to the torque converter,
2. 2nd propeller shaft the first propeller shaft, the transmission and is then
3. 3rd propeller shaft (fixed type) transmitted to the second and the third propeller shafts,
4. Pillow block and finally to the front and the rear axles.
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 second propeller

shaft.

The third propeller shaft is the fixed type with universal

joints.
 115ZV EX 22-7
22 Function & Structure Power Group
Propeller Shaft

First propeller shaft assembly

Transmission - Engine (Torque converter)

Grease nipple installation angle

1 2 1

45

View Z
1

Torque converter

2
1

Every 2000-hour greasing

Transmission K115ZV22002

1. Journal spider assy

2. Propeller shaft
115ZV EX 22-8
22 Function & Structure Power Group
Propeller Shaft

Second propeller shaft assembly

Parking brake - Transmission

Grease nipple installation angle 1 2 1

45

View Z

Every 2000-hour greasing

1

Parking brake

Transmission

Every 2000-hour greasing

Every 2000-hour 1
greasing
K115ZV22003

1. Journal spider assy

2. Propeller shaft
 115ZV EX 22-9
22 Function & Structure Power Group
Propeller Shaft

Front differential - Parking brake

1
2
Grease nipple installation angle

45

View Z

Parking brake

Every 2000-hour greasing

Front differential

K115ZV22004

1. Journal spider assy

2. Propeller shaft
115ZV EX 22-10
22 Function & Structure Power Group
Propeller Shaft

Third propeller shaft assembly

Transmission - Rear differential

Grease nipple installation angle

1 2 1

45

View Z

Rear differential

Every 2000-hour greasing

Transmission

115ZV22007

1. Journal spider assy

2. Propeller shaft
 115ZV EX 22-11
22 Function & Structure Power Group
Axle Assembly

Axle Assembly
Front axle group

1
R.H
50

22 40 (S/N 9007~) (S/N 0110~)

40 (S/N 9001~9006)
3 (S/N 0101~0144) (S/N 0101~0109)
(S/N 0145~)
44
42
45
36 43
37 28
35
45
11 2
52
49
23 26
31
16 34 6
48 12
46
47 (S/N 0143~) 30 10
29 21
14 (S/N 9021~)
24
41 25 9 18
17 19 25
18 14 (S/N 0101~0142)
17 (S/N 9001
~9020)
18 15
8 13
20
38
32
5

39 4
37
7
27 51

33
L.H
(FM)
K115ZVE22001

1. Differential assembly 14. Wear ring 26. Axle lock plate 40. Air bleeder screw
2. Axle housing 15. Wear ring 27. Snap ring 41. Spring pin
assembly 16. Brake piston 28. Floating seal 42. Ring
3. Wheel hub 17. Separation disc 29. D-ring 43. O-ring
4. Spider 18. Friction disc 30. D-ring 44. Spring pin
5. Cover 19. Brake backing plate 31. O-ring 45. Plug
6. Axle shaft 20. Plate 32. O-ring 46. Spring
7. Sun gear 21. Axle nut 33. O-ring 47. Sleeve
8. Disc gear 22. Taper roller bearing 34. Socket bolt 48. Bushing
9. Planetary gear (inner) 35. Spring 49. Socket bolt
10. Internal gear 23. Taper roller bearing 36. U-nut 50. Bolt
11. Internal gear hub (outer) 37. Magnet plug 51. Bolt
12. Snap ring 24. Separation disc 38. Bolt 52. Flange bolt
13. Planetary pin 25. Needle cage 39. Socket bolt
115ZV EX 22-12
22 Function & Structure Power Group
Axle Assembly

Rear axle group

1 (S/N 9001~9020)
(S/N 0101~0140)
61

R.H
2

45

(S/N 0110~)
40 (S/N 9007~)
50 40 (S/N 9001~9006)
(S/N 0101~0109)
60 44
42
22 43 28
37
3
(S/N
0101~0144)
(S/N 0145~) 1 (S/N 9021~)
(S/N 0141~)
36
35
45
6
11
52
34
23 26
49 31 16
48 12
46
47
30 10
29 21

24
18
(S/N 0143~)
41 14 (S/N 9021~)
17 19
18 25 9
32
25 14 (S/N 0101~0142)
17 (S/N 9001~9020)
18 15
8 13
20
38
5

4
39
37 7
27 51

33

L.H

(FM)
K115ZVE22002
 115ZV EX 22-13
22 Function & Structure Power Group
Axle Assembly

1. Differential assembly 22. Taper roller bearing (inner) 43. O-ring

2. Axle housing assembly 23. Taper roller bearing (outer) 44. Spring pin
3. Wheel hub 24. Separation disc 45. Plug
4. Spider 25. Needle cage 46. Spring
5. Cover 26. Axle lock plate 47. Sleeve
6. Axle shaft 27. Snap ring 48. Bushing
7. Sun gear 28. Floating seal 49. Socket bolt
8. Disc gear 29. D-ring 50. Bolt
9. Planetary gear 30. D-ring 51. Bolt
10. Internal gear 31. O-ring 52. Flange bolt
11. Internal gear hub 32. O-ring 53. -
12. Snap ring 33. O-ring 54. -
13. Planetary pin 34. Socket bolt 55. -
14. Wear ring 35. Spring 56. -
15. Wear ring 36. U-nut 57. -
16. Brake piston 37. Magnet plug 58. -
17. Separation disc 38. Bolt 59. -
18. Friction disc 39. Socket bolt 60. Front axle support
19. Brake backing plate 40. Air bleeder screw 61. Rear axle support
20. Plate 41. Spring pin
21. Axle nut 42. Ring
115ZV EX 22-14
22 Function & Structure Power Group
Axle Support

Axle Support
Axle support assy (S/N 0101~0107, 9001~9003)

Grease pipe connection

port (PT 1/8)

A
9
(Rear support)

Pin
Grease pipe (Axle housing)
connection port
(PT 1/8) 9

Front
Axle housing
5
16
9 4

15

6
(Front support)
2
10
A-A 1 16
A 3
11

7 14 7 13 8 11

12 10

#10 Details #11 Details

(Front support) (Rear support)
115ZV22008J

1. Shaft 11. Bushing

2. Rear axle support (front) 12. Snap ring
3. Rear axle support (rear) 13. Snap ring
4. Wear ring 14. O-ring
5. Plate 15. Bolt
6. Plate 16. Bolt
7. Lip seal
8. Lip seal
9. Breather
10. Bushing
 115ZV EX 22-15
22 Function & Structure Power Group
Axle Support

Axle support group (S/N 0101~0107,

9001~9003)

7
Grease piping
14

15

2 4
Grease piping

10 11 6
17
3
14
16
7
16
FRONT 12

1 8

13

115ZV22009J

1. Shaft 11. Bushing

2. Rear axle support (front) 12. Snap ring
3. Rear axle support (rear) 13. Snap ring
4. Wear ring 14. O-ring
5. Plate 15. Bolt
6. Plate 16. Bolt
7. Lip seal 17. Dowel pin
8. Lip seal
9. Breather
10. Bushing
115ZV EX 22-16
22 Function & Structure Power Group
Axle Support

Axle support assy (S/N 0108~0140, 9004~9020)

Grease pipe connection

port (PT 1/8)

(Rear support) A
9

Grease pipe
connection port Pin
(PT 1/8) (Axle housing)
9

Front Axle housing

5
18

9 4
17

6
(Front support)
2
10
1 18
A A 3

7 14 7 13 8 11
16
12

15
12
10
#10 Details #11 Details
(Front support) (Rear support)

115ZV22020

1. Shaft 11. Bushing

2. Rear axle support (front) 12. Ring
3. Rear axle support (rear) 13. Snap ring
4. Wear ring 14. O-ring
5. Plate 15. Plate
6. Plate 16. Bolt
7. Lip seal 17. Bolt
8. Lip seal 18. Bolt
9. Breather
10. Bushing
 115ZV EX 22-17
22 Function & Structure Power Group
Axle Support

Axle support group (S/N 0108~0140,

9004~9020)

10
16
14

12
FRONT

15

Grease piping

9
9
6
17
12
4
7
5
14
Grease piping 4

2 19 11

18

18

8 3
13

1 115ZV22025

1. Shaft 11. Bushing

2. Rear axle support (front) 12. Ring
3. Rear axle support (rear) 13. Snap ring
4. Wear ring 14. O-ring
5. Plate 15. Plate
6. Plate 16. Bolt
7. Lip seal 17. Bolt
8. Lip seal 18. Bolt
9. Breather 19. Dowel pin
10. Bushing
115ZV EX 22-18
22 Function & Structure Power Group
Axle Support

Axle support assy (S/N 0141~, 9021~)

Grease pipe connection

port (PT 1/8)

(Rear support) A
9

Grease pipe Pin

connection port (Axle housing)
(PT 1/8) 9

Axle housing
Front 5
16

9 4
15

(Front support) 2
10
A 1 16 11
A-A 3

7 13 8 1

Groove at the
bushing end

12

14 10
#10 Details #11 Details
(Front support) (Rear support)

115V2U22001

1. Shaft 11. Bushing

2. Rear axle support (front) 12. Plate
3. Rear axle support (rear) 13. Snap ring
4. Wear ring 14. Bolt
5. Plate 15. Bolt
6. Plate 16. Bolt
7. Lip seal
8. Lip seal
9. Breather fitting
10. Bushing
 115ZV EX 22-19
22 Function & Structure Power Group
Axle Support

Axle support group (S/N 0141~, 9021~)

Grease piping
7
9

10

7 9

12 6

4
2
5

Grease piping 11
15

17
FRONT

14 16
16

3
8
13
1

K115ZV22009

1. Shaft 11. Bushing

2. Rear axle support (front) 12. Plate
3. Rear axle support (rear) 13. Snap ring
4. Wear ring 14. Bolt
5. Plate 15. Bolt
6. Plate 16. Bolt
7. Lip seal 17. Dowel pin
8. Lip seal
9. Breather fitting
10. Bushing
115ZV EX 22-20
22 Function & Structure Power Group
Differential Gear

Differential Gear
Front differential

2 1 22
A
3
28 3, 31
Fill with
grease
26
when
Grease 3 assembling.
23
nipple
5
8
6 24
21
9

3
A Details
20 (S/N 0101~0146,
9001~9020)

27

25 10
11 Fill with
grease
Grease 3 when
12 assembling.
nipple

30
18

31
19
7 A Details
14 29 (S/N 0147~,
13 4 17 16 15 9021~)

K115ZV22010

1. Nut 12. Lock plate 23. O-ring

2. Flange yoke 13. Straight pin 24. Shim
3. Oil seal (single lip) 14. Bushing 25. O-ring
4. Bolt 15. Wear ring 26. Oil seal retainer
5. Case 16. Differential pinion 27. Snap ring
6. Taper roller bearing 17. Side gear 28. Bolt
7. Taper roller bearing 18. Spider 29. Bolt
8. Sleeve 19. Housing assy 30. Bolt
9. Drive pinion 20. Roller bearing 31. Oil seal (single lip)
0. Carrier 21. O-ring
1. Nut 22. O-ring
 115ZV EX 22-21
22 Function & Structure Power Group
Differential Gear

Rear differential (S/N 0101~0107, 9001~9003)

2 1
22
3
A Fill with grease
Grease nipple when assembling.
26
28
23
8
5
6 24
21
9 31

A Details

20

27

11 25 10

12

30 18

7 14 13
19

4 17 16 15 29

K115ZV22011

1. Nut 14. Bushing 27. Snap ring

2. Flange yoke 15. Wear ring 28. Bolt
3. Oil seal (single lip) 16. Differential pinion 29. Bolt
4. Bolt 17. Side gear 30. Bolt
5. Case 18. Spider 31. Oil seal (single lip)
6. Taper roller bearing 19. Housing assy
7. Taper roller bearing 20. Roller bearing
8. Sleeve 21. O-ring
9. Drive pinion 22. O-ring
10. Carrier 23. O-ring
11. Nut 24. Shim
12. Lock plate 25. O-ring
13. Straight pin 26. Oil seal retainer
115ZV EX 22-22
22 Function & Structure Power Group
Differential Gear

Rear differential (S/N 0108~0140, 9004~9020)

2 1
22
A

28 26
Fill with grease
Grease nipple when assembling.
23
8

5
6
24
21
9

A Details
20

27

11 25 10

12

30 18

7 14 19

13 4 17 16 15 29

K115ZV22012

1. Nut 14. Bushing 27. Snap ring

2. Flange yoke 15. Wear ring 28. Bolt
3. Oil seal (single lip) 16. Differential pinion 29. Bolt
4. Bolt 17. Side gear 30. Bolt
5. Case 18. Spider 31. Oil seal (single lip)
6. Taper roller bearing 19. Housing assy
7. Taper roller bearing 20. Roller bearing
8. Sleeve 21. O-ring
9. Drive pinion 22. O-ring
10. Carrier 23. O-ring
11. Nut 24. Shim
12. Lock plate 25. O-ring
13. Straight pin 26. Oil seal retainer
 115ZV EX 22-23
22 Function & Structure Power Group
Differential Gear

Rear differential (S/N 0141~, 9021~)

2 1

22 Grease nipple 3
Fill with grease
A when assembling.
28 26

23
8
5
6 31
24
21
A Details
9 (S/N 0147~)
(S/N 9021~)

20

27

25 10
11

12

18
30

19
7

14 13 4 17 16 15 29
K115ZVE22003

1. Nut 14. Bushing 27. Snap ring

2. Flange yoke 15. Wear ring 28. Bolt
3. Oil seal (single lip) 16. Differential pinion 29. Bolt
4. Bolt 17. Side gear 30. Bolt
5. Case 18. Spider 31. Oil seal (double lips)
6. Taper roller bearing 19. Housing assy
7. Taper roller bearing 20. Roller bearing
8. Sleeve 21. O-ring
9. Drive pinion 22. O-ring
10. Carrier 23. O-ring
11. Nut 24. Shim
12. Lock plate 25. O-ring
13. Straight pin 26. Trunnion
115ZV EX 22-24
22 Function & Structure Power Group
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, the pinion gears (4) in the differential assy do
2. The power is transmitted from the pinion gear (1) to not turn.
the axle shaft (2) through the bevel gear (5) and the
differential (4) in the axle housing. Torque from the carrier (6) is transmitted to each wheel
equally through the pinion gears (4), side gears (3) and
3. Finally the power is transmitted to the planetary axle shafts (2).
gears and tires to move the machine.
 115ZV EX 22-25
22 Function & Structure Power Group
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, the pinions (4) turn on the side gears (3) and
torque from the carrier (6) is transmitted to each wheel
through the pinion gears (4), side gears (3) and axle
shafts (2).
115ZV EX 22-26
22 Function & Structure Power Group

MEMO
 115ZV EX 23-1
23 Check & Adjustment Power Group

23 Check & Adjustment

Power Group

Engine ...................................................................................23-2
Propeller Shaft.......................................................................23-3
Axle .......................................................................................23-5
115ZV EX 23-2
23 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.
- Block the tires with chocks to prevent the tires from Measurement instrument install position
moving.
- Determine the signals between the service men. 1. Location (A)
- Prohibit any person from walking into dangerous
areas. 2. Measuring port: 9/16-18 UNF
- Near articulation area of the machine
- Under the machine 3. Oil pressure gauge: 1.0 MPa (10 kgf/cm2) (150 psi)
- Around the engine
- In front of or behind the machine
(A)

CAUTION
Do not touch the fan or V-belt of the engine or high-
temperature section if the engine is running.
An accident resulting in injury may occur.
Be sure to stop the engine before you open the side
cover of the engine room.
Keep all guards in place.
Avoid high temperature components even when the
engine is stopped.
115ZV23001J
Use a photo tachometer when checking engine revo-
lution.
QSK19-C Engine

Measuring engine speed

Measurement instrument

- Tachometer

Standard measurement value

For Asia and Africa For Europe

(S/N 0101~) (S/N 9001~)
Low idle (min-1) 775±50 775±50
-1
High idle (min ) 2,350±50 2,250±50
2
Low idle: 0.14 MPa (1.4 kgf/cm ) (20 psi)
High idle: 0.34~0.48 MPa (3.5~4.9 kgf/cm2) (50~70 psi)
[Engine coolant temperature 50 ºC (120 ºF)]
 115ZV EX 23-3
23 Check & Adjustment Power Group
Propeller Shaft

Propeller Shaft

Propeller shaft phase

Third propeller shaft

Second propeller shaft

Front differential Transmission Rear differential

95ZV22007

Adjust the yokes of the second and third propeller shafts

to the same direction (phase).

- The propeller shaft attaches to the transmission

shaft. The shaft from the front differential to the rear
differential is referred to as the propeller shaft. The
propeller shaft articulates as the machine turns.
When the propeller shaft is articulated due to
machine steering, differences in the yoke phases
(directions) will cause unbalance between the 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.
115ZV EX 23-4
23 Check & Adjustment Power Group
Propeller Shaft

Tightening torque

2nd propeller shaft

1st propeller shaft

T/M

Front diff. 1 Rear diff.

3 4
5 2

6 [2nd propeller shaft]

8
8

[3rd propeller shaft]

K115ZV23001

:
1. 221 N-m (22.5 kgf-m) (163 lb-ft) 1. Screw lock agent (Three Bond 1327)
2. 221 N-m (22.5 kgf-m) (163 lb-ft) 2. Screw lock agent (Three Bond 1327)
3. 142 N-m (14.5 kgf-m) (105 lb-ft) 3. Screw lock agent (Three Bond 1327)
4. 142 N-m (14.5 kgf-m) (105 lb-ft) 4. Screw lock agent (Three Bond 1327)
5. 721 N-m (73.5 kgf-m) (532 lb-ft) 5. With lubricating oil (Engine oil or gear oil)
6. 220 N-m (22.4 kgf-m) (162 lb-ft)
7. 220 N-m (22.4 kgf-m) (162 lb-ft)
8. 162 N-m (16.5 kgf-m) (119 lb-ft)
 115ZV EX 23-5
23 Check & Adjustment Power Group
Axle

Axle

Axle nut tightening procedure

11 5 13 9 10

Brake oil inlet

3
(PT3/8)

12

A 7 6 8 Details of A

K115ZV23002

1. Tighten axle nut (7) with 3,923 N-m (400 kgf-m) :

(2,894 lb-ft) tightening torque to install taper roller 1. 721 N-m (73.5 kgf-m) (532 lb-ft)
bearing (8)(9). 2. 90 N-m (9.2 kgf-m) (67 lb-ft)
3. 86.3 N-m (8.8 kgf-m) (64 lb-ft)
2. Loosen the axle nut. 4. 53 N-m (5.4 kgf-m) (39 lb-ft)
5. 50 N-m (5.1 kgf-m) (37 lb-ft)
3. Tighten the axle nut again with 3,923 N-m (400 kgf- 6. 33 N-m (3.4 kgf-m) (25 lb-ft)
m) (2,894 lb-ft) tightening torque.

4. Turn wheel hub (10) 2~3 turns back and forth, and 1, 2, 4: Screw lock agent (Three Bond 1327)
measure the preload applied to section A.

Preload measured at section A

353~392 N (36~40 kgf) (79~88 lbs) 

This is "breakaway" force. The force required to

start the wheel turning.

Note
Use jig to install the floating seal to the axle assembly.
115ZV EX 23-6
23 Check & Adjustment Power Group
Axle

Planetary gear oil drain and refill

1. Move the machine on level ground so that the

“TOP” mark on planetary gear housing (11) comes
to the top.

2. Turn ON the parking switch, lower the attachment

onto the ground, and stop the engine.

3. Remove level plug (12) and drain plug (13) from

planetary gear housing (11) using a 12 mm hex
(Allen) wrench.

4. Drain the oil into a suitable container.

5. Install and tighten drain plug (13).

6. Refill the recommended oil through level plug hole

(12) until the oil comes out from the hole.

7. Install and tighten level plug (12).

 115ZV EX 23-7
23 Check & Adjustment Power Group
Axle

Differential gear adjustment procedure

B
2
A 8
8 Grease nipple Apply grease.

3 8, 9

5
6
(S/N 0101~0146)
8 (S/N 9001~9020)
9 (S/N 9021~) (Double lips)
(S/N 0147~) (Double lips)
A-details
Differential
installation bolt

Bleeder

3 1
View B Grease nipple

(FM)
K115ZVE23001

:
1. 1,130 N-m (115 kgf-m) (832 lb-ft) 1, 3, 4: Screw lock agent (Three Bond 1327)
2. 1,030 N-m (105 kgf-m) (760 lb-ft) 2: Liquid gasket
3. 314 N-m (32 kgf-m) (232 lb-ft) (Three Bond 1215 or a locally procured Room
4. 53 N-m (5.4 kgf-m) (39 lb-ft) Temperature Vulcanizer (RTV) that does not
5. (Differential installation bolt) contain Acetic Acid)
Front: 314 N-m (32 kgf-m) (232 lb-ft)
Rear: 834 N-m (85 kgf-m) (615 lb-ft)
115ZV EX 23-8
23 Check & Adjustment Power Group
Axle

[Front differential] [Rear differential]

TOP TOP

Breather Breather

Grease nipple
Grease nipple

3mm 3mm
(0.118 in) (0.118 in)
5mm 5mm
(0.197 in) (0.197 in)

Oil lip Oil lip Single

seal Single seal lip
lip
Double Double
lips (Flange lips (Flange
yoke) Grease yoke) Grease

K95ZV23004

Preload adjustment
Note
Measure the preload at the bolt hole of cage (5). There are 20 types of spacers (6) from 29.10 mm (1.146
in) to 29.48 mm (1.161 in) in increments of 0.02 mm
Standard preload (0.0007 in). Using a thicker spacer reduces preload,
39~49 N (4~5 kgf) (9~11 lbs) and a thinner spacer increases preload.

If the preload is out of the above range, replace spacer

(6) to adjust the preload to the specified range.

Preload is the force required to start the cage moving-

breakaway force.
 115ZV EX 23-9
23 Check & Adjustment Power Group
Axle

Bearing installation

Install bearing (7) so that part faces to the drive pinion.

Pinion gear
Snap ring

Bearing (7)

K85ZV23003

Note
A snap ring is set to bearing (7) as shown above. Incor-
rect installation of bearing (7) may cause the snap ring
to drop, resulting in a serious mechanical trouble.

Oil seal installation

Before installing the oil seals (8)(9), be sure to apply

grease to the lip, and liquid gasket on the outside of the
seal.

Apply grease
when assembling.

K85ZV23004

Greasing

After reassembling the differential assembly, apply

grease to the grease nipple until the grease comes out
of the breather nipple.
115ZV EX 23-10
23 Check & Adjustment Power Group
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 make 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 make drive pinion approach the ring
Drive pinion is too far from the
E 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.
 115ZV EX 23-11
23 Check & Adjustment Power Group
Axle

Three types of tooth contact shown below are

acceptable as best tooth contact.

Tooth contact position and length (rate)

10

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 wrap the bevel gear and drive pinion as a
unit. Therefore, replace the bevel gear and drive pinion
as a unit.

Note
Single sale of the bevel gear or the drive pinion is not
available.
115ZV EX 23-12
23 Check & Adjustment Power Group

MEMO
 115ZV EX 32-1
32 Function & Structure Torque Converter and Transmission Group

32 Function & Structure

Torque Converter and Transmission Group

Torque Converter ..................................................................32-2

Torque Converter Gear Pump ...............................................32-4
Transmission .........................................................................32-5
Clutch Pack .........................................................................32-10
Power Flow Path in the Transmission .................................32-11
Hydraulic System Diagram..................................................32-16
Hydraulic Circuit Diagram....................................................32-17
T/C and T/M Oil Circulation .................................................32-18
Modulator Valve Unit ...........................................................32-20
Modulation Mechanism .......................................................32-23
Clutch Solenoid Valve .........................................................32-26
115ZV EX 32-2
32 Function & Structure Torque Converter and Transmission Group
Torque Converter

Torque Converter

10

1 6 2 7

(P) (T)
8
3

(S)

11

115ZV32001

1. Pump impeller 7. Input plate (Drive ring)

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
 115ZV EX 32-3
32 Function & Structure Torque Converter and Transmission Group
Torque Converter

Torque converter structure Torque multiplication

Torque ratio (t)

3

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
and stator (S) impellers. is "torque multiplication". Heat is also generated.

Turbine impeller speed (min – 1 ) (rpm)

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

The turbine is connected to the torque converter output

shaft to transmit the power to the transmission.

The stator is fixed to the torque converter case. The

area of the impellers is filled with oil. When the engine
is started, the pump impeller rotates, therefore the oil
will circulate to rotate the turbine impeller (circulation
order: pumpturbinestatorpump). Oil is redirected
by the fixed stator impeller back to the pump impeller.
When the turbine impeller rotates, the power will be
transmitted to the output shaft.
115ZV EX 32-4
32 Function & Structure Torque Converter and Transmission Group
Torque Converter Gear Pump

Torque Converter Gear Pump

3 7 2 4 6 1

11

Torque converter Torque converter

pump

9,10

115ZV32003

1. Front frame Gear pump specifications

2. Gear case
3. End frame
4. Drive gear Theoretical 72.6 cm3/rev (4.43 in3/rev)
5. Driven gear
Maximum
6. Side plate (A) operation pressure
3.4 MPa (35 kgf/cm2) (498 psi)
7. Side plate (B)
Maximum
8. O-ring 3,000 min-1 (rpm)
operation speed
9. O-ring Approx. 50 L/min (13.2 gpm)
10. Back-up seal Conditions:
11. Oil seal Pump speed 900 min-1
Actual discharge Oil temp. 80~100°C (176~212°F)
Oil viscosity 10CST (SAE10W)
Discharge pressure 3.4 MPa
(35 kgf/cm2) (498 psi)
 115ZV EX 32-5
32 Function & Structure Torque Converter and Transmission Group
Transmission

Transmission
15 13 14

5 3

7
6

12 11

115ZV32004

10
1. Input flange 7. 3rd speed clutch 12. Output flange
2. Low range clutch 8. Idle gear (2nd propeller shaft side)
3. High range clutch 9. Output gear 13. Modulator valve unit
4. Reverse clutch 10. Output shaft 14. Clutch solenoid valve mount
5. 1st speed clutch 11. Output flange 15. 1st speed clutch solenoid valve
6. 2nd speed clutch (3rd propeller shaft side)
115ZV EX 32-6
32 Function & Structure Torque Converter and Transmission Group
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
1
F2 for both forward and reverse.
Held in 2nd speed range
F3
2 for both forward and reverse.
F4 Downshift button operation.
(Either 1st, 2nd or
N * * * Held in 3rd speed range
3rd) 3
R1 for both forward and reverse.

R2 Automatic speed change according to shift map

(computer) for 2nd through 4th speeds forward
R3 A
and 2nd through 3rd speeds reverse.
Downshift button operation.
The transmission is equipped with six clutches:
Automatic or manual speed change is available
Forward low range, forward high range, reverse, and depending on the position of the shift lever, as shown in
1st, 2nd and 3rd speeds. Combining the clutches as the above table.
shown in the table here provides four forward speeds,
and three reverse speeds for a total of seven speeds. Automatic speed change refers to one where the best
Two clutches must be engaged at the same time to speed range is determined by a computer according to
move the machine. the machine speed detected.

Planetary gear Power up switch operation

This feature permits quick up and down shifting when in
2nd and Automatic.
Ring gear
It operates from 2nd to 1st, and 1st to 2nd.

Planetary
gear carrier

Planetary gear Sun gear

95V2E32021

Gear reduction is by the planetary gear method. As

shown, each reduction gear set consists of a sun gear
at the center, three (four) planetary gears located
around it, a ring gear around them, and a carrier (frame)
supporting the planetary gears. The speed is changed
by fixing or releasing the ring gear or the carrier.
 115ZV EX 32-7
32 Function & Structure Torque Converter and Transmission Group
Transmission

Gear train and number of teeth

2 3 L R
82 82 82
79
22 24 24
27
50
38
1 34 34 H
25
From torque converter

66

74
2nd propeller shaft 3rd propeller shaft

115ZV32005

Number Number
No. ID Gear name No. ID Gear name
of teeth of teeth
2 L Low range clutch gear 82 5 1 1st speed clutch gear 38
3 H High range clutch gear 25 6 2 2nd speed clutch gear 82
4 R Reverse clutch gear 79 7 3 3rd speed clutch gear 82

Note
Numbers (No.) above correspond to the numbers in
page 92-4.

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) dia. dia. dia. dia.
of plate New/wear limit of plate New/wear limit
(mm) (mm) (mm) (mm)
Low range clutch 5.5±0.5 8 4 ± 0.13 / 3.5 8 6
ø360 ø279 ø426 ø298 3.5 ± 0.1 / 3.3
Reverse clutch 5.5±0.5 8 (Sintered) 8 12
High range clutch 3.0±0.5 4 4 ± 0.1 / 3.4 3 12
ø236 ø159 ø252 ø173 3.2 ± 0.1 / 3.0
1st speed clutch 6.0±0.5 9 (Sintered) 8 12
2nd speed clutch 2.0±0.5 3 4 ± 0.13 / 3.8 3 12
ø360 ø279 ø426 ø298 3.5 ± 0.1 / 3.3
3rd speed clutch 3.0±0.5 4 (Paper) 4 12
115ZV EX 32-8
32 Function & Structure Torque Converter and Transmission Group
Transmission

Friction plate

For low, reverse clutch

mm (in)
3.0 (0.12)
1

0.6 (0.02)
2

Detail drawing of groove

95V2E32023

1. Plate
2. Facing (sintered)

For 2nd, 3rd speed clutch

mm (in)
2.6 (0.10)
1

1.2 (0.05)
279 +- 00.8 (11.0 +- 00.03 )

2
360 (14.2 )

0.1 (0.004) above

Detail drawing of groove

95V2E32024

1. Plate
2. Facing (paper)

For high, 1st speed clutch

mm (in)
2.6 (0.10)
1
159 +- 00.5 (6.26 +- 00.02)

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

Detail drawing of groove

95V2E32025

1. Plate
2. Facing (sintered)
 115ZV EX 32-9
32 Function & Structure Torque Converter and Transmission Group
Transmission

Steel plate

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

mm (in)

- 1.5 (16.7 - 0.06 )

- 3.0 (11.7 - 0.1 )
+ 0.04

+0
+ 1.0

+0
298

426
95V2E32026

For high, 1st speed clutch

mm (in)

252 +- 00.5 (9.92 +- 0.02

0
)

95V2E32029
115ZV EX 32-10
32 Function & Structure Torque Converter and Transmission Group
Clutch Pack

Clutch Pack

Inlets for Inlets for

2nd and 3rd reverse and
speed clutch low range
oil clutch oil
22 21 23 24 17 15 16 12 9 11
25
27 26 10
28 8

6
5
Inlet of 1st speed
clutch oil Inlet of high range
clutch oil
Lubrication
oil

1
7

4
2
3

31 29 30 33 32 34 20 18 19 13,14 115ZV32006

1. Clutch input shaft 18. Low speed range ring gear

2. High speed range clutch drum 19. Low speed range sun gear
3. Spider 20. Anchor pin
4. High speed range clutch piston 21. 3rd speed clutch piston
5. Friction plate 22. 2nd speed clutch piston
6. Steel plate 23. 3rd speed planetary gear
7. Piston return spring 24. 3rd speed ring gear
8. Reverse planetary gear carrier 25. 2nd speed ring gear
9. Reverse planetary gear 26. 2nd speed planetary gear
10. Reverse clutch piston 27. 1st speed clutch piston
11. Friction plate 28. Piston return spring
12. Steel plate 29. 1st speed clutch drum
13. Anchor pin 30. 1st speed clutch gear
14. Piston return spring 31. Drop gear (Helical type)
15. Reverse ring gear 32. Clutch output shaft
16. Low speed range clutch piston 33. 2nd speed planetary gear carrier
17. Low speed range planetary gear 34. Low/3rd speed planetary gear carrier
 115ZV EX 32-11
32 Function & Structure Torque Converter and Transmission Group
Power Flow Path in the Transmission

Power Flow Path in the Transmission

Forward
Forward 1st speed

Inlet of low
range clutch oil
23 24 18 17 Low range 16
32 clutch
1st speed clutch
30

Inlet of 1st speed

clutch oil

Input
power

Output 1
31 power

20 19

115ZV32007

When first speed forward is selected by the operator or When the 1st speed clutch is engaged, drop gear (31),
the computer, oil is sent from the modulator valve to the 1st speed clutch gear (30), 3rd speed ring gear (24) and
low range clutch and the 1st speed clutch. When the clutch output shaft (32) form one unit.
clutch plates are pressed by the low range clutch piston,
low range ring gear (18) is locked to the housing by the As a result, the rotation of the 3rd speed planetary gear
anchor pins (20). The torque converter rotates the low (23) around sun gear is output as the rotation of the
range sun gear (19) via the clutch input shaft (1). This drop gear (31).
causes low range planetary gears (17) to rotate around
sun gear (19) while rotating on their own axis. This
forces the carrier to rotate. Since the low range plane- 3rd speed planetary gear (23)
tary carrier and 3rd speed planetary carrier are one (does not rotate on its own axis)
piece, the 3rd speed planetary gears (23) also rotate
around sun gear.
3rd speed ring gear (24) and clutch
output shaft (32) form one unit
95ZV32007
Low range ring gear (18)
Sun gear (19)
The low range planetary decreases the speed of the
Low range planetary gear (17) input shaft but increases torque. The first speed clutch
is used to directly transmit this high torque-low speed to
95ZV32006
the output shaft.
115ZV EX 32-12
32 Function & Structure Torque Converter and Transmission Group
Power Flow Path in the Transmission

Forward 2nd speed

2nd speed clutch oil Low range clutch oil

Low range
2nd speed clutch clutch

Input power

Output power
115ZV32008

Forward 3rd speed

3rd speed clutch oil Low range clutch oil

Low range
3rd speed clutch clutch

Input power

Output power
115ZV32009
 115ZV EX 32-13
32 Function & Structure Torque Converter and Transmission Group
Power Flow Path in the Transmission

Forward 4th speed

2nd speed clutch oil High range clutch

2nd speed clutch

High range clutch oil

Input power

Output power
115ZV32010
115ZV EX 32-14
32 Function & Structure Torque Converter and Transmission Group
Power Flow Path in the Transmission

Reverse
Reverse 1st speed

Reverse clutch oil

Reverse clutch
1st speed clutch

1st speed clutch oil

Input power

Output power
115ZV32011

Reverse 2nd speed

2nd speed clutch oil Reverse clutch oil

Reverse clutch
2nd speed clutch

Input power

Output power
115ZV32012
 115ZV EX 32-15
32 Function & Structure Torque Converter and Transmission Group
Power Flow Path in the Transmission

Reverse 3rd speed

3rd speed clutch oil Reverse clutch oil

3rd speed Reverse clutch
clutch

Input power

Output power
115ZV32013
115ZV EX 32-16
32 Function & Structure Torque Converter and Transmission Group
Hydraulic System Diagram

Hydraulic System Diagram

Note
Numbers below correspond to page 32-17.
Shift lever

Control
box
18
10 12

L 2nd
9
H
R 3rd 20
1st
11

19
6
5
16 17 21
4

8 7
3

13

22

23 25

24 27 26

2 1

15 115ZV32014
 115ZV EX 32-17
32 Function & Structure Torque Converter and Transmission Group
Hydraulic Circuit Diagram

Hydraulic Circuit Diagram

Neutral position

12 Modulator valve unit

9
GA

H 10
16 4K 6K
GP
22 13
11
T P 5
S

R 17
GB
8
23 30K
9K 7
14
GT 6

L 18
24 4
15

1st 19

25
3

2nd 20
Note
2
26 All orifice measurements 1
( ø) are in mm.

3rd 21

27

97ZA32-15

1. Transmission oil pan 11. Check valve (2) 19. 1st speed clutch solenoid valve
2. Strainer 12. Pressure difference sensor 20. 2nd speed clutch solenoid valve
3. Torque converter gear pump 13. Torque converter 21. 3rd speed clutch solenoid valve
4. Line filter with bypass valve 14. T/C outlet relief valve 22. High speed range clutch
5. Clutch pressure regulator valve 15. Oil cooler 23. Reverse clutch
6. Modulator valve (1) 16. High speed range clutch 24. Low speed range clutch
7. Relief valve solenoid valve 25. 1st speed clutch
8. T/C inlet relief valve 17. Reverse clutch solenoid valve 26. 2nd speed clutch
9. Modulator valve (2) 18. Low speed range clutch 27. 3rd speed clutch
10. Check valve (1) solenoid valve
115ZV EX 32-18
32 Function & Structure Torque Converter and Transmission Group
T/C and T/M Oil Circulation

T/C and T/M Oil Circulation

(S/N 0101~0120, 9001~9010)

Radiator

Transmission
oil filter
T/C oil cooler

Engine

Transmission
oil filter
Torque converter

Rear chassis

Clutch solenoid
valve assembly

Modulator valve
assembly

Transmission

K115ZV32001
 115ZV EX 32-19
32 Function & Structure Torque Converter and Transmission Group
T/C and T/M Oil Circulation

Oil flow in the torque converter Oil flow to the clutch

line
Oil, regulated to a specified pressure by the modulator
valve (6) and clutch pressure regulator valve (5), flows
From torque converter charge pump to torque to each clutch solenoid valve.
converter
Assuming that the transmission shifts from 1st speed
Oil from the torque converter gear pump (3) passes forward to 1st speed reverse, the reverse clutch sole-
through the line filter (4) and enters the modulator valve noid is energized, and the clutch oil thus flows into the
unit. Since only a small amount of oil flows to the clutch reverse clutch piston chamber. As the low range clutch
circuit, most of the oil flows to clutch pressure regulator solenoid is de-energized, the oil in the low range clutch
valve (5), forces it open, and passes into the torque con- piston chamber flows through the low range clutch sole-
verter circuit. If the torque converter's inlet pressure noid valve and drains into the transmission case.
exceeds 0.9 MPa (9 kgf/cm2) (128 psi), it forces open
the torque converter inlet relief valve (8), allowing the oil
to escape to the oil pan.

From torque converter to cooling circuit

Return oil from the torque converter flows through the

outlet relief valve (14) (set pressure=0.3 MPa (3 kgf/
cm2) (42.7 psi)) in the torque converter housing and to
the torque converter cooler (15).

From cooler to lubrication circuit

Oil cooled in the cooler flows to the lubrication paths in

the transmission. This lubricates and cools each bear-
ing and the clutch plates, and then drops into the oil
pan.
115ZV EX 32-20
32 Function & Structure Torque Converter and Transmission Group
Modulator Valve Unit

Modulator Valve Unit

Torque converter

Clutch solenoid
valve assy

1st speed clutch

solenoid valve

Transmission

Modulator valve
unit

K115ZV32002

Unit configuration
1. —
2. —
3. —
4. —
9 5. Clutch pressure regulator valve
6. Modulator valve (1) (Reducing valve)
6
7. Relief valve (2.9 MPa (30 kgf/cm2) (427 psi))
8. —
9. Modulator valve (2) (Solenoid valve)
10. —
7
11. —
12 12. Pressure difference sensor (S/N ~0250)

Note
Numbers above also correspond to "Hydraulic Circuit
Diagram" page 32-17.

K115ZV32003
 115ZV EX 32-21
32 Function & Structure Torque Converter and Transmission Group
Modulator Valve Unit

Red
12

Black White E

Cross section
E-E
D

A
D
GA

GP
ø0.9 orifice ø3.0 orifice E
6
9

F 9
GT
6

GB
7
F C

Cross section
F-F

Line red Line black 5

Arrow view A
(+) (-)
Connector for modulator valve (1) and (2). ø4.5 orifice
1. —
2. —
3. —
4. —
5. Clutch pressure regulator valve
11
6. Modulator valve (1) (Reducing valve) Cross section C-C 10
7. Relief valve (2.9 MPa (30 kgf/cm2) (427 psi))
8. T/C inlet relief valve (0.9 MPa (9 kgf/cm2) (128 psi))
9. Modulator valve (2) (Solenoid valve)
10. Check valve 1 (0.6 MPa (6 kgf/cm2) (85 psi))
11. Check valve 2 (0.4 MPa (4 kgf/cm2) (57 psi))
12. Pressure difference sensor (S/N ~0250)
Cross section D-D
8 115ZV32015

Note
Numbers above also correspond to "Hydraulic Circuit
Diagram" page 32-17.
115ZV EX 32-22
32 Function & Structure Torque Converter and Transmission Group
Modulator Valve Unit

Interior schematic (not exact representation)

12 11 To clutch solenoid valve

10

0.6 Mpa 0.4 Mpa

(85 psi) (57 psi)

To torque converter
0.9 MPa 2
(9 kgf/cm )
(128 psi) 2.9 MPa
(30 kgf/cm2)
(427 psi)

Drain 8 Drain
7
From pump

1. —
2. — 12
3. —
4. — 9
5. Clutch pressure regulator valve GA
6. Modulator valve (1) (Reducing valve)
7. Relief valve
10
(2.9 MPa (30 kgf/cm2) (427 psi)) To transmission 4K 6K
8. T/C inlet relief valve clutch GP
(0.9 MPa (9 kgf/cm2) (128 psi)) 11 5
9. Modulator valve (2) (Solenoid valve) To torque converter
10. Check valve 1
GB
(0.6 MPa (6 kgf/cm2) (85 psi)) 8
11. Check valve 2 30K
(0.4 MPa (4 kgf/cm2) (57 psi)) 9K 7
12. Pressure difference sensor (S/N ~0250) GT 6

Note From pump

Hydraulic circuit
Numbers above also correspond to "Hydraulic GA~GT: gauge port: PT 1/8"
Circuit Diagram" page 32-17. 95ZV32013
 115ZV EX 32-23
32 Function & Structure Torque Converter and Transmission Group
Modulation Mechanism

Modulation Mechanism

Modulator valve function Modulator valve 1

When changing forward/reverse or speed, the modula-
tion mechanism works to reduce the time required for Pressure difference
sensor
clutch engagement (time lag), to prevent the shock at (S/N ~0250) To clutch solenoid valve

clutch engagement, to improve the work efficiency and

durability of the power system, and to ensure operator's
comfort.
Modulator
valve 2
For such effects, the modulation mechanism controls 6 kgf/cm2 4 kgf/cm2
the clutch oil pressure rising time as follows:

An electrical signal from the shift control unit (SCU) con- Clutch pressure
regulator valve
trols the trimmer operation. For information on the SCU Modulator
valve 1
refer to "Electrical Group" section. Port P

F
f

To torque
converter
9 kgf/cm2
30 kgf/cm2

From pump Drain Drain

95ZV32009

The modulator valve 1 is a solenoid-operated propor-

tional pressure reducing valve. Downward magnetic
force (F) acts on the top of the spool in proportion to the
amount of current applied to the coil.

The bottom of the spool is acted upon by the upward

hydraulic force (f). When this upward force (f) and mag-
netic force (F) are in balance, the spool is stationary,
which generates the specified pressure at port P.

The hydraulic force adjusted by modulator valve 1 acts

on the left end of the clutch pressure regulator valve,
and so the hydraulic force from the pump to the clutch is
also controlled by modulator valve 1.

In other words, when the control pressure from the mod-

ulator valve 1 is low, oil from the pump easily moves the
clutch pressure regulator valve to the right end and
relieves the oil to the torque converter or, above 0.9
MPa (9 kgf/cm2) (128 psi) to the drain port, reducing
clutch oil pressure.
115ZV EX 32-24
32 Function & Structure Torque Converter and Transmission Group
Modulation Mechanism

Modulator valve 2 Clutch oil pressure control at the time of

engine starting
As mentioned above, the clutch oil pressure is con-
trolled depending on the size of current applied to the
coil of modulator valve 1. Even at a minimum value of
Starter
current, however, the clutch oil pressure is too high for SW Engine
smooth clutch engagement due to the resistance of flow ON start

Clutch oil pressure

across the clutch pressure regulator valve. The modula- Specified
tor valve 2 is used to reduce the clutch oil pressure to pressure
3 sec
appropriate pressure for clutch engagement.

When the modulator valve 2 is energized, the spool

moves to the left and the oil in the clutch circuit is
drained through the ø 0.9 orifice. The oil from the pump
forces open the 0.6 MPa (6 kgf/cm2) (85 psi) check 0
Time
valve and flows to the clutch. The pressure drop due to 95ZV32010
the check valve allows a lower minimum clutch oil pres-
sure maintained. This lower pressure allows some
clutch slippage for smooth clutch engagement. Just after the engine starting, the clutch oil pressure is
unstable and the pulse pressure arises.

To prevent the pulse pressure, the current applied to the

modulator valve 1 is kept at a minimum value in 3 sec-
Pressure difference sensor (S/N ~0250) onds after the starter switch is ON.

The shock and the time lag when engaging the clutch (This program does not work over 3 seconds after the
vary by the clutch oil pressure rising time after the com- starter switch is ON.)
pletion of the oil charging into the clutch piston chamber.

In the case that the clutch oil pressure rising time is

early, it causes a large shock. If it is late, it causes a
large time lag.

As the modulator valve 2 is ON during the oil is charging

into the clutch piston chamber, oil flows to the clutch pis-
ton chamber through the check valve 0.4 MPa (4 kgf/
cm2) (57 psi) and the ø 4.5 orifice.

Oil stops flowing through the check valve and the ø 4.5
orifice at the completion of the oil charging into the
clutch piston chamber. As a result, there is no oil pres-
sure difference between the both sides of the ø 4.5 ori-
fice. The pressure difference sensor detects the
changing of the pressure difference and transfers the
signal to the controller.

The controller decides the completion of the oil charging

into the clutch piston chamber and transfers the signal
to the modulator valve 1 to increase the clutch pressure.
 115ZV EX 32-25
32 Function & Structure Torque Converter and Transmission Group
Modulation Mechanism

Modulator valve operation 1. Initial oil charging (t1) into the clutch piston
chamber
Modulation chart (Neutral1st forward) When the shift lever is shifted from the neutral to the 1st
speed forward, the low range clutch solenoid valve is
ON
energized and oil under pressure flows into the clutch
Low range clutch OFF piston chamber.
solenoid valve
1st speed clutch ON
The 1st speed clutch solenoid valve remains energized.
solenoid valve
Oil filling After a given time, the control current to the modulator
completed about 400 mA valve 1 is reduced. At the same time, the modulator
Modulator valve 2 is energized and the main clutch oil pressure is
valve 1 Current sharply reduced, concluding the initial oil charging into
(mA) about the chamber.
170 mA
0
The time taken for this initial charging, which depends
ON on the capacity of the clutch piston chamber, is con-
Modulator
valve 2 OFF OFF trolled by a microcomputer.

Main 2. Low pressure holding (t2)

pressure
Pressure
MPa (kgf/cm2) P2 P3 To reduce clutch engagement shock, it is necessary to
P1
engage the clutch while allowing some slippage of it. To
0 do this, the current to modulator valve 1 is held low for a
Low range given time. During this time, the clutch piston moves
clutch while compressing the piston return spring.
pressure
Pressure
MPa (kgf/cm2) This low pressure holding time depends on the speed of
the engine: longer with lower engine speed, shorter with
0 higher speed. Modulator 2 is kept energized allowing
some oil to escape to drain.
t1 t2 t3 t4
This time is also controlled by the microcomputer.
When shifted Shift completed
3. Pressure rise (t3)

When the clutch piston comes into contact with the

95ZV32011 clutch plate and the clutch plates start to transmit power,
the control current to modulator valve 1 is gradually
raised. This causes the clutch oil pressure to also grad-
t1 Initial
time
charging Changes with combination of
clutches
0~0.12 sec
ually rise, and the clutch completes engagement while
some slippage occurs. This rise time is also controlled
t2 Low pressure
holding time
Changes with engine speed
Less than
0.5 sec by the microcomputer.
t3 Pressure
time
rise Changes with combination of
clutches
0.3~0.7 sec
4. Restoration of clutch pressure (t4)
t4 Restoration time Changes
clutches
with combination of
0.5~1.3 sec

At the completion of clutch engagement, the circuit

P1 0.2~0.5 MPa (2~5 kgf/cm2) (28~71 psi) opened by modulator 2, which maintained the lower
pressure by draining part of the clutch oil since the initial
P2 2.3~2.7 MPa (23~28 kgf/cm2) (327~398 psi)
charging, is closed. When the power to modulator valve
2.5 MPa (25~26 kgf/cm2) (356~370 psi)
P3 1st speed
Except 1st speed 2.6~2.9 MPa (27~30 kgf/cm2) (384~427 psi)
2 is turned off, the clutch oil pressure is restored to the
specified pressure.
- E/G high idle
115ZV EX 32-26
32 Function & Structure Torque Converter and Transmission Group
Clutch Solenoid Valve

Clutch Solenoid Valve

Torque converter

Clutch solenoid
valve assy

1st speed clutch

solenoid valve

Transmission

Modulator valve
unit

K115ZV32002

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

Unit configuration

2nd

R H

3rd L

Solenoid valve

K115ZV32004
 115ZV EX 32-27
32 Function & Structure Torque Converter and Transmission Group
Clutch Solenoid Valve

7 1

8
9

2 3

R L

3 2

5 4

11 10

115ZV32016

1. High range clutch solenoid valve

2. Reverse clutch solenoid valve
3. Low range clutch solenoid valve
4. 2nd speed clutch solenoid valve
5. 3rd speed clutch solenoid valve
6. Main clutch pressure measuring port (PT3/8)
7. High range clutch pressure measuring port (PT3/8)
8. Low range clutch pressure measuring port (PT3/8)
9. Reverse clutch pressure measuring port (PT3/8)
10. 2nd speed clutch pressure measuring port (PT3/8)
11. 3rd speed clutch pressure measuring port (PT3/8)
115ZV EX 32-28
32 Function & Structure Torque Converter and Transmission Group
Clutch Solenoid Valve

For high/reverse and speed clutches

After power-off (Clutch disengaged status)

From modulator valve

3
4

To T/M oil pan

1 2

From clutch piston chamber

95ZV32023

When the coil (3) is not energized, main spool (1) is

moved back to the right end by spring (2). Thus, oil from
the modulator valve to the clutch piston chamber is dis-
connected. Oil from the clutch piston chamber is open
to the transmission oil pan.
 115ZV EX 32-29
32 Function & Structure Torque Converter and Transmission Group
Clutch Solenoid Valve

After power-on (Clutch engaged status)

From modulator valve

To T/M oil pan

1 2

To clutch piston chamber

3

95ZV32024

When the coil (3) is energized, the main spool (1)

moves to the left end, and this causes the modulator
valve and the clutch piston chamber to be connected,
allowing the clutch oil to flow to the clutch piston cham-
ber.

Inserting a push rod into the hole at the end of the clutch
solenoid valve will push down on the pin (4). This forces
the main spool down and engages the clutch. This may
be used for testing the movement of the main spool.
115ZV EX 32-30
32 Function & Structure Torque Converter and Transmission Group

MEMO
 115ZV EX 33-1
33 Check & Adjustment Torque Converter and Transmission Group

33 Check & Adjustment

Torque Converter and Transmission Group

Clutch Oil Pressure and Time Lag ........................................33-2

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

Clutch Oil Pressure and Time Lag

Measuring clutch oil pressure Gauge port

1. Location:
WARNING
Unexpected movement of the machine may cause an 3rd speed clutch pressure Reverse clutch pressure

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. 3 R
- Apply the parking brake. H
- Block the tires with chocks to prevent the tires from
moving.
- Determine the signals between the service man. 2 L
- Prohibit any person from walking into dangerous
areas.
- Near articulation areas of the machine
2nd speed clutch pressure Low speed clutch pressure 115ZV33001
- Under the machine
- Around the engine
- In front of or behind the machine

3rd speed clutch Main clutch

pressure pressure

Measurement instrument Solenoid

valve mount
2nd speed
- Pressure gauge clutch pressure

- Tachometer

- Stop watch

1st speed
clutch pressure

Transmission oil pressure test port location

115ZV33002

2. Measuring port:
1st clutch PF 1/4
Except 1st clutch PT 3/8

3. Oil pressure gauge: 5 MPa (50 kgf/cm2) (1,000 psi)

with 2 ~ 3 m (6 ~ 10 ft) hose

Note
Warm-up the engine before measuring the clutch oil
pressure and time lag.
 115ZV EX 33-3
33 Check & Adjustment Torque Converter and Transmission Group
Clutch Oil Pressure and Time Lag

Standard measurement value Possible causes for low clutch oil pressure

2.2 -2.3 Possible cause Solution

1st
(22 - 23) Inspection &
speed Malfunctioning modulator valve (1) operation
Low (313 - 327) repair
idle 2.5 - 2.6
Except Inspection &
(25 - 26) Malfunctioning modulator valve (2) operation
1st repair
Clutch pressure Engine (356 - 370)
MPa (kgf/cm2) (psi) speed Defective controller Replacement
2.5 - 2.6
1st Disassembly &
(25 - 26) Oil leakage from clutch
speed repair
High (356 - 370)
idle 2.6 - 2.9
Except
(27 - 30)
1st
(384 - 427)
Neutral1st forward speed
Clutch time lag (sec) (engine speed: 1,500 min-1 0.3 ± 0.1
(rpm))

Clutch oil pressure measurement proce-

dure

- Lower the boom to the lowest limit, and lower the

bucket onto the ground.

- Set the parking brake to the "ON" position.

- Set the transmission shift lever to the neutral posi-

tion.

- Stop the engine. Attach the pressure gauge to the

pressure measurement port. Place the gauge inside
the operator's area, start the engine.

- As the clutch oil pressure rises just after the engine

is started, adjust the engine to the specified speed
before the pressure measurement.

- Measure and record the pressure in each speed

range.

- Change the transmission speed range while keeping

the shift lever at the neutral position. Check that the
pressure instantaneously lowers just after speed
change, and then rises to the original pressure
again.
115ZV EX 33-4
33 Check & Adjustment Torque Converter and Transmission Group
Clutch Oil Pressure and Time Lag

Measuring clutch time lag

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

Time lag measurement procedure

- Lower the boom to the lowest limit, and fully roll back
the bucket until the bucket contacts to the stopper.

- Set the parking brake switch to the "OFF" position.

Do not apply the service brakes.

- Set the transmission shift lever to the neutral 1st

speed.

- Keep the engine speed at 1,500 min-1 (rpm).

- Move the shift lever to the forward position. At the

same time, start the stop watch to measure the time
required before the machine moves.

Possible causes for clutch time lag

Possible cause Solution

Defective pressure difference sensor (S/N
Replacement
~0250)
Inspection &
Malfunctioning modulator valve (1) operation
repair
Inspection &
Malfunctioning modulator valve (2) operation
repair
Defective controller Replacement
Disassembly &
Defective clutch
repair
 115ZV EX 42-1
42 Function & Structure Hydraulic Group

42 Function & Structure

Hydraulic Group

Flushing Hydraulic Circuit......................................................42-2

Cautions on Hydraulic Parts Replacement............................42-3
Hydraulic Circuit Symbols .....................................................42-4
Hydraulic System Operation..................................................42-8
Layout of Hydraulic Units ....................................................42-10
Hydraulic Tank.....................................................................42-11
Hydraulic Pump ...................................................................42-16
Hydraulic Cylinder ...............................................................42-21
Loading System ..................................................................42-23
Reducing Valve (for Pilot Pressure) ....................................42-24
Pilot Valve (S/N 0101~0140, 9001~9020) ...........................42-25
Pilot valve (S/N 0141~0172, 9021~) ...................................42-30
Pilot valve (S/N 0173~0176) ...............................................42-35
Pilot valve (S/N 0177~) .......................................................42-40
Multiple Control Valve (KML35A/2T103) .............................42-45
Adapter (Orifice) ..................................................................42-57
Vibration Damper (OPT)......................................................42-58
Steering System ..................................................................42-69
Orbitrol® ...............................................................................42-70
Steering Valve (KVS32-A4.0/21) .........................................42-77
Stop Valve ...........................................................................42-89
Reducing Valve (for Orbitrol®) .............................................42-93
Steering Line Filter ..............................................................42-94
Fan Motor System ...............................................................42-95
Fan Motor Line (S/N 0101~0120, 9001~9010)....................42-96
Fan Motor Line (S/N 0121~, 9011~)..................................42-104
Emergency Steering ..........................................................42-114
115ZV EX 42-2
42 Function & Structure Hydraulic Group
Flushing Hydraulic Circuit

Flushing Hydraulic Circuit

Purpose of flushing

Debris

To tank

95ZV42001

If the inside of a cylinder, pump, or a valve of the

hydraulic system is broken, the debris will be sent into
the hydraulic line together with the oil. Most of the
debris will flow into the return filter or hydraulic tank.

However, there are some debris that will remain in the

valves, cylinders, or pipes. Therefore, even if the 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 or relief valves, and cause another mal-
function. To prevent such problems, be sure to remove
all the debris from the system.
 115ZV EX 42-3
42 Function & Structure Hydraulic Group
Cautions on Hydraulic Parts Replacement

Cautions on Hydraulic Parts Replacement

After oil or a part is replaced, malfunction or seizure
may occur during running-in. Such trouble is often
caused by faulty air bleeding or lubrication after 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.
115ZV EX 42-4
42 Function & Structure Hydraulic Group
Hydraulic Circuit Symbols

Hydraulic Circuit Symbols

Hydraulic lines Pumps & motors

(1)
Working hydraulic
line Fixed
displacement,
Hydraulic pump
(1) Unidirectional (2)
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
 115ZV EX 42-5
42 Function & Structure Hydraulic Group
Hydraulic Circuit Symbols

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

115ZV EX 42-6
42 Function & Structure Hydraulic Group
Hydraulic Circuit Symbols

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
 115ZV EX 42-7
42 Function & Structure Hydraulic Group
Hydraulic Circuit Symbols

Miscellaneous hydraulic symbols

(1)

Hydraulic tank
(1) Vented
(2) Pressurized (2)

Manual shut off

valve

Pressure switch

Accumulator

Electric motor M

Internal
combustion M

Power source

Filter or strainer

Heater

Cooler

Pressure gauge

Temperature
gauge

Flow meter
115ZV EX 42-8
42 Function & Structure Hydraulic Group
Hydraulic System Operation

Hydraulic System Operation

Hydraulic system operation out- Loading system

line
The loading system consists of the following compo-
The hydraulic system consists of the following systems: nents. All numbers base on page 92-7.

- Loading system - Hydraulic pump (2)

- Unloader valve (22)
- Steering system - Line filter (81)
- Reducing valve (45)
- Fan motor system - Check valve (32)
- Reducing valve (28)
- Vibration damper system (OPT) - Pilot valve (16)
- Multiple control valve (3)
- Boom cylinders (5)
- Bucket cylinders (6)

Oil from pump (2) flows to pilot valve (16) through

unloader valve (22), line filter (81), reducing valve (45),
check valve (32) and reducing valve (28). Oil to pilot
valve (16) is reduced to 3.5 MPa (36 kgf/cm2) (512 psi)
by reducing valve (28).

When the pilot control lever is operated, the pilot valve

line is opened, and the oil pressure is generated
depending on the position of the pilot control lever.

The pilot pressure entering the oil pack to multiple con-

trol valve (3) moves the spool against its return spring.

The spool press-in distance (displacement) depends on

the pilot valve pressure.

Oil from the loader pump is then directed through multi-

ple control valve (3) to boom cylinders (5) and bucket
cylinders (6).

Return oil from the cylinders flows through multiple con-

trol valve (3) to oil cooler or cooler bypass valve (11),
return filter (12) and into the hydraulic tank.

Even if no hydraulic pump supplies oil to the loading

and pilot control circuits due to trouble, or if the engine
is shut off, the boom can be lowered to the ground by
the pressure in accumulator (33) in the brake circuit in
case of an emergency.
 115ZV EX 42-9
42 Function & Structure Hydraulic Group
Hydraulic System Operation

Steering system Fan motor system

The steering system consists of the following compo- The fan motor system consists of the following compo-
nents. nents.

- Hydraulic pump (1) - Hydraulic pump (2)

- Steering valve (4) - Unloader valve (22)
- Line filter (81) - Fan motor (71)
- Reducing valve (17) - Relief valve (two-step relief) (73) (S/N 9001~9010)
- Orbitrol® (14) - Thermo sensing valve (74) (S/N 9011~)
- Stop valve (15)
- Steering cylinders (8) The cooling fan is driven by hydraulic motor (71). The
pressure oil from unloader valve (22) flows into the port
Oil from pump (1) flows to Orbitrol® (14) through steer- P of the fan motor assy and then turns fan motor (71).
ing valve (4), line filter (81) and reducing valve (17). Oil
to Orbitrol® (14) is reduced to 3.5 MPa (36 kgf/cm2) (512 (S/N 0101~0120, 9001~9010)
psi) by reducing valve (17). The fan revolution is regulated by two-step relief valve
(73) integrated into the line.
A small amount of pilot oil supplied from Orbitrol® (14) When the water temperature is below 94ºC (200ºF),
controls steering valve (4) to realize steering operations. relief valve (73) is set to the low pressure, and the max-
imum fan speed is set to 1,120 min-1 (rpm).
When the steering wheel is turned, the flow rate in pro- When the water temperature is over 94ºC (200ºF), it
portion to the turning speed is supplied from Orbitrol® sets relief valve (73) to the high pressure, as a result,
(14) to steering valve (4) oil pack. the maximum fan speed is set to 1,600 min-1 (rpm).

At this time, the pilot pressure is generated. The pilot (S/N 0121~, 9011~)
pressure strokes the spool of the steering valve (4), and The fan revolution is regulated by thermo sensing valve
supplies hydraulic oil at large flow rate proportional to (74). The setting pressure of thermo sensing valve (74)
the flow rate of the supplied pilot oil to the cylinder line. is changed in accordance with the engine cooling water
temperature, and the regulated maximum number of
The excessive pilot oil flows through the steering valve revolutions varies depending on the cooling water tem-
(4) to the other side of the pilot port. perature.

Stop valves (15) are used in the circuit to stop the flow
of oil from Orbitrol® (14) to steering valve (4) when the
machine reaches full turn. Vibration damper system (OPT)
When the steering wheel is not turned, almost all Refer to "Vibration Damper (OPT)" page 42-58 for the
amount of the hydraulic oil from steering pump (1) is information.
sent to the loading circuit by the action of the flow con-
trol spool.

Oil returns from steering cylinders (8) flows through

steering valve (4) and oil cooler or cooler bypass valve
(11).

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

115ZV EX 42-10
42 Function & Structure Hydraulic Group
Layout of Hydraulic Units

Layout of Hydraulic Units

2 5 8

4 6

9 10 1 3 11 7

5, 6

115ZV42003J

1. Multiple control valve

2. Pilot valve (for loading)
3. Orbitrol®
4. Steering valve
5. Hydraulic pump (for loading, for pilot & brake)
6. Hydraulic pump (for steering)
7. Fan motor
8. Relief valve (for fan)
9. Bucket cylinder
10. Boom cylinder
11. Steering cylinder
 115ZV EX 42-11
42 Function & Structure Hydraulic Group
Hydraulic Tank

Hydraulic Tank

Hydraulic tank specifications

Type Semi-closed type
Capacity (at center of oil level sight gauge) L (gal) 225 (59 US gal)
2
Filtration area (cm ) 16,900 x 2

Return filter Filtration particle size (µm) 28

Relief valve opening pressure (filter bypass)
0.1 ± 0.02 (1 ± 0.2) (14 ± 2.8)
(MPa) (kgf/cm2) (psi)
Loading Filtration area (cm2) 2,550
Suction strainer pilot & brake
Steering Filtration particle size (µm) 105
2
Suction valve setting pressure (kPa) (kgf/cm ) (psi) 1 (0.01) (0.14)
2
Discharge valve setting pressure (kPa) (kgf/cm ) (psi) 29 (0.3) (4.3)
Breather valve (oil filling port) 2
(S/N 0101~0200) Filtration area (cm ) 235
(S/N 9001~) Filtration particle size (µm) 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)
2
Suction valve setting pressure (kPa) (kgf/cm ) (psi) 3.9 (0.04) (0.57)
2
Breather valve (oil filling port) Discharge valve setting pressure (kPa) (kgf/cm ) (psi) 29 (0.3) (4.3)
(S/N 0201~) 2
Filtration area (cm ) 160
Filtration particle size (µm) 10

Hydraulic oil level check

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 on ground
bucket level on the ground.

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

Oil amount
225 L (59 US gal)

Note
If the oil is at operating temperature 60 ~ 90°C (140 ~
(59 US Gal.)

200°F), the oil level may be at or near the top of the oil
225 L

level sight gauge.

115ZV42005
115ZV EX 42-12
42 Function & Structure Hydraulic Group
Hydraulic Tank

Hydraulic tank (S/N 0101~0200, 9001~)

13 10
A
9
A

(S/N 0101~0102, 9001~9003)

7 8

A
Cross section A-A

Viewed from top A

3
4
B
Chassis side

12
5 6

11 Arrow view B-B

B K115ZV42001

1. Oil tank 11. Drain plug

2. Oil level gauge 12. Inspection port
3. Breather valve (tank cap) 13. Vent pipe (to axle housing)
4. Filter
5. Suction strainer (loading, pilot & brake)
6. Suction strainer (steering)
7. Return filter element
8. Filter bypass valve
9. Spring
10. Cover
 115ZV EX 42-13
42 Function & Structure Hydraulic Group
Hydraulic Tank

Hydraulic tank breather valve (tank cap) (S/N 0101~0200, 9001~)

1 2 3 4 5 6
Standard specification:

7 7
a
b
c
Viewed from section A

Europe specification:

7 7

Viewed from section A

K95V42001

1. Cover Therefore 29 kPa (0.3 kgf/cm2) (4.3 psi) pressure is

2. Filter element always applied to the inside of the hydraulic tank.
3. Spring (for exhaust valve)
4. Valve assembly The pressure applied to the inside of the hydraulic tank
(a) Exhaust valve prevents the dust and dirt from being drawn into the
(b) Suction valve tank and improves performance of the pump.
(c) Air bleeder valve
5. Spring (for suction valve) The positive pressure pushes the oil to the pump reduc-
6. Key (same as starter key) ing the possibility of pump cavitation.
7. Attaching bolts (3 pcs) socket head
To release the internal pressure from the hydraulic tank,
When the pressure inside the hydraulic tank drops press downward on the cover (1). The air bleeder valve
below the outside air pressure, the outside air flows (c) will be lowered to release the internal pressure.
through the filter element (2) and to the valve assembly
(4). The suction valve (b) is then opened to let the air The pressure is also applied to the axles.
flow into the tank.

When the air pressure inside the hydraulic tank rises to

Installing cap
a certain point 29 kPa (0.3 kgf/cm2) (4.3 psi), the
exhaust valve (a) is lifted (opened) so that the air can
The cap can be installed in any boom or bucket position.
flow out of the tank through the filter element (2).

One cycle (down and up) of the boom applies pressure

to the inside of the tank.
115ZV EX 42-14
42 Function & Structure Hydraulic Group
Hydraulic Tank

Hydraulic tank (S/N 0201~)

13 10
A
9
A

7 8

A
Cross section A-A

Viewed from top A 3

B
Chassis side

12
5 6

11,14 B
Arrow view B-B
115ZVE42001

1. Oil tank 11. Drain plug

2. Oil level gauge 12. Inspection port
3. Breather valve (tank cap) 13. Vent pipe (to axle housing)
4. Filter 14. Magnet plug (S/N 0220~)
5. Suction strainer (loading, pilot & brake)
6. Suction strainer (steering)
7. Return filter element
8. Filter bypass valve
9. Spring
10. Cover
 115ZV EX 42-15
42 Function & Structure Hydraulic Group
Hydraulic Tank

Hydraulic tank breather valve (tank cap) (S/N 0201~)

When the pressure inside the hydraulic tank drops

below the outside air pressure, the outside air flows
through filter element (2) and to valve assembly (4).
PUSH Suction valve (b) is then opened to let the air flow into
the tank.

When the air pressure inside the hydraulic tank rises to

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

One cycle (down and up) of the boom applies pressure

2
to the inside of the tank.

3
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

4 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-

a
ing the possibility of pump cavitation.
b
5 To release the internal pressure from the hydraulic tank,
K65D2J42001 press down cap (1). Air bleeder valve (b) will be lowered
to release the internal pressure.
1. Cap
The pressure is also applied to the axles.
2. Filter element
3. Spring (for exhaust valve)
4. Valve assembly
(a) Exhaust valve Installing cap
(b) Suction valve (Air bleeder valve)
5. Spring (for suction valve) The cap can be installed in any boom or bucket position.
6. Hex nut
115ZV EX 42-16
42 Function & Structure Hydraulic Group
Hydraulic Pump

Hydraulic Pump

Hydraulic pump
(for loading, pilot&brake)

Torque converter

Hydraulic pump
(for steering)

(S/N 0121~,
9011~)

Hydraulic tank

K115ZVE42001
 115ZV EX 42-17
42 Function & Structure Hydraulic Group
Hydraulic Pump

Loading and pilot and brake pump

5 6 6 2

4 7

8
(S/N 0162~) K115V42002

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) 8. Damper (Sleeve) (S/N 0162~)

Pump specifications

Front Rear
Applicable circuit Loading circuit Pilot & Brake circuit
Theoretical discharge cm3/rev 80.2 86.3
Maximum operation pressure MPa (kgf/cm2) (psi) 23.5±0.5 (240±5) (3,414±71) 18.6 (190) (2,702)
Maximum speed min-1 2,810

Measurement conditions:
Oil temperature 50~80ºC (120~180ºF)
Hydraulic oil ISO VG46
115ZV EX 42-18
42 Function & Structure Hydraulic Group
Hydraulic Pump

Steering pump

5 6 6 2

4 7

8
(S/N 0162~) K115V42003

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) 8. Damper (Sleeve) (S/N 0162~)

Steering pump specifications

Front Rear
Applicable circuit Steering circuit
Theoretical discharge cm3/rev 90.7
Maximum operation pressure MPa (kgf/cm2) (psi) 24.5 (250) (3,556)
Maximum speed min-1 2,810

Measurement conditions:
Oil temperature 50~80ºC (120~180ºF)
Hydraulic oil ISO VG46
 115ZV EX 42-19
42 Function & Structure Hydraulic Group
Hydraulic Pump

Hydraulic pump principle

Inlet Outlet

Inlet Outlet

Inlet Outlet

95ZV42040

The oil at the inlet area is taken in the cavities between

the gear teeth right after disengagement and transferred
towards the outlet area enclosed in between the teeth
and the gear casing.

When the gear teeth mesh again, the oil is extruded out
of the tooth cavities and forwarded to the outlet.
115ZV EX 42-20
42 Function & Structure Hydraulic Group
Hydraulic Pump

Hydraulic pump wear plate Both sides of the gear consists of floating type pressure
plates having balancing functions. The pressure plates
maintain optimum clearance on both sides of the gear
(pressure balance mechanism) so that the high 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 (more than 20°C (68°F)).
Discharge

115ZV42006
 115ZV EX 42-21
42 Function & Structure Hydraulic Group
Hydraulic Cylinder

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

Boom cylinder
5,
19,22 27 16 20 14 12,13 1 2 9 10,11 8 17 (S/N 0121~, 9011~)
6,7 5,17

3 4 18 (FM)
K115ZV42007

: 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
(Gauge port PF1/4)
19,22 21 16 20 14 13 12 10 15 1 2 8 7 6 11 9 17 5 19,22 25,26 (RH cylinder only)

23,24

A
A
25,26 (Gauge port PF1/4) 3 4
(RH cylinder only) K115ZV42008

: Piston nut (16): 5,884 N-m (600 kgf-m) (4,340 lb-ft)

: Bolt (23): 883 N-m (90 kgf-m) (651 lb-ft)
115ZV EX 42-22
42 Function & Structure Hydraulic Group
Hydraulic Cylinder

Steering cylinder

19,22 16,21 20 14 13 12 1 2 8 6,7 10,11 9 11 17 5 19,22

3 4

115ZV42047

1. Piston 9. Bushing 17. Stop ring

2. Piston rod 10. Backup ring 18. —
3. Cylinder tube 11. O-ring 19. Dust seal
4. Rod cover 12. Slipper ring 20. Wear ring
5. Dust seal 13. Back ring 21. Stop ring
6. Backup ring 14. O-ring 22. Bushing
7. U-packing 15. —
8. Buffer ring 16. Piston nut

: 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)

Hydraulic cylinder specifications

mm (in)
ø225 x ø120 x 1,132
Inner dia. x rod dia. x stroke
(8.85 x 4.72 x 44.56)
Boom ø120 x 272
Piston rod
cylinder Pin hole (4.72 x 10.70)
(inner dia. x width) ø120 x 208.5
Cylinder
(4.72 x 8.21)
ø190 x ø100 x 767
Inner dia. x rod dia. x stroke
(7.48 x 3.93 x 30.19)
Bucket ø100 x 120
Piston rod
cylinder Pin hole (3.93 x 4.72)
(inner dia. x width) ø100 x 120
Cylinder
(3.93 x 4.72)
ø110 x ø60 x 720
Inner dia. x rod dia. x stroke
(4.33 x 2.36 x 28.34)
Steering ø70 x 80
Piston rod
cylinder Pin hole (2.75 x 3.14)
(inner dia. x width) ø70 x 80
Cylinder
(2.75 x 3.14)
 115ZV EX 42-23
42 Function & Structure Hydraulic Group
Loading System

Loading System
The pilot operation system uses the pilot valve pressure
to control the spool of the multiple control valve and
move the boom cylinder(s) and bucket cylinder(s).

When the control lever is operated, the pilot valve line is

opened, and the oil pressure is generated depending on
the position of the control lever.

The pilot pressure entering the oil pack to the multiple

control valve moves the spool against its return spring.

The spool press-in distance (displacement) depends on

Control lever the pilot valve pressure.
Pilot valve
(S/N 0141~, 9021~) Oil from the loader pump is then directed through the
valve to the cylinder.

Return oil from the cylinders flows through the valve to

Control lever the oil cooler, return filter and into the tank.
Pilot valve
(S/N ~0140, Oil to the pilot valve is supplied from the brake line while
~9020) being reduced to 3.5 MPa (36 kgf/cm2) (512 psi) by the
reducing valve.

Even if no hydraulic pump supplies oil to the loading

Reducing and pilot control circuits due to trouble, or if the engine
valve
is shut off, the boom can be lowered to the ground by
Multiple Oil the pressure in the accumulator in the brake circuit in
Oil packs
control valve packs case of an emergency.

From
From
brake line Cooler
steering valve

P
Return filter

K90ZV42004
115ZV EX 42-24
42 Function & Structure Hydraulic Group
Reducing Valve (for Pilot Pressure)

Reducing Valve (for Pilot Pressure)

(S/N 0127~, 9021~) (S/N ~0126,
Pressure
~9020)
adjustment stud

Locknut

Ball
Passage Y

(P) (T)

(TA)
(PI) (PARKING)

(PA)
(Z1) (Z2)

(ACCR) (ACCF) (Z) (PPI)

T Tank
Valve assembly
Note: Valve is shown rotated 180º 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 K115ZV42009

This valve provides pilot oil pressure to operate the When the oil pressure on the pilot oil circuit side
parking brake and loader pilot valve functions. becomes less than the set pressure, the ball moves
The oil fed from the brake accumulator circuit flows into down and the pressure at chamber C becomes equiva-
the pilot oil circuit by way of passage Z. The oil pressure lent to the pressure on the pilot oil circuit side (B). As a
in the pilot oil circuit is applied also on chamber C by result, the plunger moves down by a spring, opens the
way of orifice 1. passage Z, then introduces the accumulator pressure to
the pilot oil circuit side so that the pressure is main-
When the oil pressure in the pilot oil circuit is at or tained at the specified value.
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)
 115ZV EX 42-25
42 Function & Structure Hydraulic Group
Pilot Valve (S/N 0101~0140, 9001~9020)

Pilot Valve (S/N 0101~0140, 9001~9020)

For bucket control

Neutral For bucket For boom

1 control control
Roll back Dump
(Detent)

8
2

3
To tank port
4

5 P
6
From pump port
7

Bucket Boom
spool in spool in
To / from MCV oil packs MCV MCV

80ZV42017

1. Lever
2. Disc
3. Push rod
4. Spring seat
5. Spring for secondary pressure
6. Return spring
7. Spool
8. Detent magnet solenoid
115ZV EX 42-26
42 Function & Structure Hydraulic Group
Pilot Valve (S/N 0101~0140, 9001~9020)

For boom control

Raise Neutral Down Float

(Detent) (Detent)

To tank port

95ZV42012

Note
Color coded and reverse coupled connectors help keep
wires plugged correctly.

The pilot valve applies oil pressure in proportion to the

operating angle of the lever, there-by carrying out
remote control of the spool in the multiple control valve.
 115ZV EX 42-27
42 Function & Structure Hydraulic Group
Pilot Valve (S/N 0101~0140, 9001~9020)

Pilot valve operation When the lever (1) is in the neutral position, the spool
(7) closes the pump port and the tank port is opened.
(Modulated position) Therefore the oil pressure is not applied to the multiple
control valve oil pack. The spool of the multiple control
valve is held in neutral by its centering springs. There is
1 no oil flow to the cylinder.

When the lever (1) is shifted from the neutral, the spool
(7) is forced down by the spring (5).

Then the tank port is closed and the pump port is

opened. As a result, the pressurized oil from the pump
flows into the multiple control valve oil pack. The spool
of the multiple control valve moves allowing oil from the
loading pump to flow to the cylinder.
T
When the oil pressure in the multiple control valve oil
5
pack reaches over the desired pressure, the spool (7)
P moves up. As a result, the tank port is opened and the
7 pump port is closed.

- Spool diameter at tank side is greater than spool

Reducing
diameter at pump side.
valve
Accordingly the oil pressure in the multiple control valve
oil pack is reduced below the desired pressure. The
Multiple From front spool (7) moves down again by the spring (5) and
control valve brake closes the tank port. The pump port is opened. It raises
accumulator the oil pressure in the multiple control valve oil pack
Oil pack 70ZV42051 again. This cycling action maintains a constant pres-
sure to the multiple control valve.

The oil pressure to the multiple control valve is propor-

tional to the lever (1) angle, and is balanced with the
lever angle. This results in the multiple control valve
spool being moved the desired amount. Oil flow from
the loading pump to the cylinder is also proportional.
Cylinder speed is easily controlled.
115ZV EX 42-28
42 Function & Structure Hydraulic Group
Pilot Valve (S/N 0101~0140, 9001~9020)

(Full pressure position)

To tank port
To tank port
4
5
From pump port
From pump port
7
7

Port 3 Port 4 Port 3 Port 4

When lever is in neutral When lever is shifted from neutral
95ZV42078

When the lever (1) is moved fully forward or back the

multiple control valve spool should also be moved full
stroke.

This allows maximum oil flow to the cylinders for the

fastest cylinder movement. In the boom down circuit
the multiple control valve spool must be fully stroked to
reach the “FLOAT” position.

To be sure when the multiple control valve spool is fully

stroked, a special spring (5) and spring seat (4) are
used. This allows the spool (7) to be fully stroked and
full pilot pressure will be directed into the oil pack fully
stroking the multiple control valve spool.
 115ZV EX 42-29
42 Function & Structure Hydraulic Group
Pilot Valve (S/N 0101~0140, 9001~9020)

Pilot valve detent magnet solenoid Detent adjustment procedure

Solenoid Steel ball for detent

Plate

Lock nut
Solenoid

Lock nut
70ZV42052
Disc
To tank port
The detent magnet works to hold the lever at it's posi-
tion, when the lever is shifted to “Bucket Roll Back” or
“Boom Raise” or “Boom Float” position. 70ZV42053

When the proximity switch for the bucket leveler or the 1. Turn on key switch and position the boom or bucket
boom kick-out (option) is turned on, the magnet coil is so that the proximity switch will complete the circuit,
energized and magnetized so that the holding plate is energizing the coil of the detent solenoid. [Float is
held by magnetic force. always on.]

When the lever is shifted, the steel ball is positioned at 2. Loosen the lock nut to the solenoid coil.
the detent notch and the lever is held at that position.
3. Turn the magnet counterclockwise so it will back
As a result, pilot oil moves the multiple control valve the steel ball away from the “pocketed” disc.
plunger to the full stroke position, and the pressurized
oil fed from the main pump flows to the cylinder. 4. Position the lever so that the steel ball will drop into
the detent “pocket”.
When the proximity switch is turned off, the magnet coil
is de-energized and de-magnetized. The steel ball is 5. Begin to turn the magnet clockwise until the magnet
pushed out of the detent notch by the return spring so exerts a detent 'influence', because ball begins to
that the control lever is returned to the neutral position. drop into the “pocket” of the disc. Mark the position
of where the magnet is in rotation.
When the control lever is set to the “Boom Float” posi-
tion, the control lever will be held at the “Float” position. 6. Continue to turn the magnet in until detent influence
The “Boom Float” magnet is not switched and is ener- is no longer felt on the lever. Again, mark the posi-
gized and magnetized whenever the key switch is on. tion of where the magnet is in rotation.

For “Boom Float” position, manually reset the control 7. Reverse the rotation of the detent to exactly the 1/2
lever. way point between the two marks.

8. Tighten the lock nut in its' position.

115ZV EX 42-30
42 Function & Structure Hydraulic Group
Pilot valve (S/N 0141~0172, 9021~)

Pilot valve (S/N 0141~0172, 9021~)

Float/Down

Raise (Detent)

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

18.20 16.20
White (Male) A B
(for port 4 solenoid) For For
bucket control boom control

A B
(Port 1, 2) (Port 3, 4)
1 2

3 4

From Bottom
K115V2U42003
 115ZV EX 42-31
42 Function & Structure Hydraulic Group
Pilot valve (S/N 0141~0172, 9021~)

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, port 2 and port 3)
9. Fixing disc (with identifying mark) 22. Spring seat
10. Push rod 23. Spring seat
11. Spring 24. Casing
12. Plug 25. Spring
13. Spring seat
115ZV EX 42-32
42 Function & Structure Hydraulic Group
Pilot valve (S/N 0141~0172, 9021~)

Pilot valve operation

1

The pilot valve applies oil pressure in proportion to the 21

19
operating angle of the lever, there-by carrying out 20
remote control of the spool in the multiple control valve.

(modulated position)

3
Predetent section
10
10

12 12
22 23
14 14

15 16
24

17

Lever is in the neutral position

T
85V2E42009

P The pilot valve has holes of lengthwise direction in

which the reducing valve is built. The reducing valve
Reducing section are consist of spool (17), spring for secondary
valve
pressure (15)(16), return spring (14) and spring seat
(22)(23). Being inserted in the plug (12), push rod (10)
Multiple
control valve
From front can be moved smoothly to change the bending quantity
brake of secondary pressure spring (15)(16).
Oil pack accumulator 85V2E42008

Return spring (14) contacts casing (24) and spring seat

(22)(23). This spring works on returning the push rod
(10) to it’s original position without relation to secondary
pressure, therefore it ensures returning the spool to
neutral. Also it has the effect as reactive force spring to
give the modulation feeling to operator.

When the lever (1) is in the neutral position, the force of

secondary pressure spring (15)(16) is not worked on
spool (17) and spool is pushed up to push rod (10) by
return spring (14). As the spool (17) close the pump port
and the tank port is opened, the oil pressure is not
applied to the multiple control valve oil pack. The spool
of multiple control valve is held in neutral by its center-
ing springs. There is no oil flow to the cylinder.
 115ZV EX 42-33
42 Function & Structure Hydraulic Group
Pilot valve (S/N 0141~0172, 9021~)

Accordingly the oil pressure in the multiple control valve

oil pack is reduced below the desired pressure. The
spool (17) moves down again by the spring (16) and
21
1 19 closes the tank port. The pump port is opened. It raises
20 the oil pressure in the multiple control valve oil pack
again. This cycling action provides pressure reduction
to only have sufficient pilot pressure pass to the multiple
control valve to actuate it in a normal modulated manner
18
3 and maintains a constant pressure to the multiple con-
trol valve.
Predetent section
The oil pressure to the multiple control valve is propor-
10 10 tional to the lever (1) angle, and is balanced with the
lever angle. This results in the multiple control valve
spool being moved the desired amount. Oil flow from
25
the loading pump to the cylinder is also proportional.
13 Cylinder speed is easily controlled.
22 23

15 16
(Full pressure position)
17 17
When the lever (1) is moved fully forward or back the
multiple control valve spool should also be moved full
Lever is shifted from the neutral stroke.
85V2E42010
This allows maximum oil flow to the cylinders for the
fastest cylinder movement.
When the lever (1) is shifted from the neutral, the push
rod (10) and spring seat (23) are pushed down at the In addition, spring seat (13) and spring (25) are installed
same time, the value of secondary pressure spring is inside of the push rod (10) in the “Boom Float” or
changed. Spool (17) is forced down by the secondary “Bucket Dump”. When the lever (1) is shifted more than
pressure spring (16) and then the tank port is closed a desired angle, spring (25) makes contact with the bot-
and the pump port is opened. tom of push rod (10) inside diameter. The inclination of
second pressure changed by this spring force. Then, to
As a result, the pressurized oil from the pump flows into be sure the multiple control valve spool is fully stroked,
the multiple control valve oil pack. The spool of the mul- spring (25) and spring seat (13) are used. This allow the
tiple control valve moves allowing oil from the loading spool (17) to be fully stroked and full pilot pressure will
pump to flow to the cylinder. be directed into the oil pack, thus fully stroking the multi-
ple control valve spool.
When the oil pressure in the multiple control valve oil
pack reaches over the desired pressure, the spool (17)
moves up. As a result, the tank port is opened and the
pump port is closed. This action also contributes to feel-
ing of modulation.

- Spool diameter at tank side is greater than spool

diameter at pump side.
115ZV EX 42-34
42 Function & Structure Hydraulic Group
Pilot valve (S/N 0141~0172, 9021~)

Pre-detent and detent magnet solenoid

1
21
19 21
20
19 20

2
18 3
18
3

7
8 The figure that fixing
disc (8) is absorbed
by the detent sole-
9
noid coil (7).
10

T T

P P

Actuation of pre-detent Actuation of electromagnetic detent

85V2E42011 85V2E42012

The pre-detent function is installed in the “Bucket Roll In addition, the detent magnet works to hold the lever at
Back” or “Boom Float” position that extends the change it’s position, when the lever is shifted to “Bucket Roll
of feeling to operator just before electromagnetic detent. Back” or “Boom Raise” or “Boom Float” position.

The pre-detent section consists of detent bush (18), Detent magnet section consists of detent solenoid sub
spring (19), detent ring (20) and steel ball (21). (7), fixing disc (8)(9) and push rod (2)(3).

The push rod (3) installed in the “Bucket Roll Back” or When the circuit for the bucket leveler or the boom
“Boom Float” position has the notch that steel ball is fit- cookout (option) is turned on, detent solenoid sub (7) is
ted in. energized and magnetized so that fixing disc (8) of
forced up side (opposite side) is held by magnetic force
When the push rod (3) is shifted and steel ball run upon of detent solenoid coil (7). For this reason, the lever (1)
the step, operation torque grows big by reactive force of is held at that position if you keep the hand away from
spring, because the spring is shorted. the lever (1).

This extends the change of feeling to operator just Therefore displacement of the push rod (10) is main-
before electromagnetic detent. tained, and the second pressure continues to be gener-
ated constantly.

When the proximity switch is turned off, detent solenoid

coil (7) is de-energized and de-magnetized and the
lever (1) is returned to the neutral position.

In addition, the detent magnet can be cancelled if the

lever is operated toward the neutral direction with
enough force to overcome the power of detentes.
 115ZV EX 42-35
42 Function & Structure Hydraulic Group
Pilot valve (S/N 0173~0176)

Pilot valve (S/N 0173~0176)

Float/Down

Raise (Detent)

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

18.20 16.20
White (Male) A B
(for port 4 solenoid) For For
bucket control boom control

A B
(Port 1, 2) (Port 3, 4)
1 2

3 4

From Bottom
K115V2U42003
115ZV EX 42-36
42 Function & Structure Hydraulic Group
Pilot valve (S/N 0173~0176)

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
12

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) K92V2E42001

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
13. —
 115ZV EX 42-37
42 Function & Structure Hydraulic Group
Pilot valve (S/N 0173~0176)

Pilot valve function

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

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

K92V2E42003

The pilot valve has holes of lengthwise direction in

P which the reducing valve is built. The reducing valve
section are consist of spool (17), spring for secondary
Reducing pressure (15)(16), return spring (14) and spring seat
valve (22)(23). Being inserted in plug (12), push rod (10) can
be moved smoothly to change the bending quantity of
Multiple
From
secondary pressure spring (15)(16).
control valve
front brake
Oil pack accumulator
K92V2E42002 Return spring (14) contacts casing (24) and spring seat
(22)(23). This spring works on returning push rod (10) to
it’s original position without relation to secondary 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) close the pump port
and the tank port is opened, the oil pressure is not
applied to the multiple control valve oil pack. The spool
of multiple control valve is held in neutral by its center-
ing springs. There is no oil flow to the cylinder.
115ZV EX 42-38
42 Function & Structure Hydraulic Group
Pilot valve (S/N 0173~0176)

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
3 maintains a constant pressure to the multiple control
18
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-
ing pump to the cylinder is also proportional. Cylinder
speed is easily controlled.
22 23
When lever (1) is moved fully forward or back the multi-
15 16
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

K92V2E42004

When lever (1) is shifted from the neutral, push rod (10)
and spring seat (23) are pushed down at the same time,
the value of secondary pressure spring is changed.
Spool (17) is forced down by the secondary pressure
spring (16) and then the tank port is closed and the
pump port is opened.

As a result, the pressurized oil from the pump flows into

the multiple control valve oil pack. The spool of the 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.
 115ZV EX 42-39
42 Function & Structure Hydraulic Group
Pilot valve (S/N 0173~0176)

Pre-detent and detent magnet solenoid

1

21

19 20
21
19
20 3

2
18 3

7
18
3 8 The figure that fixing
disc (8) is absorbed
by the detent
9
solenoid sub (7).
10

T P

P
Actuation of electromagnetic detent

K92V2E42006
Actuation of pre-detent

K92V2E42005 In addition, the detent magnet works to hold the lever at

it’s position, when the lever is shifted to "Bucket Roll
The pre-detent function is installed in the "Bucket Roll Back" or "Boom Raise" or "Boom Float" position.
Back" or "Boom Float" position that extends the change
of feeling to operator just before electromagnetic detent. Detent magnet section consists of detent solenoid sub
(7), fixing disc (8)(9) and push rod (2)(3).
The pre-detent section consists of detent bush (18),
spring (19), detent ring (20) and steel ball (21). When the circuit for the bucket leveler or the boom kick-
out (option) is turned on, detent solenoid sub (7) is ener-
Push rod (3) installed in the "Bucket Roll Back" or gized and magnetized so that fixing disc (8) of forced up
"Boom Float" position has the notch that steel ball is fit- side (opposite side) is held by magnetic force of detent
ted in. solenoid coil (7).

When push rod (3) is shifted and steel ball run upon the For this reason, lever (1) is held at that position if you
step, operation torque grows big by reactive force of keep the hand away from lever (1).
spring, because the spring is shorted.
Therefore displacement of push rod (10) is maintained,
This extends the change of feeling to operator just and it is the structure that continues generating the sec-
before electromagnetic detent. ond pressure constantly.

When the proximity switch is turned off, detent solenoid

coil (7) is de-energized and de-magnetized and lever (1)
is returned to the neutral position.

In addition, the detent magnet can be cancelled if the

lever is operated toward the neutral direction with
enough force to overcome the power of detents.
115ZV EX 42-40
42 Function & Structure Hydraulic Group
Pilot valve (S/N 0177~)

Pilot valve (S/N 0177~)

Float/Down

Raise (Detent)

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

Blue (Female)
Dump
From Top
(for port 2 solenoid)

18.20 16.20
White (Male)
A B
(for port 4 solenoid)
For For
bucket control boom control

P T

1 2 2 4

A B
1 2 (Port 1, 2) (Port 3, 4)

3 4

From Bottom
90Z542003
 115ZV EX 42-41
42 Function & Structure Hydraulic Group
Pilot valve (S/N 0177~)

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
9
10 10 10 10
11
12

23

22 23 22 16
14
14
15 To tank port
16 15

From pump 24
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) 90Z542004

1. Lever 13. —
2. Push rod 14. Spring
3. Push rod 15. Spring
4. Push rod 16. Spring
5. Detent solenoid coil (boom down / float) 17. Spool
6. Detent solenoid coil (boom raise) 18. Detent bushing
7. Detent solenoid coil (bucket level) 19. Spring
8. Fixing disc 20. Detent ring
9. Fixing disc (Identifying mark) 21. Steel ball (4 pieces per spool)
10. Push rod 22. Spring seat
11. Spring 23. Spring seat
12. Plug 24. Casing
115ZV EX 42-42
42 Function & Structure Hydraulic Group
Pilot valve (S/N 0177~)

Pilot valve function

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

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

90Z542006

T
The pilot valve has holes of lengthwise direction in
P which the reducing valve is built. The reducing valve
section are consist of spool (17), spring for secondary
Reducing pressure (15)(16), return spring (14) and spring seat
valve (22)(23). Being inserted in plug (12), push rod (10) can
be moved smoothly to change the bending quantity of
Multiple
From
secondary pressure spring (15)(16).
control valve
front brake
Oil pack accumulator
90Z542005 Return spring (14) contacts casing (24) and spring seat
(22)(23). This spring works on returning push rod (10) to
it’s original position without relation to secondary 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) close the pump port
and the tank port is opened, the oil pressure is not
applied to the multiple control valve oil pack. The spool
of multiple control valve is held in neutral by its center-
ing springs. There is no oil flow to the cylinder.
 115ZV EX 42-43
42 Function & Structure Hydraulic Group
Pilot valve (S/N 0177~)

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
3 maintains a constant pressure to the multiple control
18
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-
ing pump to the cylinder is also proportional. Cylinder
speed is easily controlled.
22 23
When lever (1) is moved fully forward or back the multi-
15 16
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

90Z542007

When lever (1) is shifted from the neutral, push rod (10)
and spring seat (23) are pushed down at the same time,
the value of secondary pressure spring is changed.
Spool (17) is forced down by the secondary pressure
spring (16) and then the tank port is closed and the
pump port is opened.

As a result, the pressurized oil from the pump flows into

the multiple control valve oil pack. The spool of the 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.
115ZV EX 42-44
42 Function & Structure Hydraulic Group
Pilot valve (S/N 0177~)

Pre-detent and detent magnet solenoid

1

21

19 20
21
19
20 3

2
18 3

7
18
3 8 The figure that fixing
disc (8) is absorbed
by the detent
9
solenoid sub (7).
10

P
T

P
Actuation of electromagnetic detent

90Z542009
Actuation of pre-detent

90Z542008 In addition, the detent magnet works to hold the lever at

it’s position, when the lever is shifted to "Bucket Roll
The pre-detent function is installed in the "Bucket Roll Back" or "Boom Raise" or "Boom Float" position.
Back" or "Boom Float" position that extends the change
of feeling to operator just before electromagnetic detent. Detent magnet section consists of detent solenoid sub
(7), fixing disc (8)(9) and push rod (2)(3).
The pre-detent section consists of detent bush (18),
spring (19), detent ring (20) and steel ball (21). When the circuit for the bucket leveler or the boom kick-
out (option) is turned on, detent solenoid sub (7) is ener-
Push rod (3) installed in the "Bucket Roll Back" or gized and magnetized so that fixing disc (8) of forced up
"Boom Float" position has the notch that steel ball is fit- side (opposite side) is held by magnetic force of detent
ted in. solenoid coil (7).

When push rod (3) is shifted and steel ball run upon the For this reason, lever (1) is held at that position if you
step, operation torque grows big by reactive force of keep the hand away from lever (1).
spring, because the spring is shorted.
Therefore displacement of push rod (10) is maintained,
This extends the change of feeling to operator just and it is the structure that continues generating the sec-
before electromagnetic detent. ond pressure constantly.

When the proximity switch is turned off, detent solenoid

coil (7) is de-energized and de-magnetized and lever (1)
is returned to the neutral position.

In addition, the detent magnet can be cancelled if the

lever is operated toward the neutral direction with
enough force to overcome the power of detents.
 115ZV EX 42-45
42 Function & Structure Hydraulic Group
Multiple Control Valve (KML35A/2T103)

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

Boom Bucket Multiple control valve specifica-

B2 A2 a2 B1 A1 a1 T tions
Model KML35A/2T 103
20.6 MPa
Main relief valve setting pressure (210 kgf/cm2)
(2,990 psi)
P1
23.5 MPa
Overload relief valve setting pressure
(240 kgf/cm2)
(Port A1, B1)
(3,410 psi)
Rod side Installed
b2 b1 P Bucket
OLRV Bottom side Installed
Hydraulic line diagram 95ZV42023 installation
point Rod side Non-installed
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: MUV Bucket
Bottom side Installed
installation
point Rod side Installed
1. Main relief valve Boom
Bottom side Non-installed

Relieves the pressure when the working pressure

exceeds the relief setting pressure.

2. Bucket spool

Used for bucket operation, such as roll back, hold-

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”.
 115ZV EX 42-47
42 Function & Structure Hydraulic Group
Multiple Control Valve (KML35A/2T103)

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
Tank port
stroke end, or if the pressure is above the set pressure,
the oil fed from the pump will be discharged into the
tank through this valve (main relief valve) to prevent Pump
pump and pipe damage. A port

Spring Body
Spring seat

Seat Filter Passage A

Passage C Passage D

Tank
Adjusting screw port

Pump
A
port

Lock nut
Plunger
Cap nut Plug
90ZV42018

1. 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.

2. When the oil pressure exceeds the set point

- When the oil pressure in the cylinder line rises above

the pressure set by the spring, the poppet is moved
to the left and opens the port. Then the oil in the
chamber A flows to the tank through passage C and
D.
As a result, the pressure in the chamber A rapidly
lowers and the plunger is moved to the left. Then the
plunger opens the port to the tank port and the pres-
surized oil in the pump port escapes to the tank port.
115ZV EX 42-48
42 Function & Structure Hydraulic Group
Multiple Control Valve (KML35A/2T103)

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
Another possible cause of low pressure is contamina- the 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
20.6 ± 0.5 MPa (210 ± 5 kgf/cm2) (2,990 ± 71 psi)

IMPORTANT
Always be certain to tighten locknut when finished
adjustment.
Only set pressures in accordance with setting specifi-
cations.
 115ZV EX 42-49
42 Function & Structure Hydraulic Group
Multiple Control Valve (KML35A/2T103)

Multiple control valve overload Overload relief valve operation

relief valve
When the oil pressure is at the set point or below:
(Installed on both the rod and bottom sides of the bucket
circuit)
Orifice1 Plunger
seat
Relief poppet Passage A Plunger
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
strong and the oil pressure is greatly increased, the
A
overload relief valve will return the oil to the tank to pro-
tect the cylinders and pipes from breakage.

Tank Cylinder
Spring port port
Passage B
Seat 90ZVE42013

The pressurized oil from the cylinder flows to the

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

When the oil pressure exceeds the set point:

Passage C Passage D
Adjusting screw Plunger

Lock nut Tank Cylinder

Body port port
90ZVE42014

When the oil pressure in the cylinder line rises above

the pressure set by the spring, the relief poppet is
moved to the left and opens the port. Then the oil in
the chamber A flows to the tank through passage C
and D.
As a result, the pressure in the chamber A rapidly
lowers and the plunger is moved to the left. Then the
plunger opens the port to the tank port and the pres-
surized oil in the cylinder port escapes to the tank
port.
115ZV EX 42-50
42 Function & Structure Hydraulic Group
Multiple Control Valve (KML35A/2T103)

Make-up valve operation Adjusting set pressure

Plunger Plunger Spring

seat
Adjusting screw

Tank Cylinder
port port Lock nut Tank Cylinder
Passage E port port
90ZVE42015 90ZVE42026

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
than tank pressure, the plunger seat is moved to the Set pressure
right by the pressure area difference of the plunger seat 23.5 ± 0.5 MPa (240 ± 5 kgf/cm2) (3,410 ± 71 psi)
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
cylinder.
 115ZV EX 42-51
42 Function & Structure Hydraulic Group
Multiple Control Valve (KML35A/2T103)

Multiple control valve make-up valve

(Installed on the rod side of the boom circuit)

The make-up valve is installed in the circuit between the

control spool and boom cylinder.

Extremely quick boom lowering may generate low 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 operation“for the
makeup valve operation.
115ZV EX 42-52
42 Function & Structure Hydraulic Group
Multiple Control Valve (KML35A/2T103)

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.
left 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.
 115ZV EX 42-53
42 Function & Structure Hydraulic Group
Multiple Control Valve (KML35A/2T103)

2. “Bucket Dump” position

E D
B1 A1

To pilot valve

Pa1

From pilot valve Spool

Pb1

C
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. As valve (E) opens so that the oil in the tank port flows
a result, the oil from the pump opens the load check into the rod side of the cylinder.
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.
115ZV EX 42-54
42 Function & Structure Hydraulic Group
Multiple Control Valve (KML35A/2T103)

Multiple control valve boom spool

Boom spool operation

1. “Boom Raise” position

D
B2 A2

From pilot valve

Pa2

To pilot valve Spool

Pb2

C
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. As
a result, the oil from the pump opens the load check
valve (D), flows from the A2 port into the bottom side
of the boom cylinder, and finally raises the boom.

- On the other hand, the oil on the rod side of the

boom cylinder returns from the B2 port to the tank.
 115ZV EX 42-55
42 Function & Structure Hydraulic Group
Multiple Control Valve (KML35A/2T103)

2. “Boom Down” position

E D
B2 A2

To pilot valve

Pa2

From pilot valve Spool

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. As
a result, the oil from the pump opens the load check
valve (D), flows from the B2 port into the rod side of
the boom cylinder, and finally moves down the
boom.

- On the other hand, the oil on the bottom side of the

boom cylinder returns from the A2 port to the tank.

- Extremely quick lowering of the boom while the

engine (pump) revolution is low generates negative
pressure (or a void) on the rod side of the cylinder.
To prevent generation of negative pressure (or a
void), the make-up valve (E) of the overload relief
valve opens so that the oil in the tank port flows into
the rod side of the cylinder.
115ZV EX 42-56
42 Function & Structure Hydraulic Group
Multiple Control Valve (KML35A/2T103)

3. “Boom Float” position

B2 A2

To pilot valve
Pa2

From pilot valve Spool

Pb2

From pump 95ZV42028

- When the control lever is pushed downward beyond

the “Boom Down” position to the “Boom Float” posi-
tion, the spool moves fully to the right by the pres-
sure oil from the Pb2.

- As a result of this, all ports (i.e., pump port, cylinder

rod end port and cylinder bottom end port) are con-
nected 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.
 115ZV EX 42-57
42 Function & Structure Hydraulic Group
Adapter (Orifice)

Adapter (Orifice)

O-ring ø1.3 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 posi- tion.
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.
115ZV EX 42-58
42 Function & Structure Hydraulic Group
Vibration Damper (OPT)

Vibration Damper (OPT)

Vibration damper hydraulic circuit
4

(16) (18) (15)

(H)

(X)
(Ac) 3

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 Vibration damper function

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

When the machine travelling speed goes down to 5 km/

h (3.1 mile/h) or slower, no signal transferred from the
transmission controller, as a result, the vibration damper
does not work.
 115ZV EX 42-59
42 Function & Structure Hydraulic Group
Vibration Damper (OPT)

Vibration damper operation

Preparation mode (vibration damper switch is

OFF)

(16) (18) (15)

(H)

(X)
(Ac) 3

9.5 L
(T) (Ac2) (Ac1) Gas pressure
(14)
1.96 MPa
(20 kgf/cm2) From multiple
(Ac1) (284.2 psi) control valve
(5)

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

The oil from the pump is reduced to 8.3 MPa (85 kgf/
cm2) (1,209 psi) by the reducing valve (13), and the oil
flows into the accumulator (3) through the check valve
(14), port Ac1 and Ac of the valve assembly (2).

The accumulator pressure applies to the upper part of

the selector valve (15) through the shuttle valve (18)
and solenoid valve (16), and presses down the poppet.
Although the accumulator pressure applies to the lower
part of the selector valve (15), the boom cylinder bottom
pressure is being kept because the poppet is pressed
down by area difference.

When the boom cylinder bottom pressure is higher than

the accumulator pressure, the boom cylinder bottom
pressure from port H of the valve assembly (2) applies
to the upper part of the selector valve (15) through the
shuttle valve (18) and solenoid valve (16), and to the
lower part of the selector valve (15). Because the pop-
pet is pressed down by area difference of both cham-
bers, the boom cylinder bottom pressure is being kept.
115ZV EX 42-60
42 Function & Structure Hydraulic Group
Vibration Damper (OPT)

Running mode (vibration damper switch is ON)

(16) (18) (15)

(H)

(X)
(Ac) 3

9.5 L
(T) (Ac2) (Ac1) Gas pressure
(14)
1.96 MPa
(20 kgf/cm2) From multiple
(Ac1) (284.2 psi) control valve
(5)
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 115V2E42029

The vibration damper switch is ON, and when the Therefore, when the pressure develops at the boom cyl-
machine travelling speed reaches more than 7 km/h the inder rod side by pitching motion in roading, oil is
solenoid valves (11)(16) come to ON by a signal from drained to the tank. When the negative pressure devel-
the transmission controller. ops at the boom cylinder rod side, oil from the tank fills
the boom cylinder rod side.
Pressurized oil in the upper part of the check valve (15)
is drained to the tank port when the solenoid valve (16)
is switched.

In the lower part of the check valve (15), the accumula-

tor 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 the accumulator (3) is connected.
Then the accumulator absorbs the oil pressure fluctua-
tions in the boom cylinder bottom side.

On the other hand, when the solenoid valve (11) comes

to ON, the hydraulic line between the boom cylinder rod
side and the tank port is connected.
 115ZV EX 42-61
42 Function & Structure Hydraulic Group
Vibration Damper (OPT)

Vibration damper 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)
Hyd. circuit

95V2E42012
115ZV EX 42-62
42 Function & Structure Hydraulic Group
Vibration Damper (OPT)

Reducing valve Check valve

Passage A

Accumulator Bleeder
A 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)
 115ZV EX 42-63
42 Function & Structure Hydraulic Group
Vibration Damper (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 0.69 A
Resistance 34.8 Ω
115ZV EX 42-64
42 Function & Structure Hydraulic Group
Vibration Damper (OPT)

Vibration damper valve assembly (Accumulator circuit)

Outline drawing
6 2

X 1
3
4

Tank
Boom cylinder
H bottom side

Reducing
AC1
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)

Hyd. circuit
95V2E42017
 115ZV EX 42-65
42 Function & Structure Hydraulic Group
Vibration Damper (OPT)

Shuttle valve Solenoid valve

Movable iron core

Passage A Solenoid
valve

Solenoid

Passage B
Accumulator
Rod

Passage C

Ball 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.

Solenoid specifications
Voltage DC 24 V
Current 0.52 A
Resistance 45.9 Ω
115ZV EX 42-66
42 Function & Structure Hydraulic Group
Vibration Damper (OPT)

Check valve

Passage B

Pressure receive
face E
A
Reducing valve
(sol. 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.
 115ZV EX 42-67
42 Function & Structure Hydraulic Group
Vibration Damper (OPT)

Accumulator (for vibration damper)

2 1 9 8 7 6 5 6 7 4 14 8 9 3 11 13 10 12

K90ZV42014

1. Body While the vibration damper operates, the accumulator

2. Hydraulic cap absorbs fluctuation of the boom cylinder bottom pres-
3. Gas cap sure by air cushion function of the nitrogen gas charged
4. Piston in the cylinder.
5. O ring
6. Washer The cylinder contains N2 (Nitrogen) gas at 1.96 MPa
7. Ring (20 kgf/cm2) (285 psi).
8. Seal
9. Washer
10. Gas valve Accumulator specification
11. Gas valve O ring
12. Gas valve guard Maximum operation pressure
20.6 (210) (2,986)
13. Bolt MPa (kgf/cm2) (psi)
14. Name plate Nitrogen gas pressure
1.96 (20) (285)
MPa (kgf/cm2) (psi)
Capacity L (gal) 9.5 (2.5)
115ZV EX 42-68
42 Function & Structure Hydraulic Group
Vibration Damper (OPT)

Vibration damper hydraulic line

Multiple control valve

Accumulator

(S/N 0120~, 9011~)

(S/N 0101~0120,
9001~9010)

K115ZVE42002
 115ZV EX 42-69
42 Function & Structure Hydraulic Group
Steering System

Steering System
The pilot operating method is adopted in the steering
system. A small amount of pilot oil supplied from the
Orbitrol® controls the steering valve to realize steering
operations.

When the steering wheel is turned, oil at a flow rate 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
115ZV EX 42-70
42 Function & Structure Hydraulic Group
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
the steering valve. 1. Spool 5. Drive shaft
2. Sleeve 6. Centering spring
This Orbitrol® is the closed center and non-load reaction 3. Stator 7. Cross pin
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
 115ZV EX 42-71
42 Function & Structure Hydraulic Group
Orbitrol®

- Spool (1) and sleeve (2) as a set form a rotary-type Orbitrol® specifications
directional change-over valve. The spool (1) in this
valve is linked to the steering wheel by means of a
spline. (S/N ~0124, ~9011)
ND-K2-D
Model
(S/N 0125~, 9012~)
- When the steering wheel is not being turned, the ND-K5-D
spool (1) and the sleeve (2) are held in the neutral Theoretical discharge (cm3/rev) 120
position by the centering spring (6); the oil groove of
Operation pressure MPa (kgf/cm2) (psi) 3.5 (36) (512)
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.

- The rotor (4) rotation is transmitted to the valve part

by means of the connected drive shaft (5), and the
degree of valve opening is regulated depending on
how fast the steering wheel is being turned.
115ZV EX 42-72
42 Function & Structure Hydraulic Group
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
1. Spool 5. Drive shaft
2. Sleeve 6. Centering spring
3. Stator 7. Cross pin
85V2E42019
4. Rotor 8. Check valve

- The spool (1) and the sleeve (2) of the valve part
each have a slit into which the centering spring (6)
consisting of plate springs is set.

- When the steering wheel is not being turned, the

spool (1) and the sleeve (2) are kept in the neutral
position by means of the center spring (6).

- This Orbitrol® is the closed center and non-load

reaction type.
When in the neutral position, the oil groove of the
spool does not match the oil hole of the sleeve, so
the flow route of oil from the pump to the steering
valve is totally closed.
 115ZV EX 42-73
42 Function & Structure Hydraulic Group
Orbitrol®

Turn
(When the steering wheel is being turned)

To steering
valve Pa port

8
From steering
valve Pb port

T
6
7 L

R
2 P From reducing
valve (pump)
5
1

3
4

K115ZVE42003

1. Spool 5. Drive shaft

2. Sleeve 6. Centering spring
3. Stator 7. Cross pin
4. Rotor 8. Check valve
6

- When in the neutral position, the valve part is totally

1
closed and oil remains sealed inside the rotor, and
the rotor cannot move. The sleeve (2) is directly
T linked to the rotor by means of a cross pin (7) and
2 drive shaft (5); it is also fixed.

L - When the steering wheel begins to be turned, rotary

Oil hole
force is applied to the spool (1), which then pushes
and compresses the centering spring (6) set in the
slit; the oil groove of the spool matches the oil hole of
R
Oil groove 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.

65ZV42036
115ZV EX 42-74
42 Function & Structure Hydraulic Group
Orbitrol®

Orbitrol® feed-back mechanism

operation

K115ZVE42004

- 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.
 115ZV EX 42-75
42 Function & Structure Hydraulic Group
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 the
spool (1) and sleeve (2). In other words, while the
steering wheel is being turned, the sleeve (2) chases
the spool (1) in rotation, trying to close the hydraulic
circuit.

- As steering speed increases, the amount of delay

(displacement angle) of the sleeve (2) increases,
and the flow rate rises.
115ZV EX 42-76
42 Function & Structure Hydraulic Group
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

rotor due to very fast rotation or turning the steering
wheel vigorously, rotation of the sleeve and spool
takes place by means of the cross pin.

- With this rotation, and at the same time due to the

relationship of the position between the sleeve port
and the housing port, the position of oil flowing into
the rotor part is gradually delayed in sequence.
 115ZV EX 42-77
42 Function & Structure Hydraulic Group
Steering Valve (KVS32-A4.0/21)

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
3. Main relief valve
4. Overload relief valve (with make-up valve)
5. Gauge port

115V2U42001
115ZV EX 42-78
42 Function & Structure Hydraulic Group
Steering Valve (KVS32-A4.0/21)

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: 0.7
(S/N
(S/N~0121,
~9003)
T Also inside the steering spools are check valves
RF
~9003) (G) MR which apply a back pressure to oil returning from
P. B.
3.0
Orifice
the cylinders.
Pc
P
K115ZVE42005
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.
3. Main relief valve

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

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), the 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.
115ZV EX 42-80
42 Function & Structure Hydraulic Group
Steering Valve (KVS32-A4.0/21)

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

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

Steering valve flow control spool

Loading circuit Pump Spring

PA

PB

Variable throttle Steering circuit

Loading circuit Pump

PA

PB

Variable throttle Steering circuit 115V2E42018

When the pump discharge amount is small, the 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.
 115ZV EX 42-83
42 Function & Structure Hydraulic Group
Steering Valve (KVS32-A4.0/21)

Steering valve main relief valve

When the pressure is at the preset value or
less

Loading circuit Pump Flow control spool

Filter

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.

115ZV EX 42-84
42 Function & Structure Hydraulic Group
Steering Valve (KVS32-A4.0/21)

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.
 115ZV EX 42-85
42 Function & Structure Hydraulic Group
Steering Valve (KVS32-A4.0/21)

Steering valve overload relief

valve

External force

B A

Overload relief valve Overload relief valve

with make-up valve with make-up valve
(Operates as (Operates as overload
make-up valve) relief valve)

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.
115ZV EX 42-86
42 Function & Structure Hydraulic Group
Steering Valve (KVS32-A4.0/21)

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.
 115ZV EX 42-87
42 Function & Structure Hydraulic Group
Steering Valve (KVS32-A4.0/21)

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
115ZV EX 42-88
42 Function & Structure Hydraulic Group
Steering Valve (KVS32-A4.0/21)

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.
 115ZV EX 42-89
42 Function & Structure Hydraulic Group
Stop Valve

Stop Valve

17 mm (Full stroke)
From pilot valve
(0.67 in)

To steering valve

(S/N 0101~0140, 6 2 1 5
9001~9020)

DR

8 10 12 9 11 13 4 3 14 7

6 2 1 5
(S/N 0141~0179, 9021~)

DR

10 12 9 11 4 3 14 7

B
1. Housing 8. Bolt
2. Spool 9. Spacer
3. Plug 10. Boot
4. Washer 11. U-packing
5. Plug 12. Dust seal
6. Flange 13. O-ring
7. Spring 14. O-ring A DR
K115ZV42036
115ZV EX 42-90
42 Function & Structure Hydraulic Group
Stop Valve

(S/N 0180~)

(Full stroke) 14.5 0.5 mm (0.57 0.02 in)

From Orbitrol®

To steering valve

7 3 8 2 1 6

DR

11 13 10 12 5 4 14 9

K80Z542005

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
 115ZV EX 42-91
42 Function & Structure Hydraulic Group
Stop Valve

Stop valve function

(S/N 0101~0140, 9001~9020) Port B to Port A from

steering valve pilot valve

Stopper

Installed
on front chassis
Bolt

Installed on rear chassis

115ZV42021

(S/N 0141~, 9021~) Port B to Port A from

Spool steering valve pilot valve

Stopper

Installed
on front chassis

Installed on rear chassis

115V2U42009

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.
115ZV EX 42-92
42 Function & Structure Hydraulic Group
Stop Valve

Stop valve operation

(S/N 0101~0140, 9001~9020) (S/N 0141~, 9021~)

P P

B A B A

Pb Pa Pb Pa

97ZV42044 95V2E42049

Shortly before a full turn, the stopper installed on the

front chassis pushes the bolt or spool head of the stop
valve installed on the rear chassis to shut down the port
A and the port B. As a result, the pilot line is closed,
returning the steering spool to the neutral position.

After a full turn, when the steering wheel is turned in the

opposite direction, the spool of the stop valve remains
pushed in, closing the line. As a result, the pilot oil
opens the check valve and flows out.
 115ZV EX 42-93
42 Function & Structure Hydraulic Group
Reducing Valve (for Orbitrol®)

Reducing Valve (for Orbitrol®)

[S/N 0104~, 9004~] [S/N ~0103, ~9003]

TS B A

B A

T Spring
Spring Hydraulic circuit
diagram
Hydraulic circuit
diagram
Sleeve (T)
Tank

Sleeve (T) Plunger

Tank Passage Z
(A)
Pump B
Plunger A
Passage Z Passage Y
(A)
Pump B

A
Passage Y (B)
(TS)
Orbitrol®

(B)

Orbitrol® 115ZV42037

The oil fed from the pump flows into the Orbitrol® circuit This pressurized oil is supplied to the steering valve
by way of passage Y and port A in the plunger. pilot port through the Orbitrol® and moves the steering
spool.
When the oil pressure in the Orbitrol® circuit reaches or
exceeds the set pressure (spring force), the plunger is Set pressure
moved up by the oil pressure and passage Y is closed 3.5 MPa (36 kgf/cm2) (512 psi)
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.
115ZV EX 42-94
42 Function & Structure Hydraulic Group
Steering Line Filter

Steering Line Filter

From pump FILTER To reducing

(steering valve) 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-
mulator reducing valve assembly.
These filters must be removed, inspected and cleaned
or replaced every 2,000 hours of operation.

Line filter

Reducing valve

Steering valve

115ZV42032
 115ZV EX 42-95
42 Function & Structure Hydraulic Group
Fan Motor System

Fan Motor System

3
1

A
T3

T2
T1

Detail of A (S/N 0101~0120, 9001~9010)

3 2
2
1 3
1

T3

T2
T1

Nut
Detail of A (S/N 0121~, 9011~)

K115ZV42018

1. Fan motor :
2. Fan T1: 93.7 N-m (9.55 kgf-m) (69 lb-ft)
3. Flange T2: 142 N-m (5.40 kgf-m) (39 lb-ft)
T3: 474 N-m (36 kgf-m) (262 lb-ft)

T1, T2, T3: With lubrication oil (Engine oil or gear oil)
115ZV EX 42-96
42 Function & Structure Hydraulic Group
Fan Motor Line (S/N 0101~0120, 9001~9010)

Fan Motor Line (S/N 0101~0120, 9001~9010)

Cooling fan Fan motor (71)

Solenoid valve 91.0

(74)(75) cm3/rev
Number of
revolutions
T2 DR of fan (min-1)
ECM (rpm)
High speed:
A 1,600 Solenoid coil is
de-energized.
Fan motor relay
F3
B
Water temperature From reducing valve (28)
< 94 ºC...ON Low speed:
C in valve block (26) 1,120 Solenoid coil is
Water temperature Pressure is 3.5 MPa energized.
> 94 ºC...OFF 2
(36 kgf/cm ) (512 psi)
P2
T1
PG
Valve assembly
(72) TG P1
Idle Full
High pressure set: Number of revolutions of engine
19.0 MPa (194 kgf/cm2)
(2,759 psi)
Low pressure set: From unloader
9.5 MPa (97 kgf/cm2) Fan revolution status
(1,379 psi) valve (22)
Relief
valve (73) Shown with solenoid coil de-energized and
relief valve in the high pressure position.
Hydraulic line diagram

K115ZVE42006

The oil discharged from the pilot & brake pump enters When “Engine water temperature > (greater than)
the fan motor by way of the unloader valve, and drives 94ºC (200ºF)”
the fan.
The water temperature switch is OFF, and the power is
As the number of revolutions of the engine increases, not supplied to the solenoid valve (74)(75) as shown in
the number of revolutions of the fan also increases as the upper left figure. The pilot pressure from the reduc-
shown in the upper right figure. However, the maximum ing valve (28) enters the relief valve (73), and sets the
fan speed is regulated by the relief valve (73) integrated relief valve (73) to high pressure. As a result, the maxi-
into the line. mum fan speed is set to 1,600 min-1 (rpm), preventing
rise of the engine water temperature, the hydraulic oil
When “Engine water temperature < (less than) 94ºC temperature, etc.
(200ºF)”
The fan motor revolution changes as follows.
The water temperature switch is ON, and the power is 1,120 min-1 (rpm)
supplied to the solenoid valve (74)(75). As a result, the 1,600 min-1 (rpm) at 94±2ºC (200±4ºF)
relief valve (73) is set to low pressure, and the maxi-
mum fan speed is set to 1,120 min-1 (rpm). 1,600 min-1 (rpm)
1,120 min-1 (rpm) at 84±2ºC (184±4ºF)
 115ZV EX 42-97
42 Function & Structure Hydraulic Group
Fan Motor Line (S/N 0101~0120, 9001~9010)

(S/N 0101~0120, 9001~9010)

71 Fan motor

Relief valve 73

72 Fan motor
valve
assembly

74,75
Solenoid valve
assembly

26
Valve unit

22 Unloader valve
To hydraulic
oil cooler

Hydraulic tank

Note
K115ZVE42007
The numbers above correspond to those in the
"Loading/Steering Hydraulic Line (S/N 0101~0120)"
page 92-5 or “"Loading/Steering Hydraulic Circuit
(S/N 9001~9010)" page 92-7.
115ZV EX 42-98
42 Function & Structure Hydraulic Group
Fan Motor Line (S/N 0101~0120, 9001~9010)

Fan Motor (GM30C)

15 16 17 4 5

3 2

6
7

18 9 10 11 12 13 14
97ZV42049

1. Drive gear Fan motor specifications

2. Driven gear
3. Front cover Displacement capacity 91 cm3/rev
4. Center section Operating number of revolutions 1,600 min-1 (rpm)
5. Rear cover
Motor efficiency 95%
6. Oil seal (inner)
7. Oil seal (outer)
8. Retaining ring IMPORTANT
9. Gland seal
This motor is designed to rotate only in one direction.
10. O-ring
Hoses must be connected correctly or damage to
11. Wear plate (front)
motor will result from reverse rotation.
12. Wear plate (rear)
13. O-ring
14. Seal retainer
15. Bolt
16. Nut
17. Washer
18. Plug (drain)
 115ZV EX 42-99
42 Function & Structure Hydraulic Group
Fan Motor Line (S/N 0101~0120, 9001~9010)

Valve Assembly (for Fan Motor)

Oil from
unloader
valve
To fan motor

P1

PX
PG
P2

B A
T1 2. Relief valve 91.0
Oil from TG
(Two step relief)* cm3/rev
reducing DR
valve T2

A
1

T2 B
C
Oil from
fan motor P2
T1
2 PG
1. Solenoid P1
Valve TG
valve coil

Hydraulic line diagram

115ZV42034

Relief valve high pressure set value:

19.0 MPa (194 kgf/cm2) (2,759 psi)

Relief valve low pressure set value:

9.5 MPa (97 kgf/cm2) (1,379 psi)

Note
Refer to the following section, Relief Valve (Two-step
Relief).
115ZV EX 42-100
42 Function & Structure Hydraulic Group
Fan Motor Line (S/N 0101~0120, 9001~9010)

Relief Valve (Two-step Relief)

3 4 5 11 12 14 15 16 21 22 23 24

Pump Pilot
port port

1 Tank
port
2 6 7 8 9 10 13 17 18 19 20 95ZV42060

1. Piston 13. Poppet

2. Plunger 14. Body
3. Backup ring 15. O-ring
4. O-ring 16. O-ring
5. O-ring 17. Spring
6. Spring 18. Plug
7. Spring 19. Piston
8. O-ring 20. O-ring
9. Backup ring 21. Lock nut
10. Seat 22. Adjustment screw (high pressure side)
11. Filter stopper 23. Lock nut
12. Filter 24. Adjustment screw (low pressure side)

Note
For pressure adjustment, set the pressure on the high
pressure side first.
 115ZV EX 42-101
42 Function & Structure Hydraulic Group
Fan Motor Line (S/N 0101~0120, 9001~9010)

Relief valve (Two-step relief) operation

When the pressure is lower than the setting pressure

1 A

Pump port Pilot

(to fan) port

Tank
port
2
10
95ZV42061

The chamber B is filled with the pressure oil which has

entered by way of the hole (A) in the piston (1).

As a result, plunger (2) is in secure contact with the seat

(10).

When the pressure is greater than the setting pressure (low pressure)

13 17

Pump port Pilot

(to fan) port

Tank
port
10 C
14 95ZV42062

When the pump port pressure reaches the setting pres-

sure of spring (17), the oil pressure opens poppet (13)
and flows into the tank port from hole C by way of the
clearance between the seat (10) and the body (14).
115ZV EX 42-102
42 Function & Structure Hydraulic Group
Fan Motor Line (S/N 0101~0120, 9001~9010)

13 17
D
E

Pump port Pilot

(to fan) port

Tank
port
1 19
2
95ZV42063

When the poppet (13) is open, the oil pressure in cham-

ber B decreases and piston (1) moves to the right. The
pressure difference between the pump port and cham-
ber B caused by the ringlike portion of the piston (1) in
part D (where the piston diameter is a little smaller than
the inner diameter of the plunger (2)) pushes the
plunger (2) to the right, causing the oil to flow from the
pump port to the tank port.

Setting of high pressure

When the piston (19) is pushed to the left of the E stroke

by the pressure oil coming from the pilot port, the setting
pressure of the spring (17) increases.

Make-up valve operation

Pump Pilot
port port

Tank
port
10
95ZV42064

When the engine is stopped, the pump port pressure When the pump port pressure status changes to nega-
status is changed from positive to negative pressure (or tive pressure (or a void), the tank port pressure applied
a void) because the fan continues to turn by the inertia on plane A of seat (10) moves seat (10) to the right,
but oil is not sent to the fan motor. flowing oil from the tank port to the pump port so that
generation of negative pressure is prevented.
 115ZV EX 42-103
42 Function & Structure Hydraulic Group
Fan Motor Line (S/N 0101~0120, 9001~9010)

Solenoid Valve (for Fan Speed Control)

Solenoid
coil

Moveable iron core

Rod

A
Spool
B
Passage B
C B
Hydraulic circuit diagram
C B
Tank

Oil from the

reducing valve

A Passage A
To the two-stepped relief valve 95ZV42066

Solenoid valve (for fan speed control) oper-

ation
Amp
The power is supplied to the solenoid until the engine
water temperature reaches 94ºC (200ºF). Because oil
port B in the spool is connected to the passage B, the oil a
in the two-stepped relief valve circuit is released to the 0 a
Volt
tank port.

When the engine water temperature reaches 94ºC

(200ºF) or more, voltage is not supplied to the solenoid Varistor
and the status of the valve becomes as shown above.
95ZV42079

As a result, passage A is connected to oil port A in the

spool, and the pressure oil fed from the reducing valve
flows into the two-stepped relief valve and sets the two
stepped relief valve to high pressure. Solenoid valve specifications
Note Voltage DC24 V
The varistor (variable resistor) is used for the solenoid Current 0.52 A
coil to protect the circuit. Resistance 45.9 
115ZV EX 42-104
42 Function & Structure Hydraulic Group
Fan Motor Line (S/N 0121~, 9011~)

Fan Motor Line (S/N 0121~, 9011~)

Cooling fan Fan motor (71) Note
Relief is “pressure
compensated”.
90.0 Check valve (73)
cm3/rev

T1 To drain
P1 From fan motor circuit
Thermo-sensing
T Ps
valve (74)
18.1 MPa (2,625 psi) Radiator High pressure set:
18.0 MPa (184 kgf/cm2)
(2,610 psi)
Low pressure set: To thermo-sensing
8.1 MPa (83 kgf/cm2) valve
Pp (1,175 psi)
T2

Detail of relief valve (72)

Ts P 80ZV42008
From unloader
valve (22)

Relief valve (72)

Hydraulic line diagram
115ZV42040

The cooling fan is driven by the hydraulic motor. The Engine cooling water Max. number of
temperature cooling fan revolutions
maximum number of revolutions of the cooling fan is
80ºC (176ºF) or lower 1,120
regulated, as shown in the chart below, by the set tem-
93ºC (200ºF) or higher 1,600
perature of the thermo-sensing valve (74) installed to
the radiator upper tank.

High temperature
[93ºC (200ºF)] or higher
(min-1)

1,600
Number of fan revolution

Stepless control range

1,120

(645) Low temperature

[80ºC (176ºF)] or lower

0
600 800 (1,305) (1,855) (min-1)

Engine revolution
*Values in ( ) are for reference.

Fan revolution
(Controlled by thermo-sensing valve)

K115ZV42020
 115ZV EX 42-105
42 Function & Structure Hydraulic Group
Fan Motor Line (S/N 0121~, 9011~)

(S/N 0121~, 9011~)

(S/N 0126~,
9012~)

74 Thermo-sensing
(S/N 0121~0125, valve
9011)

72 72 Relief
valve

Fan motor valve

assembly 71 Fan motor
Fan motor valve
(S/N 0126~,
assembly
9012~)
(S/N 0121~0125,
9011)
73
73
Check valve

(S/N 0126~, 9012~)

(S/N 0121~0125,
9011)

22 Unloader valve

Hydraulic tank
K115ZVE42008

Note When the oil pressure reaches the set pressure [18.1
The numbers above correspond to those in the "Load- MPa (185 kgf/cm2) (2,625 psi)] or more, the relief valve
ing/Steering Hydraulic Circuit (S/N 0121~)" page 92-6 (72) releases the pressure oil to the tank, as a result,
and "Loading/Steering Hydraulic Circuit (S/N 9011~)" the maximum fan revolution is regulated.
page 92-8.
On the other hand, the relief valve (72) and the thermo-
sensing valve (74) are connected each other by way of
The pressure oil from the unloader valve flows into the the port Pp. Because the set pressure of the thermo-
port P of the relief valve assembly, enters the fan motor sensing valve (74) changes in accordance with the
from the port P1, and turns the fan motor. engine cooling water temperature, the regulated maxi-
mum number of revolutions varies depending on the
cooling water temperature.
115ZV EX 42-106
42 Function & Structure Hydraulic Group
Fan Motor Line (S/N 0121~, 9011~)

Fan Motor (GM30W)

(S/N 0143~0167, 9021~)

13

8
12

11
10
9

6
5
4
3

14

19

17
15 9
10
11

18

17

16
K115ZV42022

1. Nut 13. Center section

2. Washer 14. Steel ball
3. Stud bolt 15. Driven gear
4. Oil seal (outer) 16. Drive gear
5. Retainer ring 17. O-ring
6. Oil seal (inner) 18. Wear plate
7. Front cover 19. Rear cover
8. O-ring
9. Bushing Note
10. Oil seal (E-ring) The same fan motor model “GM30C” is used on the
11. Seal retainer machines (S/N 0121~0142, 9011~9020). Refer to "Fan
12. Wear plate Motor (GM30C)" page 42-98 for details.
 115ZV EX 42-107
42 Function & Structure Hydraulic Group
Fan Motor Line (S/N 0121~, 9011~)

Fan motor specifications

Displacement capacity 80.0 cm3/rev

Operating number of revolutions 1,500 min-1 (rpm)
Motor efficiency 95%

IMPORTANT
This motor is designed to rotate only in one direction.
Hoses must be connected correctly or damage to
motor will result from reverse rotation.
115ZV EX 42-108
42 Function & Structure Hydraulic Group
Fan Motor Line (S/N 0121~, 9011~)

Fan motor (FM30) (S/N 0168~)

13

11 12
10
9
8
7

6
5
4
3

19
15
17
9
10
18 11

16 K95V42008

1. Nut 11. Seal retainer

2. Washer 12. Wear plate
3. Stud bolt 13. Center section
4. Oil seal (outer) 14. Steel ball
5. Retaining ring 15. Driven gear
6. Oil seal (inner) 16. Drive gear
7. Front cover 17. O-ring
8. O-ring 18. Wear plate
9. Bushing 19. Rear cover
10. Oil seal (E-ring)
 115ZV EX 42-109
42 Function & Structure Hydraulic Group
Fan Motor Line (S/N 0121~, 9011~)

Fan motor specifications

Displacement capacity 80.0 cm3/rev

Operating number of revolutions 1,500 min-1 (rpm)
Motor efficiency 95%

IMPORTANT
This motor is designed to rotate only in one direction.
Hoses must be connected correctly or damage to
motor will result from reverse rotation.
115ZV EX 42-110
42 Function & Structure Hydraulic Group
Fan Motor Line (S/N 0121~, 9011~)

Thermo Sensing Valve

T 1 6 5
12
3
2

11
4
8 3
9 10 7
65ZV42022

Thermo sensing valve specifications

Relief pressure MPa (kgf/cm2) (psi)

Relief pressure MPa (kgf/cm2) (psi)

Set temperature ºC (ºF)

82 (180) 8.1 ± 0.69 (83 ± 7) (1,175 ± 100)
(2,610)(184)18.0
95 (203) 18.0 ± 0.2 (184 ± 2) (2,610 ± 28)

(1,175)(83)8.1

0
82 95 100
(180) (203) (212)

Temperature ºC (ºF)

K115ZV42023

1. Body
2. Wax element
3. O-ring
4. Spring seat
5. Poppet
6. Poppet guide
7. Orifice
8. Spring C
9. Spring B
10. Shim
11. Screen
12. Cap seat
 115ZV EX 42-111
42 Function & Structure Hydraulic Group
Fan Motor Line (S/N 0121~, 9011~)

Thermo sensing valve operation Tank

P2
Tank
1. Poppet
P2

1. Poppet
4. Spring

Relief valve
Relief valve
P1
2. Wax element
3. Piston
P1 65ZV42025

2. Wax element
3. Piston Seat face
65ZV42024 - While the engine cooling water temperature is rising
(pressure increase status):
- When the engine cooling water temperature is lower
than 82ºC (180ºF) (low pressure status): When the engine cooling water temperature exceeds
82ºC (180ºF), the wax element (2) senses the water
The piston (3) of the wax element (2) is in the short- temperature. As the engine cooling water tempera-
est position, and the load to the spring (4) is also ture increases, the piston (3) is gradually pushed
minimum. out.
The poppet (1) is pressed against the seat face by When the piston (3) is pushed out, the spring load
this spring load. When the oil quantity flowing applied on the poppet (1) increases, and the pres-
through the seat is 0.15 L/min (0.04 gal/min), the sure P1 increases also.
pressure P (P1 - P2) is set to 8.1 ± 0.69 MPa (83 ±
7 kgf/cm2) (1,175 ± 100 psi). - When the engine cooling water temperature is 95ºC
(203ºF) or higher (high pressure status):

The stroke of the piston (3) is determined by the

engine cooling water temperature. When the engine
cooling water temperature increases over 95ºC
(203ºF), the piston (3) is pushed out fully as shown
in the figure above, the spring load applied on the
poppet (1) becomes maximum, and the pressure P
increases to the maximum value.
115ZV EX 42-112
42 Function & Structure Hydraulic Group
Fan Motor Line (S/N 0121~, 9011~)

Fan Motor Relief Valve Assembly

1
To tank

PP
To thermo T1
sensing valve

From thermo
sensing valve
TS

T2
To fan motor P1

PS

P
2
From pump (unloader valve) 115ZV42044

1. Relief valve
2 2. Check valve (Make-up valve)
T1 P1

Ps : Tightening torque
T Relief valve (1):
60~65 N-m (6.12~6.63 kgf-m) (44~48 lb-ft)

Pp
T2

Ts P
Hydraulic circuit diagram
95ZV42090
 115ZV EX 42-113
42 Function & Structure Hydraulic Group
Fan Motor Line (S/N 0121~, 9011~)

Fan motor relief valve Fan motor check valve (Make-up valve)

Body

Passage A

Seat
Ball

Pump
Passage C Passage A

Passage B

To thermo Fan motor

A
sensing valve Orifice 2

A To tank
Passage D Passage B

Passage C
Plunger Poppet
Passage E
Orifice 1
Sleeve Sleeve
Tank
From pump
(unloader valve) 65ZV42028 80ZVE42017

The oil from the pump goes through orifices 1 and 2 and While the engine is running, the oil from the pump
passages A and B, then flows from the body perimeter enters the chamber A by way of passages A and B, and
to the thermo-sensing valve. presses both the spring and the poppet against the
sleeve. As a result, the oil does not flow into the tank
When the engine cooling water temperature increases port.
and reaches 93 ± 2ºC (200 ± 3.6ºF), the spring load of
the thermo-sensing valve becomes maximum, and the When the engine is stopped, the pressure in the pump
pressure in the fan motor line increases. When this port (chamber A) becomes negative pressure (or a void)
pressure reaches 18.1 MPa (185 kgf/cm2) (2,625 psi), because the oil is not fed to the fan motor though the
the pressure oil from the orifice 2 pushes up the ball and fan continues to turn by the inertia. In order to prevent
releases into the tank by way of passages C and D. generation of negative pressure, the poppet is pushed
As a result, the oil pressure in chamber A decreases, up from the tank port side, and the oil at the tank port
the pressure oil from the pump pushes up the plunger flows into the fan motor line by way of passage C.
and flows into the tank port by way of passage E.
This status continues until revolution of the fan caused
Accordingly, the maximum number of revolutions of the by the inertia is attenuated and stopped.
fan motor is determined by this relief pressure.

Set pressure (guideline)

18.1 MPa (185 kgf/cm2) (2,625 psi)
115ZV EX 42-114
42 Function & Structure Hydraulic Group
Emergency Steering

Emergency Steering
Note
Emergency steering is a standard equipment for the
European market. It is available as an optional equipe-
ment for the other area.

Steering pump
(switch pump)
Steering valve

Pressure
switch

Emergency
Transmission steering valve From fan
motor valve
(S/N ~0169,
~9011)

Emergency Hydraulic tank

steering
pump

K115ZVE42009

The emergency steering pump is installed on the trans-

mission.

The emergency steering is the grand drive type, and

when the machine is moving forward or reverse, the
emergency steering pump is being operated.
 115ZV EX 42-115
42 Function & Structure Hydraulic Group
Emergency Steering

Emergency steering operation Operating condition

The following conditions need to be satisfied to function

The emergency steering works automatically when the the emergency steering.
steering hydraulic pressure goes down or the engine
stops while the machine is operating. When the steer- - The machine is moving forward or reverse.
ing hydraulic pressure goes down while the engine is - Hydraulic pressure in the steering hydraulic circuit
running, the steering hydraulic warning lamp lights up. lowers below 0.6MPa (6.5 kgf/cm2) (92 psi).

Emergency steering hydraulic line

To pilot valve

To multiple
T TS TS control valve
A
A B

Cooling fan

Pb 5
2 Pa T
T/M 91.0
cm3/rev
P.B. T2 DR
67.3 3 A
cm3/rev
B
6
G Pc P C

P1 P2 7 P2
B T1
PG
C5
C2 C4 TS
Turns OFF when TG P1
8 pressure rises.
TC 0.4±0.002 MPa From unloader
C7
C1 C3
Rc1/4 (58±0.3 psi) valve
VB VA To unloader valve
VX X

M M
C6

G 1 TS
TS

Hydraulic oil cooler

Hydraulic tank

115ZVE42010

1. Oil pump assy 5. Fan motor

2. Emergency steering pump 6. Steering valve assy
3. Emergency steering valve assy 7. Check valve
4. Steering cylinder 8. Pressure switch
115ZV EX 42-116
42 Function & Structure Hydraulic Group
Emergency Steering

Emergency steering oil flow

When the emergency steering system does not work

- When the machine is moving forward

2 Pb 5
T
T/M 91.0
cm3/rev
P.B. T2 DR
67.3 3 A
cm /rev
3

B
G Pc P C

P1 P2 7 6 P2
B T1
PG
C5
C2 C4 TS
TG P1
8
TC
C1 C3 C7

Note: PCb PCa

Hydraulic oil cooler
C1~C7 and PC PCx X
are check valves. M M

C6
1 TS
TS
G

Hydraulic tank K115ZV42030

Oil flow: Note

Fan motor (5)  C4  Emergency steering pump (2)  When hydraulic pump (1) is operating, the hydraulic
C1  Check valve  C7  Hydraulic oil cooler  Tank pressure is added to check valve (7). It keeps check
valve (7) open.

- When the machine is moving reverse

2 Pb 5
T
T/M 91.0
cm3/rev
P.B. T2 DR
67.3 3 A
cm /rev
3

B
G Pc P C

P1 P2 7 6 P2
B T1
PG
C5
C2 C4 TS
TG P1
8
TC
C1 C3 C7

Note: PCb PCa

Hydraulic oil cooler
C1~C7 and PC PCx X
M M
are check valves.
C6
1 TS
TS
G

Hydraulic tank K115ZV42031

Oil flow: Note

Fan motor (5)  C2  Emergency steering pump (2)  When hydraulic pump (1) is operating, the hydraulic
C3  Check valve  C7  Hydraulic oil cooler  Tank pressure is added to check valve (7). It keeps check
valve (7) open.
 115ZV EX 42-117
42 Function & Structure Hydraulic Group
Emergency Steering

When the emergency steering system works

- When the machine is moving forward

2 Pb 5
T
T/M 91.0
cm3/rev
P.B. T2 DR
67.3 3 A
cm3/rev
B
G Pc P C

P1 P2 7 6 P2
B T1
PG
C5
C2 C4 TS
TG P1
8
TC
C1 C3 C7

Note: PCb PCa

Hydraulic oil cooler
C1~C7 and PC PCx X
M M
are check valves.
C6
1 TS
TS
G

Hydraulic tank K115ZV42032

Oil flow: Note

Hydraulic tank  C5  C4  Emergency steering Check valve (7) is closed due to no oil supply to check
pump (2)  C1  C6  Steering valve (6) valve (7) from the oil pump assy (1).

- When the machine is moving reverse

2 Pb 5
T
T/M 91.0
cm3/rev
P.B. T2 DR
67.3 3 A
cm3/rev
B
G Pc P C

P1 P2 7 6 P2
B T1
PG
C5
C2 C4 TS
TG P1
8
TC
C1 C3 C7

Note: PCb PCa

Hydraulic oil cooler
C1~C7 and PC PCx X
M M
are check valves.
C6
1 TS
TS
G

Hydraulic tank K115ZV42033

Oil flow: Note

Hydraulic tank  C5  C2  Emergency steering Check valve (7) is closed due to no oil supply to check
pump (2)  C3  C6  Steering valve (6) valve (7) from the oil pump assy (1).
115ZV EX 42-118
42 Function & Structure Hydraulic Group
Emergency Steering

Emergency steering pump

Counterclockwise
rotation Clockwise
Drain port rotation
Z

B A

Z
Z-Z K115ZV42034

This pump is bi-directional gear pump, mounted to the

transmission.

When rotating clockwise, side A is the outlet and side B

is inlet.
When rotating counterclockwise, side A is the inlet side
and side B is outlet.

Emergency steering pump specification

Model R20200K

Discharge (cm3/rev) 67.3

Max. discharging pressure

17.2 (175) (2,490)
MPa (kgf/cm2) (psi)
Rated speed
450 ~ 3,000
min-1 (rpm)
 115ZV EX 42-119
42 Function & Structure Hydraulic Group
Emergency Steering

Emergency steering valve assembly

1
P2
C2 P1 C4
3 1
PC
C5 TC C7

1 2
P1 (PC)
TC (C5)

X X

B B
G

TS
(C1) (C3)
TS 1 3 1

B G
3

TS C6

C1 C3
3
K115ZV42035

1. Check valve
2. Check valve
3. Plug
115ZV EX 42-120
42 Function & Structure Hydraulic Group

MEMO
 115ZV EX 43-1
43 Check & Adjustment Hydraulic Group

43 Check & Adjustment

Hydraulic Group

Loading/Steering Circuit Relief Valve ....................................43-2

Hydraulic Cylinder ...............................................................43-11
Stop Valve ...........................................................................43-13
Fan Motor Revolution ..........................................................43-14
115ZV EX 43-2
43 Check & Adjustment Hydraulic Group
Loading/Steering Circuit Relief Valve

Loading/Steering Circuit Relief Valve

Loading circuit relief valve setting Releasing residual pressure from tank and
pipes
pressures
1. Keep the bottom surface of the bucket horizontal,
WARNING and stop the engine when the bucket is approxi-
mately 30 cm (1 ft.) above the ground.
Unexpected movement of the machine may cause an
accident resulting in injury or death. 2. Tilt down the bucket until it comes in contact with
Therefore, to provide repair service with the engine the ground. Place the bucket control lever in the roll
running, be sure to observe the following items: back position, and then lower the boom.
- Park the machine on level ground.
- Apply the parking brake. 3. Push down on, then open the cap of the hydraulic
- Block the tires with chocks to prevent the tires from oil tank to release the residual pressure.
moving.
- Determine the signals between the service man.
- Prohibit any person from walking into dangerous
areas. Measurement instruments
- Near articulation areas of the machine
- Under the machine Pressure gauge
- Around the engine
- In front of or behind the machine 30 MPa (300 kgf/cm2) (5,000 psi)
(for loading line with 3 m (10 ft.) hose and steering line
with 1.5 m (4 ft.) hose)
CAUTION
5 MPa (50 kgf/cm2) (1,000 psi)
Do not touch the fan or V-belt of the engine or a high- (for pilot line) with 2~3 m (6~10 ft.) hose
temperature section if the engine is running. An acci-
dent resulting in injury may occur. Note
Be sure to stop the engine before you open the side For safety, route the gauge to an area where it may be
cover of the engine room. Keep all guards in place. safely read by the person doing the test.
Avoid high temperature components even when the
engine is stopped.

Standard measurement value

CAUTION
Loading line main relief pressure 20.6 ± 0.5
Be careful, you may get burned if the high pressure (at maximum speed) MPa (kgf/cm2) (psi) (210 ± 5) (2,986 ± 71)
oil spouts out. To prevent such an accident, be sure
to release the residual pressure from the pipe, and Loading line overload relief pressure 23.5 ± 0.5
open the cap of the hydraulic oil tank before removing (at idling speed) MPa (kgf/cm2) (psi) (240 ± 5) (3,413 ± 71)
the plug from the pressure measurement port. 3.5
Pilot line MPa (kgf/cm2) (psi)
(36) (512)

Hydraulic oil temp

50 ~ 80ºC (120 ~ 180ºF)
 115ZV EX 43-3
43 Check & Adjustment Hydraulic Group
Loading/Steering Circuit Relief Valve

Gauge port Valve assembly

Gauge port location Port size (4)

Main relief pressure (1), (2), (3) (1) (PPI) (Z)

Rc (PT) 1/4
(Z2) (Z1)

Overload relief (2), (3) (PA)

(1), (2), (3) G (PF) 1/4 with O-ring
ACF (ACCF) (ACCR)
pressure (PARKING)
(TA)
(PI)

(T) (P)
Pilot line pressure (4)
(4)
(Reducing valve) G (PF) 3/8 with O-ring

Bucket cylinder Reducing valve

(for pilot)

[R.H. cylinder shown] (S/N ~0126, ~9020) (S/N 0127~, 9021~) K115ZV43001

(1)

(2)

115ZV43001

Multiple control valve

Make-up valve

Overload relief valve

Overload relief Main relief valve

valve
(3)
95ZV43002
115ZV EX 43-4
43 Check & Adjustment Hydraulic Group
Loading/Steering Circuit Relief Valve

Measuring loading circuit main relief pres- Adjusting main relief pressure
sure

1. Unload the bucket. Adjusting screw

Tank port
2. Lower the boom to the lowest limit.

3. Attach the pressure gauge 30 MPa (300 kgf/cm2)

(5,000 psi) to the bucket cylinder bottom side (2).

4. Set the parking brake switch to the "ON" position.

Cap nut

5. Move the bucket control lever to the roll back posi- Lock nut
tion. Hold the lever at that position. Main relief valve 90ZVE43002

6. Increase the engine speed to the maximum, and

measure and record the pressure using the pres- Remove the cap and loosen the lock nut and adjust the
sure gauge. 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.
 115ZV EX 43-5
43 Check & Adjustment Hydraulic Group
Loading/Steering Circuit Relief Valve

Measuring loading circuit overload relief Adjusting overload relief pressure

pressure

1. Attach the pressure gauge to the port (3).

Lock nut
2. Adjust the main relief valve pressure to 24.5 MPa
(250 kgf/cm2) (3,555 psi) + 1/4 additional turn, so
the pressure is above the overload relief pressure.

Bucket cylinder bottom side

1. Lower the boom to the lowest limit. Adjusting screw

2. Move the bucket control lever to the roll back posi- Overload relief valve
90ZVE43003
tion.

3. Keep the engine speed at low idle. Loosen the lock nut and adjust the pressure by the
adjusting screw.
4. Hold the bucket control lever at the roll back posi-
tion and record the pressure. Turn clockwise the adjusting screw to raise the set pres-
sure, or turn counterclockwise the adjusting screw to
Bucket cylinder rod side lower the set pressure.

1. Keep the boom horizontal.

IMPORTANT
2. Move the bucket control lever to the dump position, At the completion of check and adjustment of over-
hold and then measure and record the pressure. load relief valve pressure, be sure to reset the main
relief valve to the original condition.
115ZV EX 43-6
43 Check & Adjustment Hydraulic Group
Loading/Steering Circuit Relief Valve

Measuring pilot circuit relief pressure Adjusting pilot line pressure

WARNING
Trapped pressure in brake circuit could cause serious Lock nut
injury when the plug is removed.
Fully release all residual accumulator pressure
before servicing.

C
1. Attach the pressure gauge to the port (4).
Adjusting screw

WARNING Reducing valve

70ZV43006

Loosen the lock nut and adjust the pressure by the

adjusting screw.

Turn clockwise the adjusting screw to raise the pilot line

pressure.

Injection Hazard
IMPORTANT
Depress brake pedal 80~100 After the completion of the adjustment of the pilot line
times to completely discharge pressure, be sure to tighten the lock nut.
the brake accumulators prior to
removing these plugs.
K65ZV42022

2. Keep the engine speed at low idle (when the brake

line pressure is normal) and then measure and
record the pressure.
 115ZV EX 43-7
43 Check & Adjustment Hydraulic Group
Loading/Steering Circuit Relief Valve

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 m (4 ft.) hose)
accident resulting in injury or death.
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
- Park the machine on level ground.
- 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.
- Determine the signals between the service man.
- Prohibit any person from walking into dangerous
areas.
Standard measurement value
- Near articulation areas of the machine
- Under the machine
- Around the engine
- In front of or behind the machine Steering line main relief pressure 20.6 ± 0.5
(at maximum speed) (210 ± 5) (2,986 ± 71)

Steering line overload relief pressure 24.5 +1.0

0
CAUTION (at idling speed) (250 +100 ) (3,555 +1420 )

Be careful, you may get burned if the high pressure 3.5

Pilot line
oil spouts out. To prevent such an accident, be sure (36) (512)
to release the residual pressure from the pipe, and
open the cap of the hydraulic oil tank before removing Hydraulic oil temp: 50 ~ 80ºC (120 ~ 180ºF)
the plug from the pressure measurement port.

CAUTION Gauge port

Do not touch the fan or V-belt of the engine or a high- Gauge port location Port size
temperature section if the engine is running. An acci-
dent resulting in injury may occur. Main relief pressure
Be sure to stop the engine before you open the side (1), (2) G (PF) 1/4 with O-ring
Overload relief
cover of the engine room. Keep all guards in place. pressure
Avoid high temperature components even when the
Reducing pressure (3) Rc (PT 1/8)
engine is stopped.
115ZV EX 43-8
43 Check & Adjustment Hydraulic Group
Loading/Steering Circuit Relief Valve

Measuring steering circuit main relief pres- Adjusting steering line main relief pressure
sure
Lock
Main relief valve nut

Steering cylinder Overload relief valve

(RH)

(2)
Steering cylinder
(LH)
(1) Overload relief
valve
K115ZV43002 Lock nut

1. Attach the pressure gauge to the gauge port ((1) or Steering valve
K115ZV43003
(2)).

2. 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.
Continue to hold the steering wheel fully turned. Adjusting 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
Steering valve
front and rear chassis contact each other.

WARNING Main relief valve

70ZV43009
If the machine begins to move with the articulation
stopper applied, it may cause an accident resulting in
Loosen the lock nut for the main relief valve, and adjust
injury or death.
the pressure by the adjusting screw.
After the measurement, be sure to disconnect and
store the articulation stopper.
Turn clockwise the adjusting screw to raise the steering
line main relief pressure.
3. Increase the engine speed to high idle, and mea-
sure and record the pressure.
 115ZV EX 43-9
43 Check & Adjustment Hydraulic Group
Loading/Steering Circuit Relief Valve

Measuring steering circuit overload relief Adjusting overload relief pressure

pressure
Lock nut
Adjusting
1. Attach the pressure gauge to the port ((1) for the screw
left turn, (2) for the right turn).

2. Adjust the main relief valve pressure to 25.5 MPa

(260 kgf/cm2) (3,697 psi) + 1/4 additional turn, so
the pressure is above the overload relief pressure.

3. Steer the machine until the front and rear chassis

contact each other. Continue to hold the steering
wheel fully turned.
95ZV43008
(S/N 0101~0140, 9001~9020) Port B: to Port A: from
steering valve pilot valve
Stopper Loosen the lock nut for the overload relief valve, 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.
Installed on
front chassis
Bolt
WARNING
Stop valve
(Installed on rear chassis) If the machine begins to move with the articulation
K115ZV43004 stopper applied, it may cause an accident resulting in
injury or death.
After the measurement, be sure to disconnect and
(S/N 0141~, 9021~) Port B: to Port A: from store the articulation stopper.
Spool steering valve pilot valve
Stopper
IMPORTANT
At the completion of check and adjustment of over-
load relief valve pressure, be sure to reset the main
relief valve to the original condition.
Installed
on front chassis

Stop valve
(Installed on rear chassis)
K115ZV43005

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.

4. Keep the engine speed at low idle, and measure

and record the pressure.
Raise the engine speed to 1,000 min-1 if fail to do.
115ZV EX 43-10
43 Check & Adjustment Hydraulic Group
Loading/Steering Circuit Relief Valve

Measuring pilot circuit relief pressure Adjusting pilot line pressure

(reducing pressure) (S/N 0101~, 9004~)
Loosen the lock nut and adjust the pressure by the
adjusting screw.

Turn clockwise the adjusting screw to raise the pilot line

Adjusting screw
pressure.

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

(T)

(A)

(3)

(TS)

(B)

115ZV43007

1. Attach the pressure gauge to the port (3).

Gauge port plug width across flat

5 mm (0.2 in)

2. Keep the engine speed at low idle and record the

pressure.
 115ZV EX 43-11
43 Check & Adjustment Hydraulic Group
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.
Measurement instrument
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 to 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.

Standard measurement value

mm/min (in/min)
Boom cylinder 3 (1/8) or less
Bucket cylinder 4 (5/32) or less
115ZV EX 43-12
43 Check & Adjustment Hydraulic Group
Hydraulic Cylinder

Reference

Mark
(Vinyl tape)

Scale

70ZV43012

Drift rate depends on the viscosity of the hydraulic oil

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

IMPORTANT
At the completion of measurement, if the vinyl tape
used for measurement is not removed from the cylin-
der rod, the tape may be caught by the rod seal. The
tape will cause oil leakage from the rod seal.
To prevent oil leakage, be sure to remove the vinyl
tape.
 115ZV EX 43-13
43 Check & Adjustment Hydraulic Group
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
28~32 mm Reference dimension
(0.984~1.260 in) 25~39 mm (0.984~1.535 in)

Stopper (bolt) length Clearance between machine body and stopper 115ZV43005
115ZV43004

Articulation angle (º) 37 36 35

WARNING Clearance between machine body and 25 32 39
stopper (mm) (in) (0.984) (1.260) (1.535)
When the machine turns, the clearance in the articu- 28 30 32
Stopper (bolt) length (mm) (in)
lation area closes. As a result, people may be caught, (1.102) (1.181) (1.260)
leading to a severe accident. To prevent such an
accident, observe the following items strictly when *The target value should be the articulation angle “36º”.
adjusting the steering stopper.
- Stop the engine before starting adjustment of the - After adjustment, turn the steering wheel slowly at a
stopper bolt. rate of 5 seconds or more per turn, and confirm the
- When confirming the operation after setup, keep clearance between the machine body and the stop-
proper distance from the articulation area of the per.
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 “25~39 mm
(0.984~1.535 in)” shown in the table below.
115ZV EX 43-14
43 Check & Adjustment Hydraulic Group
Fan Motor Revolution

Fan Motor Revolution

Fan maximum revolution measurement (S/N 0101~0120, 9001~9010)

WARNING Measurement instrument

Trapped hydraulic pressure in the hydraulic line could
- Pressure gauge about 30 MPa (300 kgf/cm2) (5,000
cause serious injury when the plug is removed.
psi)
Observe the following items:
- Spanner 22, 27, 32 mm (0.87, 1.06, 1.26 in)
- Park the machine on level ground, and apply the
- Tachometer (Photo tachometer)
parking brake. In addition, block the tires with
chocks to prevent the wheels from moving.
- Relieve the internal pressure from the hydraulic
tank and the hydraulic line to prevent the oil from Standard measurement value
spouting out.
- Remove the engine key, and hang a "DO NOT Engine water
Fan revolution
Set pressure
START ENGINE!" tag on the operation board. temperature MPa (kgf/cm2) (psi)
< 94ºC (200ºF) 1,120 min-1 9.5 (97) (1,380)
> 94ºC (200ºF) 1,600 min-1 19.0 (194) (2,760)
Note
Whenever the fan maximum revolution is adjusted,
always adjust the high revolution first, because when
the high revolution is changed, the low revolution is also Fan motor line
changed.

Cooling fan
Fan motor (71)
Solenoid valve
(74)(75)
91.0
cm3/rev

T2 DR

Water A
temperature From reducing
switch valve (28) in valve
Water block (26)
temperature B
< 94ºC (200ºF)
Pressure is 3.5 MPa
...ON C (36 kgf/cm2) (512 psi)
> 94ºC (200ºF)
...OFF
P2
T1
Valve PG
assembly
(72) TG P1
High pressure set:
19.0 MPa (194 kgf/cm2)
(2,760 psi)
Low pressure set:
9.5 MPa (97 kgf/cm2)
(1,380 psi) From unloader
valve (22)
Relief valve (73)

Hydraulic line diagram

K115ZV43006
 115ZV EX 43-15
43 Check & Adjustment Hydraulic Group
Fan Motor Revolution

Fan revolution adjustment procedure Low revolution (Low pressure) adjustment

1. Confirm the radiator cooling water temperature is

lower than 80ºC (176ºF), and then adjust the rpm's
keeping the solenoid valve connection wire
P1 21 22 installed on the relief block.
When the radiator cooling water temperature is low,
PG PX the solenoid valve is ON.
P2

2. Loosen the lock nut (23), adjust the rpm's (pres-

B A sure) by turning the adjusting screw (24).
T1 23 24 Turn the adjustment screw clockwise as viewed
TG
from the valve end to raise the rpm's (pressure).
Set revolution 1,120 min-1 (rpm)
T2 [Set pressure 9.5 MPa (97 kgf/cm2) (1,380 psi)]

3. After adjusting the fan rpm's, tighten the lock nut

(23) while holding the adjusting screw (24) so as
Solenoid not to turn it at the same time.
valve 95ZV42065
: Lock nut (22): 31 N-m (3.2 kgf-m) (23 lb-ft)
: Lock nut (21): 45 N-m (4.6 kgf-m) (45 lb-ft)
High revolution (High pressure) adjustment

1. Remove the solenoid valve connection wire.

When the solenoid valve is OFF, the high revolution
can be adjusted.

2. Loosen the lock nut (21), adjust the rpm's (pres-

sure) by turning the adjusting screw (22).
Turn the adjusting screw clockwise as viewed from
the valve end to raise the rpm's (pressure).

Note
Do not raise the pressure more than 19 MPa (2,760 psi)
during adjustment.

Set revolution 1,600 min-1 (rpm)

[Set pressure 19.0 MPa (194 kgf/cm2) (2,760 psi)]

3. After adjusting the fan rpm's, tighten the lock nut

(21) while holding adjusting screw (22) so as not to
turn it at the same time.
: Lock nut: 45.1 N-m (33.3 lb-ft)
115ZV EX 43-16
43 Check & Adjustment Hydraulic Group
Fan Motor Revolution

Fan maximum revolution measurement (S/N 0121~, 9011~)

WARNING Relief valve assembly

The residual oil pressure in the hydraulic line could
spout high pressure oil and cause serious injury such
Adapter
as burn when a hose or plug is removed.
Make sure to release the residual pressure from the PP
line and the internal pressure from the tank before Relief valve
starting adjustment. P

Measurement instrument
T
2
Pressure gauge about 20 MPa (200 kgf/cm ) (3,000 psi)

Standard measurement value

TS
Engine at high idle 2,350 min-1 (rpm) Plug
K115ZVE43001
Number of fan High 1,600 +75
-50 min-1 (rpm)
revolution Low 1,120 +75 min-1 (rpm)
-50

Relief set pressure High 18.0 MPa (184 kgf/cm2) (2,610 psi)
(guideline) Low 8.1 MPa (83 kgf/cm2) (1,175 psi)

Fan motor line

Cooling fan Fan motor (71)

90.0 Check valve (73)

cm3/rev

T1 P1
T Ps Thermo-sensing
valve (74)
Radiator
18.1 MPa (2,625 psi) High pressure set:
18.0 MPa (184 kgf/cm2)
(2,610 psi)
Low pressure set:
8.1 MPa (83 kgf/cm2)
T2 Pp (1,175 psi)

Ts P From unloader
valve (22)

Relief valve (72)

115ZV42040
 115ZV EX 43-17
43 Check & Adjustment Hydraulic Group
Fan Motor Revolution

Fan revolution adjustment procedure

1. Remove hose and adapter from the port Pp (port

size: PF 1/4), and plug port Pp.

2. Remove the plug from the port Ps (port size: PF 1/

4), and attach a gauge.

3. Measure the number of fan revolutions while the

engine is at high idle.

Adjusting screw

Lock nut

Relief valve
65ZV43007

4. If the maximum number of revolutions is not cor-

rect, adjust it using the adjusting screw in the relief
valve.
Turn the adjusting screw clockwise to increase both
the pressure and the number of fan revolution.

Note
- The relief valve on the low pressure side cannot be
adjusted because it accommodates a thermo-sens-
ing valve. It can be only confirmed.
- After placing hose and adapter in the port Pp to nor-
mal, measure the pressure while the fan is moving at
low speed. At this time, the engine cooling water
temperature should be 82ºC (180ºF) or lower
(Engine at HI).
115ZV EX 43-18
43 Check & Adjustment Hydraulic Group

MEMO
 115ZV EX 52-1
52 Function & Structure Brake Group

52 Function & Structure

Brake Group

Brake System Outline............................................................52-2

Brake Units Layout ................................................................52-3
Unloader Valve ......................................................................52-4
Reducing valve......................................................................52-7
Valve Unit (Main Brake Manifold Block) ................................52-8
Brake Accumulator Line ........................................................52-9
Brake Valve .........................................................................52-12
Stop Lamp Pressure Switch ................................................52-18
Service Brake ......................................................................52-20
Parking Brake......................................................................52-28
Parking Brake Manual Release...........................................52-32
Parking Brake Spring Chamber...........................................52-34
Brake Circuit Check Valve...................................................52-35
Auto Brake ..........................................................................52-36
Shuttle Valve .......................................................................52-38
115ZV EX 52-2
52 Function & Structure Brake Group
Brake System Outline

Brake System Outline

The brake system is the all-hydraulic type, and has two Adjustment of axle internal pres-
independent systems consisting of the front system and
the rear system for enhancing safety. The service brake sure
is the wet disc type. The parking brake is the internal
expansion drum type. 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.
Service brake
To prevent the brake from dragging, the axle housing air
Oil from the pump is regulated in a range from 6.9~11.8 chamber is connected to the hydraulic tank air chamber
MPa (70~120 kgf/cm2) (995~1,706 psi) by the unloader so that the pressure inside the axle housing becomes
valve (22), and accumulated in the accumulator (33) equivalent to the pressure inside the hydraulic tank.
provided for the front and rear wheels.

When the brake valves (23)(24) are depressed, the

pressure oil in the accumulator enters the disc brake
piston chamber for the front and rear wheels, pushes
the piston, and generates braking power.

Parking brake
The internal expansion type drum brake for parking is
applied by the spring chamber (55).
The spring chamber (55) operates when the pressure
oil inside the spring chamber returns to the tank while
the power is not supplied to the solenoid valve (29) (that
is, while the parking switch is ON).

Auto brake
When the machine speed exceeds the specified value,
power is supplied to the solenoid valve (27) by the sig-
nal sent from the T/M controller. As a result, the pres-
sure oil depressurized by the reducing valve (28) acts
on the brake valve (23), and applies the service brake.
 115ZV EX 52-3
52 Function & Structure Brake Group
Brake Units Layout

Brake Units Layout

The brake system is the all-hydraulic type, and has two The service brake is the wet disc type. The parking
independent systems consisting of the front system and brake is the internal expansion drum type.
the rear system for enhancing safety.

8 3 2

7 5 4 8

115ZV52002

1. Accumulator
2. Solenoid valve (for parking)
3. Solenoid valve (for auto brake)
4. Shuttle valve
5. Brake valve
6. Parking brake
7. Spring chamber (for parking brake)
8. Unloader valve
115ZV EX 52-4
52 Function & Structure Brake Group
Unloader Valve

Unloader Valve
(S/N 0101~0144, 9001~)

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
 115ZV EX 52-5
52 Function & Structure Brake Group
Unloader Valve

(S/N 0145~)

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
115ZV EX 52-6
52 Function & Structure Brake Group
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. The body (1) is equipped with ports (pump, fan
motor, accumulator, pilot and tank). While the unloader valve is not operating, the spool (3)
is pushed back by the spring (2) and the pump port to
The spool (3) which opens and closes the pump port to the fan motor port is closed. Oil flowing from the pump
the fan motor port, the orifice (6) which regulates the port is sent to the accumulator port through the orifice
flow rate to the accumulator port with high priority, and (6), and the pressure at the accumulator port increases
the pressure governor mechanism which controls the accordingly.
pressure on the accumulator port side are built in the
unloader valve. When an excess flow rate is generated, the spool (3)
moves to the fan motor port side and the excess flow
rate flows out to the port to the fan motor.

The pressure at the accumulator port is transferred to

the inside of the pressure governor through the orifice
(7).

When the pressure at the accumulator port increases

and exceeds the load of the springs (17) (18) applied on
the pilot valve (15), the pilot valve opens and increase
of the pressure at the accumulator port stops (cut-out
pressure). At this time, the pressure in the accumulator
connected to the pilot port pushes the governor plunger
(11), and continuously releases the pilot valve.

When the pressure in the accumulator decreases and

the spring attached to the pilot valve pushes back the
governor plunger, the pilot valve is closed and the pres-
sure at the accumulator port starts to increase again
(cut-in pressure).

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

pressure ON 6.9 ± 1.0 MPa (70 ± 10 kgf/cm2) (995 ± 142 psi)
 115ZV EX 52-7
52 Function & Structure Brake Group
Reducing valve

Reducing valve

In-line filter Reducing valve

Pump port
Pressure test port (From unloader valve B
(S/N 0101~, 9004~) via in-line filter) T

Ball
Passage Orifice 2
Y

B
Accumulator C
line port
(To main brake
manifold block)
Orifice 1
Passage Z
Chamber C

T
Plunger (S/N 0101~, 9004~)

Tank port

B A
(To accumulator) (From pump)

(To tank)
Hydraulic circuit diagram
K115ZV52005

The oil fed from the pump flows into the reducing valve When the oil pressure on the accumulator line side
by way of port A, and passage Y. The oil pressure in the becomes less than the set pressure, the ball moves
accumulator line is applied also on chamber C by way down and the pressure in chamber C becomes equiva-
of orifice 1. lent to the pressure on the accumulator side. As a
result, the plunger moves down due to spring force,
When the oil pressure in the accumulator line reaches opens passage Y, then introduces the oil from the pump
the set pressure or greater, the oil in chamber C pushes to the accumulator line side so that the pressure is
up the ball by way of orifice 2, and escapes to the tank maintained at the specified value.
by way of passage Z. As a result, the pressure in cham-
ber C decreases, then the plunger moves up and closes Set pressure
passage Y so that the pressure on the accumulator line 12.3 MPa (125 kgf/cm2) (1,783 psi)
side does not exceed the set pressure.
115ZV EX 52-8
52 Function & Structure Brake Group
Valve Unit (Main Brake Manifold Block)

Valve Unit (Main Brake Manifold Block)

(S/N 0127~, 9021~) (S/N 0101~0126, 9001~9020)
P = Pump supply
T = Tank circuit
PI = Pump feedback to unloader (From ACCF circuit)
ACCR = Accumulator circuit-rear
ACCF = Accumulator circuit-front
PPI = Pilot valve circuit
1
PA = Auto brake circuit 2 1

4 3

Pump port (P) (T)

(from unloader and Tank
reducing valve)

Unloader valve (TA)

Spring chamber
"feed back" signal (PARKING) for parking brake
(PI) (PA)
(Z1) (Z2) Auto brake
solenoid valve

(ACCR) (ACCF) (Z) (PPI)

Fan motor solenoid Loading line
5 valve (S/N 0101~0120, pilot valve
9001~9010) K115ZV52003

4 (S/N 0101~0120, 9001~9010) 4 (S/N 0121~, 9011~)

A B A B
ACCR ACCR
5 5
P P

A B A B
ACCF ACCF
3 3

PI 1 PI ACF 1

2 B 2 B

P T PA P T PA
A B Z2 A B Z2
T T
T T
Hydraulic circuit Z PPI Z1 K115ZV52018 Hydraulic circuit ACF Z PPI Z1 K115ZV52019

1. Solenoid valve for parking brake 3. Check valve (front brake circuit)
2. Reducing valve [3.5 MPa (36 kgf/cm2) (512 psi)] 4. Check valve (rear brake circuit)
(Serves as pressure for fan solenoid (S/N 5. Accumulator low pressure switch (2 used)
0101~0120, 9001~9010), loading pilot control, auto [3.9 ± 0.5 MPa (40 ± 5 kgf/cm2) (569 ± 71 psi)]
brake and park brake)
 115ZV EX 52-9
52 Function & Structure Brake Group
Brake Accumulator Line

Brake Accumulator Line

Solenoid valve
Valve unit (for parking)
Accumulator
(Main brake manifold block)

Solenoid valve
(for auto brake)
A

Reducing valve
(for accumulator circuit)
In-line
filter

Unloader valve
K115ZV52004
115ZV EX 52-10
52 Function & Structure Brake Group
Brake Accumulator Line

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 to prevent disability of the brakes
3. Gas cap caused by a problem with the pump, etc. Two accumu-
4. Piston lators are provided in the service brake line. Nitrogen
5. V-O-ring gas at 2.94 MPa (30 kgf/cm2) (427 psi) is charged in the
6. Backup ring gas chamber.
7. Wear ring
8. O-ring Accumulator specifications
9. Backup ring
10. Gas valve Maximum operating pressure MPa
12.3 (125) (1,778)
11. Gas valve O-ring (kgf/cm2) (psi)
12. Gas valve guard Nitrogen gas charging pressure MPa 2.94 ± 0.1
(kgf/cm2) (psi) (30 ± 1) (427 ± 14)
13. Bolt
Nitrogen gas capacity L (gal) 3.0 (0.79)

WARNING
Use only dry Nitrogen gas [N2] to charge accumula-
tors.
Any other gas will not function correctly.
Never use oxygen to charge the brake accumulators.
 115ZV EX 52-11
52 Function & Structure Brake Group
Brake Accumulator Line

In-Line Filter

From unloader To combination

valve FILTER valve (via reducing
valve)

1 3 4 2 5
70ZV42040

1. Case This 95 micron filter protects the brake manifold and

2. Nipple related valves from contamination.
3. Strainer
4. O-ring It must be back flushed to keep it clean. Replace it
5. O-ring when there has been any system contamination or if the
pilot and brake pump has failed.

Pieces of debris can be lodged and may not blow out

with compressed air, but may release later causing
erratic valve troubles.

The line filter is item No. 81 in the "Brake Circuit" page

92-9.
115ZV EX 52-12
52 Function & Structure Brake Group
Brake Valve

Brake Valve

Brake main valve (left pedal)

(S/N 0126~, 9012~)
Tandem type
Operates both with direct pedal appli-
cation of pedal, and as a pilot operated
servo valve to the right pedal.
1

2
3
36 4
35 34 5
(S/N 0101~0125,
10 6 9001~9011)
A
7
A-A 8
9
11
10

12 A

13
38 Tank port Pilot port
37 14
15
16 17
20
18

19 Rear brake port

Accumulator port
22
21
26
23 27
24
Front brake port
39 25
Accumulator
ports Accumulator port
28
29
31
30
32 33 K115ZV52006

1. Brake pedal 11. Pilot piston 21. Plunger 31. Retainer

2. Roller 12. Retainer 22. Retainer 32. Snap ring
3. Bushing 13. Spring 23. O-ring 33. End cap
4. Seat 14. Rod 24. Spool 34. Bushing
5. Pedal stopper 15. Spring 25. Secondary cylinder 35. Pin
6. Boot 16. Spring 26. Snap ring 36. Pin
7. Push rod 17. O-ring 27. Spring 37. Collar
8. Oil seal 18. Primary cylinder 28. Plunger 38. Bolt
9. Flange 19. Spool 29. Spring 39. Bolt
10. Bracket 20. Spring 30. O-ring
 115ZV EX 52-13
52 Function & Structure Brake Group
Brake Valve

Brake pilot valve (right pedal)

This is a pilot valve that sends a pilot signal to the left
pedal.
(S/N 0126~, 9012~)

2
29
27 3
28
4
5 (S/N 0101~0125,
10 9001~9011)

A
6
A-A 7
8
9
10
11

12 A
31 13
30 Tank port 14
15
18 16
19 17
32 Brake port 20
(pilot port)
Accumulator port
Accumulator port 21

24 22

25 23
26
K115ZV52007

1. Brake pedal 11. Retainer 21. Plunger 31. Bolt

2. Roller 12. Snap pin 22. Retainer 32. Bolt
3. Bushing 13. Rod 23. Snap ring
4. Seat 14. Spring 24. Spring
5. Pedal stopper 15. Spring 25. O-ring
6. Boot 16. O-ring 26. End cap
7. Push rod 17. Holder 27. Bushing
8. Oil seal 18. Cylinder 28. Pin
9. Flange 19. Spring 29. Pin
10. Bracket 20. Spool 30. Collar
115ZV EX 52-14
52 Function & Structure Brake Group
Brake Valve

Brake valve performance chart

Main valve (Left pedal, tandem type)

277 (28.3)(62.3)

233.9 (23.9)(52.6)
MPa 3.23 0.3
N(kgf)(Ibf) (kgf/cm )2
(33 3)(469 42.7)
(psi)
2.9
294 (30)(66.14) (30)

Output oil pressure (Brake port)

157 (427)
Pedal pressing force (F)

(16.0)(35.3)
122.5
(12.50)(27.6) 2.0
196 (20)(44.09) (20)
(284)
88.2 (19.0)(19.8) ~)
012
~, 9
78.4 (8.0)(17.6) 0 126 1.13 (11.6)(165)
(S/N
98 (10)(22.05) ~ 90
11) 1.0
5, (10)
~ 012
70.6 (7.2)(15.9) (S/N (142)
55.4(5.65)(12.5)
38.2 (3.90)(8.6) 46.2(4.71)(10.4) 0.20 (2)(28)
0 ( ) 0 ( )
0 5 10 12 15 16.4 0 2 5 10 12 15 16.4
2
Pedal stroke Pedal stroke

MPa
(kgf/cm ) 2
3.23 (33)(469)
(psi)
4.9
Output oil pressure (Brake port)

(50)
(711)

0 MPa
0 4.9 (kgf/cm )
2

0.33 3.41 (50) (psi)

(3.4) (34.5) (711)
(48.3) (495)

Pilot oil pressure (Pilot port input)

K115ZV52008
 115ZV EX 52-15
52 Function & Structure Brake Group
Brake Valve

Pilot valve (Right pedal)

208.2(21.24)(46.8) MPa
(kgf/cm ) 2 3.41 0.3
N(kgf)(Ibf) (psi) (34.8 3)(495 42.7)

(pilot port output to feed left pedal)

294 2.9
Pedal pressing force (F)

(30) (30)
(427)

Output oil pressure

(66.14)

196 2.0
(20) (20)
(44.09) (284)
105.2(10.73)(23.7) 1.31(13.4)(191)
98(10) 1.0
(22.05) (10)
52.7(5.38)(11.9) (142)
35.3(3.60)(7.9) 0.37(3.8)(54)
32.0(3.27)(7.2) 0
0
0 5 10 12 15 16.4 (º) 0 2 5 10 12 15 16.4 (º)
2
Pedal stroke Pedal stroke
115ZV52029

Brake valve outline

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

The main valve (in the left pedal) is the tandem type,
and consists of two independent systems. The pilot
valve (in the right pedal) is the single type. When the
right side pedal is depressed, the oil pressure from this
valve acts as the pilot pressure applied to the main
valve.

Each valve is the closed center type (in which the in-
port is closed while the pedal is released). High pres-
sure is always applied on the in-port side to improve the
response during operation.

Note
Some illustrations of a different valve model having the
same inner structure are used in the following pages for
easier understanding of valve operation.
115ZV EX 52-16
52 Function & Structure Brake Group
Brake Valve

Main valve (tandem type) operation While the valve is operating

While the valve is not operating

Brake pedal

Brake pedal

Push rod

Push rod

Pilot
piston
Pilot
chamber
Pilot T Pilot port
chamber
Tank T Pilot port Spool 1

Pilot Orifice 1 Passage 1

piston Reaction chamber
Spool 1 B1 Rear brake
Passage 1 Accumulator A1 Passage 2
Reaction chamber B1 Rear brake
Accumulator A1 Passage 2 Passage 3
Spool 2
B2 Front brake
Passage 3
Accumulator A2 Passage 4
Spool 2
B2 Front brake
Reaction
Accumulator A2 Passage 4 chamber
Orifice 2

Reaction chamber
70ZV52026

70ZV52025 When the brake pedal is pressed, the push rod and the
pilot piston are pushed by the roller, then spools (1)(2)
Oil sent from the pump is stored in the accumulator, and are pushed down by way of the spring pack. As a
sent to the in-ports A1 and A2. The passages 2 and 4 result, passages 1 and 3 and the tank port T are closed.
(out-ports B1 and B2) are closed by spools (1)(2).
When the spools (1)(2) are pushed down further, pas-
Spools (1)(2) are pushed to the non-operation position sages 2 and 4 are opened and pressure oil from the
by the springs. Oil in the brake piston chamber is sent accumulator is sent to the brake piston chamber to
into the inside of the valve from the out-ports B1 and B2, apply the brake.
and returned to the tank from the tank port T. As a
result, the pressure inside the brake piston chamber
becomes equivalent to the pressure in the tank.
 115ZV EX 52-17
52 Function & Structure Brake Group
Brake Valve

At this time, the brake line pressure acts on the reaction Pilot valve operation
chamber inside the spools (1)(2) through the orifices
(1)(2). As a result, the pressure in the reaction chamber
works as a force to return the spools (1)(2) upward.

When the pressure in the reaction chamber becomes

balanced with the spring load, it returns the spools Brake pedal
(1)(2) to close the passages A1-B1 and A2-B2 to hold
the pressure.

By this operation, the brake pressure in proportion to

the pedal pressing force is obtained, and the spring load
by deflection are transmitted to the operator as pedal
pressing force.

T
Spool 1

Main valve
pilot port
Accumulator

70ZV52027

When the pilot valve (right brake valve) pedal is

pressed, the spool is pushed down, and pressure oil
from the accumulator enters the pilot port of the main
valve (left brake valve), pushes the pilot piston, then
pushes down the spools (1)(2) by way of the spring.

After that, the pilot valve operates in the same way as

the main valve (left brake valve).
115ZV EX 52-18
52 Function & Structure Brake Group
Stop Lamp Pressure Switch

Stop Lamp Pressure Switch

Pressure switch (for stop lamp)

Pressure switch
for declutch
(with white tape)

Pressure switch
for stop lamp
(with black tape)

Left brake valve

K115ZV52017

This pressure switch is installed between the left brake

valve and the rear brake. Pressing the brake pedal
turns on this pressure switch, and lights the stop lamp.

Pressure switch structure

1 2 3 4 5 6 7 8 9 10 11 12 13

14

95ZV52056

1. Case 10. Terminal

2. Seal film 11. Terminal
3. Packing 12. Base
4. Disc 13. Cover
5. Inner cover 14. Connector
6. Guide pin
7. Spring
8. Contact
9. Contact
 115ZV EX 52-19
52 Function & Structure Brake Group
Stop Lamp Pressure Switch

Pressure switch specifications

Contact Normally open

Voltage (VDC) 24
Current (A) 3.5 (MAX)
Resistance () 6.9
Operating pressure MPa (kgf/cm2) (psi) (S/N 0101~0125, 0.5 ± 0.1 (5.0 ± 1.0) (71.1 ± 14.2)
Return pressure MPa (kgf/cm2) (psi) 9001~9010) 0.3 ± 0.05 (3.0 ± 0.5) (42.7 ± 7.1)
Operating pressure MPa (kgf/cm2) (psi) 0.25 ± 0.02 (2.6 ± 0.2) (37.0 ± 2.9)
(S/N 0126~, 9011~)
Return pressure MPa (kgf/cm2) (psi) 0.22 ± 0.02 (2.2 ± 0.2) (31.3 ± 2.9)

Pressure switch (for Declutch)

Refer to “Electrical Group: Transmission cut off
(Declutch)”.
115ZV EX 52-20
52 Function & Structure Brake Group
Service Brake

Service Brake
The service brake is an enclosed wet type multi-plate Service brake operation
hydraulic brake, and is incorporated in the axle housing.

This type of service brake ensures good braking power Oil from the pump is regulated in a range from 6.9~11.8
even in muddy or sandy soil. MPa (70~120 kgf/cm2) (995~1,710 psi) by the unloader
valve, and accumulated in the accumulator provided for
Even if the brake disc is worn, the integrated adjustment the front and rear wheels.
mechanism always adjusts for a constant pedal stroke.
When the brake valves are depressed, the pressure oil
Piston stroke adjuster in the accumulator enters the disc brake piston chamber
15 16 13
for the front and rear wheels, pushes the brake piston
(2), and generates braking power.

While the brake pedal is not pressed, the internal pres-

sure of the hydraulic oil tank is always applied on the
brake piston chamber, and there is a possibility that the
7 6 8 9
Wheel hub brake may drag. To prevent the brake from dragging,
14
the axle housing air chamber is connected to the
Brake oil
inlet port hydraulic oil tank air chamber so that the pressure
inside the axle housing becomes equivalent to the pres-
sure inside the hydraulic oil tank.

12
Axle housing

5 4 2 3 10 11 115ZV52003

1. Internal gear hub

2. Brake piston
3. Piston return spring
4. Steel plate
5. Friction plate
6. Disc gear
7. Axle shaft
8. O-ring (for brake piston)
9. O-ring (for brake piston)
10. O-ring (for gear hub)
11. O-ring (for gear hub)
12. Air bleeder nipple
13. Socket bolt
14. Tolerance ring
15. Sleeve
16. Bushing
 115ZV EX 52-21
52 Function & Structure Brake Group
Service Brake

Service brake friction plate

7 0.1 mm (0.276 0.004 in) (S/N ~9020) (S/N ~0141)

6.8 0.1 mm (0.268 0.004 in) (S/N 9021~) (S/N 0142~)
5 0.15 mm (0.197 0.006 in)

430 mm (16.93 in)

1.2 mm (0.047 in)

(S/N ~0141)(S/N ~9020)

0.65 mm (0.026 in)
(S/N 0142~)(S/N 9021~)
0.55 mm (0.022 in)
Detailed drawing of groove
(FM)
K115ZVE52001

Each friction plate has linings (paper material) on the

contact faces on both sides.

To reassemble the brake disc plates, be sure to align

holes (A) of two friction plates with each other to ensure
smooth flow of gear cooling oil.
115ZV EX 52-22
52 Function & Structure Brake Group
Service Brake

Service brake steel plate

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.
Spring pins
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
Friction plate
as there is no inward or outward direction.

The steel plate shown in the lower figure has the section
(A) where several teeth are intentionally absent. This
(A) steel plate should be installed on the brake retainer side
(outer side of the machine body). The section (A) of this
Cooling plate is used for measurement of friction plate wear. If
holes (A) this steel plate is installed incorrectly, measurement of
wear is disabled.

Steel plate Therefore, this steel plate should be installed correctly

with regard to the tooth location so that the teeth cut-off
section is located (or indexed) as shown in the lower fig-
ure.
Spring pins
There is no inside or outside on this plate either. It may
be installed either way.

Internal gear

Friction plate wear

measurement point

115ZV52005
 115ZV EX 52-23
52 Function & Structure Brake Group
Service Brake

Service brake piston

Upper

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

(4 equivalent divisions of circumference)

4. Hole for removing piston

(6 positions on circumference)

5. Hole to drain the oil trapped behind piston

6. Cooling oil hole

115ZV EX 52-24
52 Function & Structure Brake Group
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 is worn and the brake piston is
shifted by approximately 1.8 mm (0.07 in) or more, the
This is the automatic adjuster function which always sleeve is gradually pulled out to the left by the socket
offers a constant pedal stroke even if the brake disc is bolt by the amount corresponding to the wear. At that
worn. 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.
 115ZV EX 52-25
52 Function & Structure Brake Group
Service Brake

Tolerance ring

Wave

Tolerance ring
95ZV52020

The tolerance ring tightens easily the shaft (sleeve) and

the boss (bushing) to transmit the torque and the thrust
force. The tolerance ring is a press-in ring made of elas-
tic wave sheet steel.

Tolerance ring installation procedure

Boss (bushing) Tolerance ring

Shaft (sleeve)

K90ZV52010

- Attach the tolerance ring to the boss (bushing).

- Press-fit the shaft (sleeve).

115ZV EX 52-26
52 Function & Structure Brake Group
Service Brake

Brake circuit air bleeding procedure

Before air-bleeding the service brake:
WARNING 1. Verify that the wheels are securely blocked, and the
Unexpected movement of the machine may cause a articulation lock is in the "locked" position.
severe accident. To prevent such an accident, take
the following safety measures when performing air
bleeding with the engine running.
- Park the machine on level ground.
- Apply the parking brake.
- Block the tires with chocks to prevent the wheel
from moving. Air bleeder nipple
- Determine the signals between the persons related
to this work for engine starting to prevent an acci-
dent.
- When moving up the boom, install a safety column
under the boom.
- Apply the articulate stopper.

IMPORTANT
Before bleeding the service brakes, it is important to Left brake valve
remove all air from the brake valve manifold block, K115ZV52010

and all related valves.

These include the reducing valve and park brake 2. Connect a clear vinyl tube [About 1.5 m (5 ft.) long]
valve. Failure to do this correctly will result in unsat- to the left brake pedal air bleeder nipple, and open
isfactory brake modulation with use of the right brake the bleeder valve.
pedal due to air being trapped in the top of the left
brake pedal. 3. Charge the accumulator to full pressure, then shut
off the engine, and complete the procedure.
Solenoid valve
for auto-brake

Solenoid valve
for parking

Front Valve assembly

Transmission

K115ZV52020
 115ZV EX 52-27
52 Function & Structure Brake Group
Service Brake

Park brake solenoid

Bleeding air from the brake valves
valve release knob
1. Depress the right brake pedal five times at intervals
of five seconds.
Valve
assembly 2. Check for air in the line.
Auto brake
solenoid valve If air is observed, repeat step 1 until air is com-
pletely purged.

3. Close the left brake valve bleed fitting.

: Air bleeder nipple

K115ZV52012
9 N-m (0.9 kgf-m) (6.5 lb-ft)

4. Turn the park brake solenoid valve release knob 7 mm (0.28 in)
counterclockwise then back to neutral five times
with a five second wait period between each turn.
Position the knob back to the normal position when
finished.

Solenoid valve (S/N 0104~, 9004~)

Bleeding air from brake pipes and axle
pressure nut Solenoid valve housing hubs

Air bleeder nipple

Button
(diameter:
approximately
4 mm)
Auto brake solenoid valve (S/N 0101~0126, 9001~9020) K115ZV52013

Vinyl tube
Solenoid valve
pressure nut Solenoid valve 70ZV52019

1. Connect a vinyl tube to the air bleeder nipple pro-

vided in the axle housing, and place an oil can for
hydraulic oil recovery.
(The air bleeder nipple is equivalent to the one pro-
vided in the left brake valve).
Button
(diameter:
approximately 4 mm)
2. Loosen the air bleeder nipple a little. Press and
hold the left brake pedal until oil containing no air
Auto brake solenoid valve (S/N 0127~, 9021~) K115ZV52011
comes from the air bleeder nipple. After that,
tighten the air bleeder nipple.
5. Press the auto-brake solenoid valve release button Perform this operation for each of the four wheels.
five times with a five second wait period between
each turn. : Air bleeder nipple
Position the knob back to the normal position when 9 N-m (0.9 kgf-m) (6.5 lb-ft)
finished.
115ZV EX 52-28
52 Function & Structure Brake Group
Parking Brake

Parking Brake
The parking brake is a propeller shaft braking drum
type, and is connected to the transmission output shaft.

21

3
14
15 f
e o er
s t rok amb ke 1
2 8
ll h
Bra N)
22 Fu ing c 20 9
s pr (O 12 13 19
16 6
Brake 18
(OFF) FRONT 5
17
Apply grease

11

4 7
Front chassis

115ZV52012

1. Parking brake assembly 11. Oil seal 21. Lock nut

2. Housing 12. Pipe 22. Adjusting bolt
3. Spring chamber 13. Spring pin
4. Second propeller shaft 14. Joint yoke
5. Flange yoke 15. Arm
6. Brake drum 16. Head pin
7. Plate 17. Nut
8. Roller bearing 18. Bolt
9. Oil seal 19. Bolt
10. — 20. Bolt
 115ZV EX 52-29
52 Function & Structure Brake Group
Parking Brake

2
3

5 4
8 4 7

Lining thickness A
16±0.5 mm (0.63±0.02 in)

Wear limit
11.0 mm (0.43 in)

6 115ZV52013

When the parking switch is turned on, oil in the spring

chamber is returned to the tank, and the spring chamber
2 rod pulls up the lever (8).

Since the lever (8) is connected to the cam shaft (7), the
cam shaft rotates when the lever is pulled up.

The rotation of the cam shaft causes the shoes (4) on

Operating both sides of the cam to expand. As a result, the rotat-
direction ing brake drum is stopped.

8
115ZV52014

23. Adjuster
24. Bracket
25. Brake cover
26. Brake shoe
27. Spring
28. Anchor pin
29. Cam shaft
30. Lever
115ZV EX 52-30
52 Function & Structure Brake Group
Parking Brake

Parking brake operation Parking brake operation chart

Parking switch ON OFF

Solenoid valve Power-off Power-on
Spring chamber Oil discharge Oil feeding
Parking brake Braking Released

Solenoid valve
Oil
OFF
+
ON
Parking switch

Spring chamber

ke
Br a )
(ON

Brake
(OFF)

Parking brake

115ZV52011

Turning on (pulling out) the parking switch turns off the

power of the solenoid valve. Oil is discharged from the
spring chamber to the tank, and the spring in the spring
chamber pulls the parking brake lever.

Since the lever is connected to the cam shaft, the cam

shaft rotates when the lever is pulled up. The rotation of
the cam shaft causes the shoes on both sides of the
cam to expand. As a result, the rotating brake drum is
stopped.
 115ZV EX 52-31
52 Function & Structure Brake Group
Parking Brake

Parking brake solenoid valve

Spring chamber (brake actuator)

Solenoid (S/N 0101~0126, 9001~9020)
B Knob
Solenoid (S/N 0127~, 9021~)

Reducing
valve P

Manual release
T (counterclockwise rotation)
Spool
Seat Seat
face A face B Tank B

P T
Hydraulic circuit diagram K90ZV52012

Solenoid valve operation

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
Amp
closed. As a result, the oil from the reducing valve
enters the spring chamber, and the parking brake is
released.
a
0 a
Volt Note
The varistor (variable resistor) is used for the solenoid
coil to protect the circuit.

Varistor
95ZV42079

Solenoid valve specifications

While the parking switch is ON (that is, while the power
is not supplied to the solenoid), the seat face A is closed Voltage DC24 V
and the seat face B is open. As a result, the spring Current 0.69 A
chamber port is connected to the tank, and the parking Resistance 34.8 
brake is applied.
115ZV EX 52-32
52 Function & Structure Brake Group
Parking Brake Manual Release

Parking Brake Manual Release

Method 1
Solenoid valve
for auto-brake
(S/N 0127~, 9021~) (S/N 0101~0126,
Park brake solenoid 9001~9020)
valve release knob

Turn it counterclockwise.

Knob
Front Valve assembly Solenoid valve for parking

Transmission

K115ZV52020

WARNING
Sudden accidental movement of the machine could
result in serious injury or death.
Before manually operating the parking brake sole-
Valve assembly
noid: (Main brake
- Lower the boom and attachment to the ground. manifold block)
- Place chocks on both sides of the tires. K115ZV52014
- Be sure the machine is in neutral and engine is
stopped.
Turn the park brake solenoid valve release knob coun-
terclockwise. When you feel the detent position of the
Note solenoid valve, this will turn the park brake valve "OFF",
If the park brake cannot be released due to an electrical and supplies oil to the spring chamber, thereby releas-
problem, such as a failed park brake solenoid valve coil ing the park brake.
or electrical circuit, perform the following operation.

WARNING
If the manual operation knob is not returned to the
running position, the parking brake is disabled and
may result in a severe accident. Be sure to return the
manual operation knob to the OFF position after
releasing the parking brake by hand. Test the opera-
tion of park brake by using the controls in the opera-
tors cab.
 115ZV EX 52-33
52 Function & Structure Brake Group
Parking Brake Manual Release

Method 2
Dimension of parking brake releasing bolt

M12 X 1.75
Spring chamber

130

115ZA5410
1

115ZV52017
Remove two bolts (1) from the spring chamber head
cover. Evenly push in the parking brake releasing bolts
Spring chamber
offered as accessories of the front chassis until back-
lash is generated in the head pin (4) areas which con-
nect the lever and the arm (2) or connect the arm (2)
and the joint yoke (3) so that the spring force is
restrained. In this status, remove the head pins (4).
3

115ZV52018

Parking brake
releasing bolt

Front chassis

Parking brake releasing bolt installation position

115ZV52019
115ZV EX 52-34
52 Function & Structure Brake Group
Parking Brake Spring Chamber

Parking Brake Spring Chamber

13 17 9 6 22 2 12 16 12 4 3 14 15 7 5 20 19 1
10

11

Stroke
65 mm
18
8
Oil

21

23

Rod cover tightening hole

Width across flat: 24 mm 24

115ZV52021

1. Cylinder tube 10,954 N

2. Piston rod (1,117 kgf)
(24,149 lb)±10%
3. Piston 7,482 N
4. Cover (763 kgf)
(16,495 lb)±10%
5. Spring seat (A)
6. Spring seat (B)
7. Coil spring
8. Head cover
9. Rod cover Stroke
65 230 mm
10. Plane washer 140 295 (mounting length)
11. Hexagon bolt 435 (free length)
12. Filter
13. Stud bolt Spring specifications 115ZV52022

14. U-packing
15. Wear ring
The oil applies pressure to the internal spring to release
16. Wear ring
the parking brake.
17. Wear ring
18. O-ring
19. Set screw WARNING
20. U-nut Careless disassembling work may cause serious
21. O-ring injury or death.
22. Set screw The spring applies high force to the rod cover, there-
23. Hexagon bolt fore carefully disassemble the spring chamber using
24. Plane washer a press.
 115ZV EX 52-35
52 Function & Structure Brake Group
Brake Circuit Check Valve

Brake Circuit Check Valve

(S/N 0101~0126,
(S/N 0127~, 9021~) 9001~9020)

Poppet

(P) (T)
Seat face (TA)
Pump supply A (PI) (PARKING)
through
reducing valve (PA)
(Z1) (Z2)

(ACCR) (ACCF) (Z) (PPI)

B (ACCF)
Valve assembly
Reducing valve Accumulator
P = Pump supply
T = Tank circuit
PI = Pump feedback to unloader
(from ACCF circuit)
A B ACCR = Accumulator circuit-rear
ACCF = Accumulator circuit-front
Hydraulic circuit diagram PPI = Pilot valve circuit
PA = Auto brake circuit K115ZV52015

The pressure oil fed from the pump pushes down the
poppet, opens the seat face, and flows into the reducing
valve and the accumulator circuit.

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.
115ZV EX 52-36
52 Function & Structure Brake Group
Auto Brake

Auto Brake
When the traveling direction is switched over between Auto brake circuit
forward and reverse at a machine speed of 12 km/h (7.5
mph) or more, the auto brake is applied to protect the 61 To rear To front
transmission clutches. service brake service brake
31
A
When the machine speed is too high, the auto brake is C

applied also to prevent problems caused by excess B

speed in the engine and the transmission (over speed- 23 24
ing).
Pi AR AF Ap

Pp
Auto brake operation set value PR T PF Tp

1. When the traveling direction is switched over 1.0

between forward and reverse at a machine speed
1.0
of 12 km/h (7.5 mph) or more while the shift lever is
set to position A. B
From unloader 37
2. When the machine speed is too high in each speed valve (Pump)
range. Actual speed will vary with tire size.
T/M controller P T 27
Speed range Set value signal
1st Approximately 15 km/h (9.3 mph)
From reducing
2nd Approximately 22 km/h (13.7 mph) valve (Pump)
3rd
Approximately 36 km/h (22.4 mph) Shown in the "released" position K115ZV52021
4th/A

When the auto brake signal enters from the T/M control-
ler to the solenoid valve for auto brake (27) the solenoid
Solenoid valve valve (27) is energized and magnetized. The pilot oil
for auto-brake from the reducing valve enters the pilot port of the left
brake valve (23) through the shuttle valve (31), and
Solenoid valve
for park brake
actuates the pilot piston and the spool of the brake
valve.

When the spool is moved over, the high-pressure oil

coming from the pump through the unloader valve and
the reducing valve enters the front and rear brake piston
Front Valve assembly chambers to apply the service brake.

Transmission

K115ZV52020
 115ZV EX 52-37
52 Function & Structure Brake Group
Auto Brake

Solenoid valve (for auto brake circuit)

Not activated
Brake valve (shuttle valve)
B Spool

P
Reducing
valve

(S/N ~0126, ~9020)

(S/N 0127~, 9021~)

T
Tank
Seat face A Seat face B

B Solenoid

P T
Hydraulic circuit diagram
K115ZV52016

When the auto brake actuation signal is not given by the Solenoid specifications
transmission controller (that is, when the power is not
supplied to the solenoid), the seat face A is closed and Voltage DC24 V
the seat face B is open. As a result, the brake valve port Current 0.69 A
is connected to the tank, and the auto brake is not
Resistance 34.8 
applied.

When the auto brake actuation signal is given by the

transmission controller (that is, when the power is sup-
plied to the solenoid), the spool is pushed to the left, the Amp
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. a
0 a
Volt

Varistor
95ZV42079

Note
The varistor (variable resistor) is used for the solenoid
coil to protect the circuit.
115ZV EX 52-38
52 Function & Structure Brake Group
Shuttle Valve

Shuttle Valve

1 2
To brake valve port
C
C

A B

Hydraulic line diagram

To auto To brake
brake A B valve port
valve Ap

3 4

115ZV52027

1. Block
2. Plug
3. Ball
4. O-ring

The shuttle valve is a check valve, functioning as a kind

of direction control valve having two inlet ports (A)(B)
and one common outlet port (C).
The outlet port is automatically connected to either inlet
port which is having higher pressure.
 115ZV EX 53-1
53 Check & Adjustment Brake Group

53 Check & Adjustment

Brake Group

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

Service Brake ........................................................................53-8
Parking Brake......................................................................53-12
115ZV EX 53-2
53 Check & Adjustment Brake Group
Brake Circuit Oil Pressure

Brake Circuit Oil Pressure

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

WARNING
Unloader valve
K115ZV53008

Brake line main pressure is regulated by the unloader

valve.

Injection Hazard Measurement instrument

Depress brake pedal 80~100
times to completely discharge Hydraulic pressure gauge
the brake accumulators prior to 20 MPa (200 kgf/cm2) (3,000 psi)
removing these test plugs.
65ZV03009
 115ZV EX 53-3
53 Check & Adjustment Brake Group
Brake Circuit Oil Pressure

Gauge port Adjusting unloader valve setting pressure

Rc (PT) 1/8 (S/N 0101~0144, 9001~)

Tightening torque 24
22
: 14.7 N-m (1.5 kgf-m) (10.8 lb-ft) 21
Fan motor port

Standard measurement value

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

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

Measurement procedure Pump port

Unloader valve
1. Lower the boom to the lowest limit, and tilt the
70ZV53001
bucket down to the ground.
Then set the parking brake switch to the "ON" posi- (S/N 0145~)
tion.
21 22
2. Stop the engine. Repeatedly depress and release Fan motor port
the brake pedal till you feel light brake to discharge
accumulator pressure.

3. Remove the gauge port plug on the unloader valve

and attach the pressure gauge to the port.

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-
sure).
Pump port
5. Keep the engine at low idle, and repeatedly
Unloader valve
depress and release the brake pedal to reduce the K115ZV53002
accumulator pressure. Measure and record the
pressure when the pointer of the pressure gauge
stops and then starts rising again (cut-in pressure). 1. Remove the cap nut (24) and loosen the lock nut
(22).

2. Adjust the pressure by the adjusting screw (21).

Turn the screw clockwise to raise the pressure.

Note
In a case that the "ON" or "OFF" pressure does not
match the standard setting pressure, set the "ON" (cut-
in) pressure to the standard setting pressure.

Tightening torque
: Lock nut (22): 16.7 N-m (1.7 kgf-m) (12.3 lb-ft)
: Cap nut (24): 78.5 N-m (8.0 kgf-m) (57.86 lb-ft)
115ZV EX 53-4
53 Check & Adjustment Brake Group
Brake Circuit Oil Pressure

Accumulator circuit pressure measurement and adjusting

Accumulator line pressure is regulated by the unloader Standard measurement value
valve. However, the reducing valve also may affect
brake manifold pressure or accumulator pressure, as it 12.3 MPa (125 kgf/cm2) (1,783 psi)
is installed between the unloader valve and brake mani-
fold. Measure pressure at the ACF ports to determine
the manifold pressure when there is a brake pressure
problem. Measurement procedure

Measuring reducing valve setting pressure

WARNING
(S/N 0127~, 9021~) (S/N 0101~0126,
9001~9020)

Injection Hazard
Depress brake pedal 80~100
times to completely discharge
the brake accumulators prior to
removing these test plugs.
65ZV03009

1. Lower the boom to the lowest limit, and tilt the

bucket down to the ground.
Then, set the parking brake switch to the "ON" posi-
tion.

2. Stop the engine. Repeatedly depress and release

the brake pedal till you feel light brake to discharge
ACF port accumulator pressure.
Valve assembly
K115ZV53001 3. Remove one of the ACF port plug on the valve
assembly and attach the pressure gauge to the
port.
Measurement instrument
4. Start the engine, and keep the speed at low idle.
Hydraulic pressure gauge Measure and record the pressure.
20 MPa (200 kgf/cm2) (3,000 psi)
Note
In case the pressure is lower than the unloader cut-in
Gauge port pressure, adjust the reducing valve setting pressure to
see if this may affect the pressure setting. It may have a
ACF port on valve assembly: Rc (PT) 1/8 stuck plunger or another malfunction.
Tightening torque
: ACF port plug: 11.3 N-m (1.15 kgf-m) (8.3 lb-ft)
 115ZV EX 53-5
53 Check & Adjustment Brake Group
Brake Circuit Oil Pressure

Adjusting reducing valve setting pressure

Pressure test port (S/N 0104~, 9004~)

P

Lock nut

Adjusting screw

Reducing valve TA
K115ZV53007

1. Install an additional pressure gauge to the unloader Tightening torque

valve. (Refer to page 53-3.) : Lock nut: 7.8 N-m (5.8 lb-ft)

2. Start the engine, and keep the speed at low idle.

3. Raise the setting pressure of the unloader valve to

12.7 MPa (1,850 psi).

4. Loosen the locknut of the reducing valve and adjust

the pressure by the adjusting screw. Turn clockwise
the screw to raise the pressure.

Note
After raising the pressure to check function of valve, be
sure to reset the unloader valve pressure to the original
setting pressure.
115ZV EX 53-6
53 Check & Adjustment Brake Group
Brake Circuit Oil Pressure

Brake valve oil pressure Gauge port

Remove air bleeder nipple on the axle housing, and

(S/N 0126~, 9012~) then install the pressure gauge to the bleeder position.

Size of air bleeder port

Rc (PT) 3/8

(In case of the bleeder valve

M10 X 1.0)

Force
Air bleeder nipple
Pedal angle (S/N 0110~, 9007~)
16.4º
(S/N 0101~0125, 9001~9011) Air bleeder
nipple fitting
(S/N ~0109,
~9006)
15
0m
m

K115ZV53004

Air bleeder nipple fitting

: 59 N-m (6.0 kgf-m) (43 lb-ft)
K115ZV53003 : Loctite® 262 or equivalent

Measurement instrument

Hydraulic pressure gauge

10 MPa (100 kgf/cm2) (1,500 psi)
 115ZV EX 53-7
53 Check & Adjustment Brake Group
Brake Circuit Oil Pressure

Brake valve performance Measurement procedure

Check to be sure the brake valve is fully released.

Main Valve (Left pedal)
Press down the brake pedal to check that the oil pres-
277 (28.3)(62.3) sure rises in proportion to the pedal angle.
233.9 (23.9)(52.6)
Release the brake pedal to check that the oil pressure
N(kgf)(Ibf) drops to zero in proportion to the pedal angle. In addi-
tion, visually check for brake oil leakage.
294 (30)(66.14)
157
Pedal pressing force (F)

(16.0)(35.3)
122.5 When the measured value does not match the per-
(12.50)(27.6)
196 (20)(44.09) formance curve, check the following points.
88.2 (19.0)(19.8) 0 12~
)
78.4 (8.0)(17.6) 6 ~, 9
012 Possible cause Solution
(S/N
98 (10)(22.05) 90 11)
2 5, ~ Malfunctioning brake valve Repair or replacement
~ 01
70.6 (7.2)(15.9) (S/N
55.4(5.65)(12.5) Brake line oil pressure low
Check and repair
38.2 (3.90)(8.6) 46.2(4.71)(10.4) (Pump, reducing valve malfunction)
0 ( )
0 2 5 10 12 15 16.4
Pedal stroke
K115ZV53005
IMPORTANT
After measuring oil pressure, be sure to tighten the
air bleeder valve. Also be sure to bleed air.
Pilot Valve (Right pedal)

208.2(21.24)(46.8)

N(kgf)(Ibf)

294
(30)
(66.14)

196
(20)
(44.09)
105.2(10.73)(23.7)
98(10)
(22.05)
52.7(5.38)(11.9)
35.3(3.60)(7.9)
32.0(3.27)(7.2) ( )
0
0 2 5 10 12 15 16.4

K115ZV53006

Refer to the curve shown in the above figure.

115ZV EX 53-8
53 Check & Adjustment Brake Group
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
WARNING
1. Test course
Level, straight, dry and the paved ground. Unexpected movement of the machine may cause an
accident resulting in injury or death.
2. Run the machine and depress the brake pedal at Before starting brake performance check, be sure to
35 km/h (22 mph). observe the following items:
Measure and record the braking distance. - Place the machine on level ground.
- Check that there is enough clearance for brake
performance check around the machine.
- During performance check, prohibit any person to
Standard measurement value walking near the machine.

Braking distance
20 m (22 1/4 yard) or shorter 1. Lower the boom to the lowest limit, and roll back
the bucket fully until the bucket contacts to the stop-
per.

Possible causes of extremely long braking dis- 2. Set the parking brake switch to the "OFF" position.
tance
3. Set the T/M (transmission) cut-off switch to OFF,
Possible cause Solution and then depress the brake pedal all the way to the
Low brake line pressure Check and repair floor.
Friction plate wear Check and repair
Brake valve malfunction Check and repair 4. Set the shift lever to the 2nd reverse speed.

Note 5. Gradually increase the engine speed. The machine

The brake performance check condition and standard should not move at the maximum engine speed.
measurement values are based on the law and the reg-
ulation in Japan.
When checking the service brake performance, follow Possible cause of machine moving during
the law and/or local regulation in your country, state, or brake performance check.
province.
Possible cause Solution
Low brake line pressure Check and repair
Friction plate wear Check and repair
Brake valve malfunction Check and repair
 115ZV EX 53-9
53 Check & Adjustment Brake Group
Service Brake

Service brake friction plate wear measurement

A
Air bleeder nipple 200 mm
slide caliper

Slide
A caliper

Steel Retainer
plate

Friction plate

115ZV53002

Top
IMPORTANT
Internal gear
Oil inlet port Approx. After inserting calipers, do not rotate the wheels. If
Spring pin 2.5º Spring pin the wheels are rotated, the calipers may be caught
and broken by the reduction gear. In this case, the
reduction gear must be disassembled.

Outer steel
Inner steel plate teeth
plate teeth

115ZV53003

WARNING
Unexpected movement of machine could cause seri-
ous injury or death. To prevent such an accident,
observe the following items before checking the
brake friction plate wear:
- Park the machine on level ground.
- Apply the parking brake.
- Stop the engine.
- Determine the signals between the persons related
to this work for engine starting to prevent an acci-
dent.
- Prohibit any person from walking into the danger-
ous area.
115ZV EX 53-10
53 Check & Adjustment Brake Group
Service Brake

Measurement procedure

Turn the planetary gear so that the oil supply plug is

positioned at ±2.5º from the top. Check that the teeth of
steel plate are as shown in the right figure (only one
section of the plate circumference is as shown in the fig-
ure).

Insert calipers to the inner steel plate to measure the

dimension A.

Note
During measurement, be sure the service brake is
applied.

The wear limit for dimension A is 35.2 mm (1.386 in).

Note that dimension A is 41.0 mm (1.614 in) when the
plate is new and unused.

Note
To aid quick measurement on the front axle-raise the
front of the machine so the front tires clear the ground
by about 25 mm (1 in). This allows easy rotation of the
wheel to align the gear teeth.
 115ZV EX 53-11
53 Check & Adjustment Brake Group
Service Brake

Cautions on installing brake discs

When only the friction plates or the steel plates are to be A

replaced, if the brake piston and brake stroke adjusting B Wheel hub
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

Brake piston
mechanism by using the following procedure.

1. Loosen the axle housing air bleeder nipple.

115V2E53002

Upper side 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 the top and the bottom.

For pushing down A ...186.85 ~ 188.25 mm (7.356 ~ 7.411 in)

brake piston
Ref.: Stroke B ... 1.45 ~ 4.35 mm (0.057 ~ 0.171 in)

4. After confirming that the piston is fully retracted (the

dimension A falls within the specified range),
remove all four bolts.

5. After finishing the installation work, bleed air com-

pletely from the brake line.

115V2E53001

2. Insert bolts into four holes for pushing back the

brake piston, then tighten the four bolts evenly. The
piston should return evenly.

Bolt size for pushing brake piston back (4 required)

M10 x 1.5 - 45~50 mm (1.8~1.97 in) long
(Fully threaded)
115ZV EX 53-12
53 Check & Adjustment Brake Group
Parking Brake

Parking Brake

Parking brake performance check Method 2

If no test course available as described "Method 1",

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.
- During performance check, prohibit any person to
walking near the machine.
WARNING
Unexpected movement of the machine may cause an
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. 11º 19') - Place the machine on level ground.
- Check that there is enough clearance for brake
2. Bucket empty performance check around the machine.
- During performance check, prohibit any person to
3. Parking switch ON walking near the machine.

1. Set the parking brake switch to the "ON" position.

Standard measurement value
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 4. Place the shift lever to the 3rd reverse position.
brake performance check
5. Gradually increase the engine speed. The machine
Possible cause Solution should not move at the maximum speed.
Clearance between brake drum and shoe
Clearance adjustment
too large
Improperly adjusted spring chamber link Check and adjustment
IMPORTANT
Broken spring chamber spring Check and repair If the machine begins to move with the parking brake
Parking brake solenoid valve malfunction Check and repair applied, the brake shoes are burnt or misadjusted.
At the completion of parking brake test, be sure to
Note connect the connector of electrical line to the sole-
The brake performance check condition and standard noid valve again.
measurement values are based on the law and the reg-
ulation in Japan.
When checking the service brake performance, follow
the law and/or local regulation in your country, state, or
province.
 115ZV EX 53-13
53 Check & Adjustment Brake Group
Parking Brake

Possible cause Solution

Clearance between brake drum and shoe
Clearance adjustment
too large
Improperly adjusted spring chamber link Check and adjustment
Broken spring chamber spring Check and repair
Parking brake solenoid valve malfunction Check and repair
115ZV EX 53-14
53 Check & Adjustment Brake Group
Parking Brake

Parking brake clearance adjust- Adjustment procedure

ment
Rivet Brake shoe

A
Spring chamber
A: 11 mm (0.433 in)
Brake lining
Brake Rivet
shoe

B Wear limit

Adjusting bolt Lining 115ZV53004

1. Turn off the parking brake switch.

Inspection
window
2. Turn clockwise the adjusting bolt to expand the
brake shoes until the lining comes in contact with
the brake drum.

3. Turn counterclockwise the adjusting bolt by 3

notches.

Adjustment range

Standard shoe clearance

115ZV52020
0.3 ± 0.1 mm (0.012 ± 0.004 in)

WARNING
Brake lining wear check
Unexpected movement of the machine may cause a
severe accident. Checking the brake lining wear and
adjusting the parking brake clearance require the
parking brake to be released. Accordingly, take the
following safety measures to prevent accidental
movement.
- Park the machine on level ground.
- Block the tires on the ground with chocks.
- Place the bucket on the ground.
- Stop the engine, pull out the starter key, and place
a "DO NOT OPERATE!" tag on the operator's seat.
- Prohibit any person from walking into the danger-
ous area.
115ZV53005J

The rivets are inserted to fix the lining to the brake shoe.
If the distance from the lining to the rivet head "B" is 0.5
mm or less at one of the rivets areas, replace the shoe
assembly.
 115ZV EX 62-1
62 Function & Structure Electrical Group

62 Function & Structure

Electrical Group

How to Use Electrical Wiring Diagram ..................................62-2

Electrical Cable Color Codes ................................................62-8
Electrical Circuit Symbols......................................................62-9
Sensor Mount ......................................................................62-10
Fuse ....................................................................................62-11
Engine Start Circuit..............................................................62-14
Power Generating/Charging Circuit.....................................62-22
ECM (Engine Controller) .....................................................62-23
Transmission Control Circuit (S/N 0101~0153, 9001~).......62-42
Transmission Control Circuit (S/N 0154~)...........................62-63
Monitor Circuit .....................................................................62-68
Instrument Panel and Switch...............................................62-74
Electrical Detent Circuit .......................................................62-82
Diode ...................................................................................62-85
Diagnostic System (S/N 0101~0153, 9001~) ......................62-89
MODM (S/N 0154~) ............................................................62-99
115ZV EX 62-2
62 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 VIBRATION NEUTRAL BACK LAMP HORN RELAY CONTROLLER

RELAY DAMPER RELAY RELAY RELAY FAULT 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.
 115ZV EX 62-3
62 Function & Structure Electrical Group
Utilisation des schémas des câblages électriques (FRANÇAIS)

Utilisation des schémas des câblages électriques

(FRANÇAIS)
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 défaillance

d’ écartement contrôle de marche Relais neutre arrière Relais du klaxon du contrôleur

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
(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

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

Les schémas des câblages électriques sont basés sur Exemple 3

la méthode de l’adressage. Suivant cette méthode, un Contrôle de la borne du connecteur à laquelle F704 RL
symbole correspond à chaque connecteur et à chaque (point (3)) est connectée:
borne du connecteur de manière à localiser facilement
la borne de connection de l’autre extrémité du câble. 1. F704
Indique que la borne est connectée à la 4ème
Exemple 1 borne du connecteur F7.
Symbole au-dessous (ou au-dessus) du connecteur, Contrôlez la description de la 4ème borne du con-
comme F6: necteur F7 (F704), elle indique que la borne F704
Il indique l’adresse du connecteur. est connectée à H128. Ceci signifie que la 4ème
borne du connecteur F7 est connectée à la 28ème
Exemple 2 borne du connecteur H1.
Symbole sur le connecteur multibornes, comme 1 et 10: 2. RL
Il indique le numéro de la borne et le sens de la Indique la couleur du fil. “RL” signifie que la couleur
numérotation. de l’isolation est rouge, et “L” que la raie bleu est
sur l’isolation rouge.
115ZV EX 62-4
62 Function & Structure Electrical Group
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 Rückleuchtenrelais Hupenrelais Reglerfehlerrelais

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
(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

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

Für den elektrischen Schaltplan wird die Adressenmeth- Beispiel 3

ode verwendet. Damit wird jeder Steckvorrichtung und Überprüfung der anderen Steckvorrichtungsklemme, wo
jeder Anschlußklemme ein Symbol zugeordnet, damit F704 RL (Artikel (3)) angeschlossen ist:
die Klemme, an die das andere Ende des Kabels ange-
schlossen werden muß, leicht gefunden werden kann. 1. F704
Zeigt, daß die Klemme an die vierte Klemme der
Beispiel 1 F7-Steckvorrichtung angeschlossen ist.
Symbol unterhalb (oder oberhalb) der Steckvorrichtung, Überprüfen Sie die Beschreibung in der vierten
wie z. B. F6: Klemme des F7-Steckvorrichtung (F704). Zie gibt
Zeigt die Adresse der Steckvorrichtung an. an, daß die Steckvorrichtung F704 an H128 ange-
schlossen ist. Dies bedeutet, daß die vierte
Beispiel 2 Klemme der F7-Steckvorrichtung an die 28.
Symbol an der Mehrklemmen- Anschlußstelle, wie z. B. Klemme der H1-Steckvorrichtung angeschlossen ist.
1 und 10: 2. RL
Zeigt die Klemmennummer und die Zählrichtung an. Zeigt die Farbe des Kabels an. „ RL ” bedeutet, daß
der lsolierdraht rot ist, und „ L ” bedeutet, daß sich
auf dem roten lsoliermaterial ein blauer Streifen
befindet.
 115ZV EX 62-5
62 Function & Structure Electrical Group
Modalità di utilizzo dello schema dei collegamenti elettrici (ITALIANO)

Modalità di utilizzo dello schema dei collegamenti elettrici

(ITALIANO)
Esempio
10 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

Relè di larghezza Relè di controllo Relè della lampada Relè del controller
della lampada della guida Relè neutro posteriore Relè del clacson d’ errore

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
(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

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

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 dell’altro connettore cui è collegato
tatto viene associato un simbolo che permette di identifi- F704 RL (elemento (3)):
care agevolmente il contatto cui è collegata l’altra
estremità del cavo. 1. F704
Indica che il terminale è 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 l’indirizzo del connettore. è collegato a H128. Ciò indica che il contatto n.4
del connettore F7 è collegato al contatto n. 28 del
Esempio 2 connettore H1.
simbolo presso un connettore a più 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. dell’isolante è rosso, e “L” rappresenta che una
linea blu è presente sull’isolazione rossa.
115ZV EX 62-6
62 Function & Structure Electrical Group
Cómo utilizar un Diagrama de Alambrado Eléctrico (ESPAÑOL)

Cómo utilizar un Diagrama de Alambrado Eléctrico

(ESPAÑOL)
Ejemplo
10 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

Relé de la lámpara Relé de control Relé de la lámpara Relé de fallos

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

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
(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

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

El método de dirección se utiliza para diagrama de Ejemplo 3

alambrado eléctrico. Para este método, se pega un Comprobando el otro terminal de conector donde se
símbolo a cada conector y terminal de conector a fin de conecta F704 RL (ítem (3)):
localizar fácilmente el otro terminal al cual se conecta el
otro extremo del cable. 1. F704
Muestra que el terminal está conectado al terminal
Ejemplo 1 4o del conector F7.
Símbolo debajo (o encima) de conector, tal como F6: Compruebe la descripción en el terminal 4o del
Muestra la dirección del conector. conector F7 (F704). Esto muestra que el terminal
F704 está conectado a H128 y significa que el ter-
Ejemplo 2 minal 4o del conector F7 está conectado al terminal
Símbolo en el conector del multiterminal, tal como 1 y 28o del conector H1.
10: 2. RL
Muestra el número de terminal y la dirección de numer- Muestra el color del alambre “RL” y representa que
ado. el color aislante es rojo, y “L” representa que una
raya azul está en el aislamiento rojo.
 115ZV EX 62-7
62 Function & Structure Electrical Group
Como Utilizar o Diagrama de Ligações Eléctricas (PORTUGUÊS)

Como Utilizar o Diagrama de Ligações Eléctricas

(PORTUGUÊS)
Exemplo
10 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

Relé de luz Relé de controlo Relé de controlo

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

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
(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

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

O método de endereçamento é utilizado para os diagra- Exemplo 3

mas de ligações eléctricas. Para este método, cada Verificar o outro terminal de conectores, no qual F704
conector e terminal de conector tem um símbolo acop- RL (item (3)) é ligado:
lado para facilitar a localização do outro terminal onde a
outra extremidade do cabo deve ser ligada. 1. F704
Ilustra que o terminal é ligado ao 4o terminal do
Exemplo 1 conector F7.
Símbolo por baixo (ou por cima) do conector, como F6: Verifique a descrição no 4o terminal do conector F7
Indica o endereço do conector. (F704), indica que o terminal F704 está ligado ao
H128. Isto significa que o 4o terminal do conector
Exemplo 2 F7 está ligado ao 28o terminal do conector H1.
Símbolo no conector de multiterminais, como 1 e 10: 2. RL
Indica o número do terminal e a direcção da numer- Indica a cor do fio. “RL” representa que a cor do
ação. isolamento é vermelha e “L” representa uma faixa
azul está no isolamento vermelho.
115ZV EX 62-8
62 Function & Structure Electrical Group
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 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) V

Insulation color

Stripe color

70ZV62001
 115ZV EX 62-9
62 Function & Structure Electrical Group
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
Mechanical coupling
(Not connected)

Relay contact
Terminal
("a" contact)

Relay contact
Ground
("b" contact)

Resistance or Resistor Switch

Variable resistance or Variable Pressure switch or

resistor Temperature switch

Inductance or Electromagnetic Negative -positive-

coil negative (NPN) transistor

Positive -negative-
Battery or Direct voltage source
positive (PNP) transistor
115ZV EX 62-10
62 Function & Structure Electrical Group
Sensor Mount

Sensor Mount

2 10 7 1

9 8 3

1
9
3 A

5
A 115ZV62013J

1. Engine water level alarm sensor 7. Engine speed sensor

2. T/M oil temperature switch 8. T/C oil temperature switch
3. T/C oil temperature sensor 9. Air cleaner clogging switch
4. Engine water temperature sensor 10. Machine speed sensor
5. Engine water temperature switch (S/N ~0120,
~9010)
Cold starter temperature switch (S/N 0121~,
9011~)
6. Cold starter temperature switch (S/N ~0120,
~9010)
Air conditioner water outlet (S/N 0121~, 9011~)
 115ZV EX 62-11
62 Function & Structure Electrical Group
Fuse

Fuse
The following fuses are provided to protect electrical cir- Fuse box location
cuits.
(S/N 0101~0140, 9001~9020)
Fusible link 2
70 A x 2, 30 A x 1

Fuse box
15 fuses x 2 (for chassis and cab)

CAUTION
Possible burn hazard. Before replacing a fuse, be
sure to turn off the starter switch.
S97ZVOM0086

IMPORTANT
(S/N 0141~, 9021~)
Replace a fuse with the same capacity.
If a fuse blows immediately after replacement, the 2
electric system is defective. Locate the defective part, 1
and then repair it.

S97ZV8210

1. For chassis
2. For cab

(For installation positions, refer to "Electrical Equipment

Layout" too.)
115ZV EX 62-12
62 Function & Structure Electrical Group
Fuse

Fuse box 2. For cab

Fuse
1. For chassis Fuse No. capacity Protective circuit
(A)
Fuse 16 5A Spare
Fuse No. capacity Protective circuit 17 5A Spare 20A
(A)
18 5A R. wiper
1 20A Lighting head light Spare
19 10A F. wiper
2 15A R. work light 20A
20 10A Cigar lighter 15A
Boom kickout
3 10A 21 15A Spare
Bucket leveler Spare
Back lamp Spare 22 3A Radio
4 15A Stop lamp 23 10A Spare 10A
Turn signal
24 10A Spare
5 10A Parking brake controller 15A Spare
25 20A Spare
6 15A F. work light
Spare 26 5A Air conditioner 5A
7 10A Spare
27 5A Air conditioner
8 15A Spare 10A Spare
28 10A Air conditioner
9 15A Spare
29 20A Air conditioner
4-way flasher
Spare 30 20A Spare
Horn
10 15A
Room lamp
Radio backup
11 10A Spare 5A
12 15A Cold starter
Buzzer Spare
13 5A
Monitor
14 5A Neutral relay
Battery relay
15 5A
ECM
 115ZV EX 62-13
62 Function & Structure Electrical Group
Fuse

Fusible link (003)W

(002)W5
(001)
[W5]
12V 12V
30A
[W](004,005,
009) ECM Battery
(006) (008)
1.25 (018)
R1 BR WR F15 WR WP
B AC
R2 C 5A [WV]
(010)
G 1.25
(013) Battery

F14
5A
relay
G1.25
(014)
Starter

70A
(1)
B C

Fusible link Magnetic S/W (012)

[R5] (011) BW5 Voltage
relay
RL1.25 (015) [WG](016)
NR

(108)
(Lg) (WG) (019)
F13 WL Monitor
Charge lamp WL1.25
controller
S115ZV0005 (017)
(2)
20 R
70A B I
E
R5X6 Alternator 20
Fusible link (020~025)

Cover Cold starter Thermo Ether

Fuse S/W S/W (032) Injector
F12 [BrR]
element (029)
(007)
R 15A WB WP
(030) (031)
1.25
WR
(108)
F13 (Lg)
T/M
5A controller
B ACC’ E
(BR)

Fusible link location

K115ZV62001

Box for fusible link Fusible link Problems caused by fused fusible link
70ZV62010

Fuse Problem (symptom)

The fusible link is located in the box at the left rear of the damaged During engine operation During engine stop
machine as shown in the above figures. - Engine will stop auto-
- All the electrical circuit
matically.
will not function.
30A - All the power for all
If excessive current flows through the starter switch or - Engine can not be
electrical circuit will be
started.
the electric line downstream of the starter switch due to OFF.
shortcircuit, the fuse element will be blown to protect the - Horn [and optional
circuit. The condition of the fuse element can be seen flasher] will operate.
- All the others will not
through the transparent cover. operate and the
- The same conditions
Determine the cause before replacing the fusible link. 70A
machine can not be
as “During engine oper-
operated.
(1) ation” but engine can
- Engine will not stop
For replacement of a fusible link, remove 2 bolts and automatically but can
not be started.
pull it up. be stopped by turning
the starter switch to
“OFF”.
- The machine can be
operated but the batter- - The same conditions
70A
ies can not be charged as “During engine oper-
(2)
and the batteries will be ation”.
discharged soon.
115ZV EX 62-14
62 Function & Structure Electrical Group
Engine Start Circuit

Engine Start Circuit

Engine start circuit diagram (S/N 0101~0153, 9001~)

Starter switch
Terminal
B C AC
OFF
ON Fusible link
Start
Battery (24 V)

T/M controller
F15
5A
Shift lever
Shift lever F/R position

Battery relay
N ECM
R F
Diode unit
Starter motor
From alternator
F14
+24V 5A Magnetic S/W

3
LED
4
(Indication: N)
1 2

Neutral relay
Voltage relay

+24V Neutral
current
* When shift lever is in F/R position: OFF alternator
When shift lever is in N position: ON

95ZV62014
 115ZV EX 62-15
62 Function & Structure Electrical Group
Engine Start Circuit

Engine start circuit diagram (S/N 0154~)

Starter switch
B BR ACC R1 R2 C
Preheat
Off
On
Start

MCU

12V 12V
Shift lever F/R position

B18 30A
E24
B12 Fusible link Battery
D11 B11
D04
F N R F15 Diode unit
F14
5A

5A

1
23A
D12
D05
D03 Battery relay Starter motor
D10
70A
(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

95ZVE62058
115ZV EX 62-16
62 Function & Structure Electrical Group
Engine Start Circuit

Neutral starter
To prevent the machine from unexpected movement at
engine start up, the machine is so designed that the
engine can start only while the shift lever is in the 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.
 115ZV EX 62-17
62 Function & Structure Electrical Group
Engine Start Circuit

Starter switch

OFF
30º ON
35º
Start
B
C
C
AC
BR

R1

R2

Connection table
W3 W5 B ACC C
OFF
BW R1 BR WRx2
B ACC WBx2 ON
R2
BG C G
Start
To magnetic switch
To battery relay
From battery

BW WR WR G W
BG WB WB W

95ZV62116

OFF
Starter Enables insertion and removal of the starter key.
switch All the electrical circuits (except the horn and optional
hazard flasher) will be turned off.

ON
Supplies power to the charge, lamp, and monitor cir-
cuits.

Start
Starts the engine.
S65ZV5088
115ZV EX 62-18
62 Function & Structure Electrical Group
Engine Start Circuit

Battery relay Alternator I terminal wire

12V 12V
30A

ECM Battery (1)

Terminals for coil Moving contact R1 BR F15 (2) (3)
energizing current B AC
5A
(4 mm) Main contacts R2 C

(2)(3) Diode unit

Battery

F14
5A
relay Suppression diode
BR
B
Charge circuit
Terminals for Monitor circuit
main current From alternator
Coil for energizing (8 mm) Neutral relay terminal
95ZV62017 K115ZV62003

When the starter switch is turned to ON or the Start Engine motion-active circuit:
position, the battery relay is turned on. When the starter
switch is set to the OFF position, the alternator stops When the starter switch is turned OFF, the battery relay
generating power, and the battery relay is automatically is automatically turned OFF since the command current
turned off so that the electrical circuits will not function. from the starter switch terminal ACC stops flowing and
the coil is demagnetized. Then the charging circuit from
If the battery relay was not used, a large amount of cur- the alternator is shut down.
rent would be directly sent through the starter switch
when it is turned on. However, use of the battery relay However, the alternator is still generating power and the
reduces the amount of current because this relay needs load dump surge may be generated. This may damage
only a small amount of current to energize it. the related circuits and equipment. In order to prevent
this trouble, this circuit (1) is provided to hold the battery
relay in the "ON" position.
Battery relay operation

Starter switch

ACC B
From
charge Battery relay
circuit
(B)
To main
circuit (E)
Battery

Suppression
diode 65ZV62028

Battery relay
Rated voltage DC 24 V
Minimum operating voltage 20 V or less
Release voltage 9 V or less

When current flows from the starter switch terminal

ACC, the coil will be energized, and the moving contact
will lower to close the main contact. As a result, current
will flow from the battery to the main circuit.
 115ZV EX 62-19
62 Function & Structure Electrical Group
Engine Start Circuit

Diode unit
1. Diode (2)
This diode is provided to prevent the roundabout
current from the alternator to the controller.
WV: To battery relay
WR: To starter switch terminal ACC (VIA F15), ECM 2. Diode (3)
WP: To alternator This diode is provided to prevent the roundabout
WV
current from the starter switch ACC to the alternator
WR WP
I terminal.

Diode storage section

70ZV62017

The diode unit is incorporated in the milky white connec-

tor near the battery relay. It is provided for the following
purpose.

Neutral relay

1 4

SbP

L
RL

G
2 3

Internal connection dia.

Body black

K90ZV62005

Position of Between Between

Starting
When the shift lever is in the N position while the starter
shift lever 1 and 4 2 and 3 switch is kept at the Start position, the neutral relay is
F or R Not energized OFF Impossible magnetized and electric current flows from the battery
N Energized ON Possible to the neutral relay / magnetic switch / voltage relay
through the starter switch terminal C.
The structures of the neutral relay, back-up relay, horn
relay, width lamp relay, head lamp relay, oil pressure Rating DV 24 V
relay and water temperature relay are identical each Operating voltage 16 V or less
other. Reset voltage 2.4 V or more
Coil resistance 320 
Note
The illustration shows the de-energized condition.
115ZV EX 62-20
62 Function & Structure Electrical Group
Engine Start Circuit

Magnet switch

Rating 24V x 200A

M C

C C’

M’
M’ C’

70ZV62019

Note On the other hand since the battery relay is already ON

The illustrations show the de-energized condition. at this time, electric current flows from the battery to the
starter motor terminal C through the battery relay and
When the neutral relay is magnetized, electric current the magnetic switch, engaging the starter motor to start
flows from the battery to the neutral relay and the mag- engine.
netic switch through the starter switch terminal C. It
magnetizes the magnetic switch.

Voltage relay
(S/N 0101~0145, 9001~) (S/N 0146~)

Blue
1
2 3

1 4
4

70ZV62020

Note
The illustrations show the de-energized condition.
K70V2J62005

Voltage relay
Contact point closed 6V Voltage relay
Contact point open 9V Contact point closed 6V
Contact point open 8V
 115ZV EX 62-21
62 Function & Structure Electrical Group
Engine Start Circuit

Once the engine is started, the alternator starts generat-

ing electric power.

When electric current is supplied from the alternator R

terminal to the voltage relay, the voltage relay is magne-
tized and is turned OFF.

Consequently the magnetic switch turns OFF and no

electric current flows to the starter motor terminal C, dis-
engaging the starter motor.
115ZV EX 62-22
62 Function & Structure Electrical Group
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.
 115ZV EX 62-23
62 Function & Structure Electrical Group
ECM (Engine Controller)

ECM (Engine Controller)

Function of ECM
- Stops the engine.
- Operates the engine.
- Monitors the engine, and diagnoses it for faults.

Connection diagram
B (S/N 0123~,
W 9011~)
B
(Y)
C
(YB)
D Data link
(YG) connector
E
(YL)
14 F
(YO)
B 15 G
A
[W] E
(W) G
10A
[W] Throttle pedal
B 10A D
BrW
Throttle
4 opening
YO YV
To tachometer converter 22 5 sensor
BLg
6
WR IDLE SW
F15 1
Power supply to ECM
is from ACC terminal
of starter switch. (Lgh) OFF IDLE
F13 7
GyY
(BrR)
STOP R 16 BL
31
(BrB)
WARNING Y 17 GyW
8
(BrW) IDLE
E/G PROTECTION O 18

E
Diagnostic S/W

INC/DEC SW
INC PG (071)
12 V
PW
(m) 13 T
DEC (072)
U
E/G mode selection S
BR
14
GyR Remote throttle
(S/N 0103~, EP A
BrL
9004~) FR C GR
P
(Lg) GY
F13 N
E/G mode selection BR BG
14 X
GyR
EP A
GyO
WT C

15
E

ECM K115ZVE62002
115ZV EX 62-24
62 Function & Structure Electrical Group
ECM (Engine Controller)

Monitor lamp test

ON
Key switch Approx.
OFF
2 sec
ON
Engine protection lamp Orange
OFF

ON
Engine warning lamp Lights when
abnormality Yellow
OFF
occurs.
ON
Engine stop lamp Red
OFF
95ZV62025

POWER

STOP

Engine protection lamp

Engine warning lamp

Engine stop lamp

K115ZV62005

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.
 115ZV EX 62-25
62 Function & Structure Electrical Group
ECM (Engine Controller)

Failure diagnosis Diag. Inc/Dec switch assembly (option)

There are two optional equipment for the engine failure

Diag. switch Inc./Dec. switch
diagnostic. (Part Number: 35010-60130) (Part Number: 35010-60180)
One is mounted in the instrument panel of the machine.
The other is the assembled parts of cable and switches
to be temporarily connected to the provided connector.

G R R
L W G Y

Cable assembly
(Part Number: 33191-49150)
70ZV62069

Diagnostic switch Increment/decrement switch

K85ZV62007

When premounted in the instrument panel:

1 2
95ZV62115

1. Diagnostic switch (option)

2. Increment / decrement switch (option)
115ZV EX 62-26
62 Function & Structure Electrical Group
ECM (Engine Controller)

When temporarily connected to the provided con- The engine diagnostic switch is used to check the
nector: engine failure when any one of the engine warning lamp
is turned on.

SHIFT
Refer to the following "Engine diagnostic switch
S/W (option)" page 62-27 for details.
DIAG. INC./DEC. PILOT VALVE
SWITCH KICK POSITIO
OUT -NER FLOAT

The increment/decrement switch is used to check the

history of the engine failure.
BY
YL

H106

H112
BrW
E116

E119

BrB

B
PG PW
H658 H644
Br Br Br
BrW BL
H602 H669
1 D112 D112 D112 The increment/decrement switch is also used to adjust
1 1 1
2 1
Br Br
(BLUE) the engine idle revolution.
BrB BrW
G1 G2 G3 G4 G5 Refer to "Increment decrement switch (option)" page
K115ZVE62004 62-29 for details.

Fuse box (Cab)

Diag Inc/Dec switch connector
(S/N 0108~, 9004~) Fuse box (Main)

Front

Diag Inc/Dec
switch
connector
(S/N ~0107,
~9003)
K115ZVE62005

The Diag. Inc/Dec switch assembly is available to be

temporarily connected to the Diag. Inc/Dec switch con-
nector at the cab control box.
 115ZV EX 62-27
62 Function & Structure Electrical Group
ECM (Engine Controller)

Engine diagnostic switch (option) After checking the fault, terminate the fault diagnosis
with the following procedure.
When any one of the engine warning lamp is turned on,
use this switch to check the engine failure as follows. 1. Set the engine diagnostic switch to OFF.
2. Set the starter switch to OFF.

When no fault has occurred:

OFF
ON
The three engine monitor lamps remain lit.
START
When any fault has occurred:

The three engine monitor lamps light, become extin-

guished once, then the red (engine stop) and yellow
(engine warning) lamps flash to indicate a recorded
three-digit fault code.
95ZV62028
The chart below shows how the flashing pattern should
be converted into a three-digit fault code.
1. Set the starter switch to OFF.
At first, the yellow lamp lights and becomes OFF.

Next, the red lamp flashes to indicate a fault code

recorded in a 3-digit number. After a fault code is indi-
cated once, the yellow lamp lights again and becomes
? OFF again.

Refer to the chart on the next page for example.

The same fault code is continuously indicated until the

next fault code is indicated by pressing the inc/dec
Diagnostic switch
switch (option).
95ZV62027

2. Set the engine diagnostic switch to ON.

3. Set the starter switch to ON.

ON
OFF
Orange
1 sec 1 sec
ON
OFF
Yellow

0.5 sec
ON
OFF
Red Second
First digit digit Third digit
1 sec 1 sec

Fault code Indicated repeatedly

95ZV62029
115ZV EX 62-28
62 Function & Structure Electrical Group
ECM (Engine Controller)

Failure diagnostic chart

ON
Key switch
OFF

ON
Diagnostic switch
OFF

[When there is not fault code]

ON
Engine protection lamp
OFF

ON
Engine warning lamp
OFF
ON
Engine stop lamp
OFF

[When there is fault code]

ON
Engine protection lamp
OFF
1 sec 1 sec
ON
Engine warning lamp
OFF

ON
Engine stop lamp
OFF

100's digit 1 sec 10's digit 1 sec 1's digit

Fault code
[Example: Failure code 131]
High voltage detected at throttle
position signal circuit.

ON
Engine protection lamp
OFF
1 sec 1 sec
ON
Engine warning lamp
OFF

ON
Engine stop lamp
OFF
1 3 1

Following page explains more.

95ZV62026
 115ZV EX 62-29
62 Function & Structure Electrical Group
ECM (Engine Controller)

Increment decrement switch (option) This switch is used to

1. Check the history of the engine failures

2. Adjust the engine idle revolution

Check the engine failure history

Set the starter switch to ON and set the engine diagnos-

tic switch to ON.

When a fault code is indicated, pressing this switch on

the + side indicates the next fault code, and pressing
Increment/decrement switch on the - side indicates the previous fault code.

After indicating all currently present fault codes, press-

ing this switch to the + side to indicate the third or fourth
When premounted in the instrument panel: fault code, and pressing this switch to the - side to indi-
cate 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" page 62-

30 for details.

Adjust the number of revolutions of the engine

in the idle status
2
1 Set the starter switch to ON, set the engine diagnostic
95ZV62115
switch to OFF, and run the machine in the idle status.

1. Diagnostic switch (option) In this status, press this switch either the + or - side to
2. Increment / decrement switch (option) change the number of revolutions of the engine within
the range between 650 min-1 (rpm) and 900 min-1 (rpm).
When temporarily connected to the provided con-
nector: Pressing the switch + side increments the revolution
number by “25 min-1 (rpm)” up to 900 min-1 (rpm).
Fuse box (Cab) Pressing the switch - side decrements the revolution
Diag Inc/Dec switch connector
(S/N 0108~, 9004~) Fuse box (Main) number by “25 min-1 (rpm)” down to 650 min-1 (rpm).

The engine idle revolution number is not changed over

900 min-1 (rpm) or below 650 min-1 (rpm) even if press-
ing the switch.
Front

Diag Inc/Dec
switch
connector
(S/N ~0107,
~9003)
K115ZVE62005
115ZV EX 62-30
62 Function & Structure Electrical Group
ECM (Engine Controller)

Quantum fault code information

These codes show the fault codes for the engine failure
checked by the diagnostic switch (option).

Please note that not all are used in the 115ZV machine
application. Refer to Cummins Engine troubleshooting
fault codes list for more information.

QST30 (135ZV)
QSK19 (115ZV)
QSB5.9 (70ZV)

QSM11 (90ZV)

QSX15 (95ZV)
QSL9 (85ZV)
FAULT
CODE/ DESCRIPTION
LAMP

EG111
Engine Control Module (ECM) - critical internal failure.
Red
EG115 Engine Speed / Camshaft Position Sensor Circuit - lost both of two signals from the
Red magnetic pickup sensor.
EG121 Engine Speed / Position Sensor Circuit - lost one of two signals from the magnetic
Yellow 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 high.
Yellow
EG145
Engine Coolant Temperature Sensor Circuit - voltage below normal or shorted low.
Yellow
EG146
Engine Coolant Temperature High - warning.
Yellow
EG147
Accelerator Pedal Position Sensor Circuit - low frequency.
Red
EG148
Accelerator Pedal Position Sensor Circuit - high frequency.
Red
EG151
Engine Coolant Temperature High - critical.
Red
EG153 Intake Manifold Air Temperature Sensor Circuit - voltage above normal or shorted
Yellow high.
EG154
Intake Manifold Air Temperature Sensor Circuit - voltage below normal or shorted low.
Yellow
EG155
Intake Manifold Air Temperature Sensor High - critical.
Red
 115ZV EX 62-31
62 Function & Structure Electrical Group
ECM (Engine Controller)

QST30 (135ZV)
QSK19 (115ZV)
QSB5.9 (70ZV)

QSM11 (90ZV)

QSX15 (95ZV)
QSL9 (85ZV)
FAULT
CODE/ DESCRIPTION
LAMP

EG187
Sensor Supply Voltage #2 Circuit - shorted low.
Yellow
EG195
Coolant Level Sensor Circuit - shorted high.
Yellow
EG196
Coolant Level Sensor Circuit - shorted low.
Yellow
EG197
Coolant Level Low - warning.
Yellow
EG212
Engine Oil Temperature Sensor Circuit - shorted high.
Yellow
EG213
Engine Oil Temperature Sensor Circuit - shorted low.
Yellow
EG221
Ambient Air Pressure Sensor Circuit - shorted high.
Yellow
EG222
Ambient Air Pressure Sensor Circuit - shorted low.
Yellow
EG223
Engine Oil Burn Valve Solenoid Circuit - shorted low.
Yellow
EG227
Sensor Supply Voltage #2 Circuit - shorted high.
Yellow
EG234
Engine Speed High - critical.
Red
EG235
Engine Coolant Level Low - critical.
Red
EG238
Sensor Supply Voltage #3 Circuit - shorted low.
Yellow
EG241
Vehicle Speed Sensor Circuit - data incorrect.
Yellow
EG242
Vehicle Speed Sensor Circuit - invalid signal detected.
Yellow
EG245
Fan Control Circuit - shorted low.
Yellow
EG253
Engine Oil Level - below normal operating range.
Red
EG254
Fuel Shutoff Solenoid Supply Circuit - less than +6 VDC detected.
Red
EG255
Fuel Shutoff Solenoid Supply Circuit - externally supplied voltage detected.
Yellow
EG256
Ambient Air Temperature Sensor Circuit - shorted low.
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
EG268
Fuel Pressure Sensor Circuit - data incorrect.
Yellow
EG271
Fuel Control Actuator Circuit - shorted low.
Yellow
EG272
Fuel Control Actuator Circuit - shorted high.
Yellow
115ZV EX 62-32
62 Function & Structure Electrical Group
ECM (Engine Controller)

QST30 (135ZV)
QSK19 (115ZV)
QSB5.9 (70ZV)

QSM11 (90ZV)

QSX15 (95ZV)
QSL9 (85ZV)
FAULT
CODE/ DESCRIPTION
LAMP

EG284
Engine Speed / Position Sensor #1 (Crankshaft) Supply Voltage Circuit - shorted low.
Yellow
EG285
SAE J1939 Data Link Multiplexing PGN Timeout Error.
Yellow
EG286
SAE J1939 Data Link Multiplexing Configuration Error.
Yellow
EG287
SAE J1939 Multiplexing Accelerator Pedal Sensor System Error.
Red
EG288
SAE J1939 Multiplexing Remote Accelerator Pedal Sensor System Error.
Red
EG293
Auxiliary Temperature Sensor Input #1 Circuit - shorted high.
Yellow
EG294
Auxiliary Temperature Sensor Input #1 Circuit - shorted low.
Yellow
EG295
Ambient Air Pressure Sensor Circuit - data incorrect.
Yellow
EG296
Auxiliary Pressure Sensor Input #2 Engine Protection - critical.
Red
EG297
Auxiliary Pressure Sensor Input #2 Circuit - shorted high.
Yellow
EG298
Auxiliary Pressure Sensor Input #2 Circuit - shorted low.
Yellow
EG311
Injector Solenoid Valve Cylinder #1 Circuit - grounded circuit.
Yellow
EG312
Injector Solenoid Valve Cylinder #5 Circuit - grounded circuit.
Yellow
EG313
Injector Solenoid Valve Cylinder #3 Circuit - grounded circuit.
Yellow
EG314
Injector Solenoid Valve Cylinder #6 Circuit - grounded circuit.
Yellow
EG315
Injector Solenoid Valve Cylinder #2 Circuit - grounded circuit.
Yellow
EG319
Real Time Clock - power Interrupt.
Yellow
EG321
Injector Solenoid Valve Cylinder #4 Circuit - grounded circuit.
Yellow
EG322
Injector Solenoid Valve Cylinder #1 Circuit - open circuit.
Yellow
EG323
Injector Solenoid Valve Cylinder #5 Circuit - open circuit.
Yellow
EG324
Injector Solenoid Valve Cylinder #3 Circuit - open circuit.
Yellow
EG325
Injector Solenoid Valve Cylinder #6 Circuit - open circuit.
Yellow
EG331
Injector Solenoid Valve Cylinder #2 Circuit - open circuit.
Yellow
EG332
Injector Solenoid Valve Cylinder #4 Circuit - open circuit.
Yellow
EG334
Coolant Temperature Sensor Circuit - data erratic, intermittent, or incorrect.
Yellow
EG341
Engine Control Module - data lost.
Yellow
EG343
Engine Control Module - warning internal hardware failure.
Yellow
 115ZV EX 62-33
62 Function & Structure Electrical Group
ECM (Engine Controller)

QST30 (135ZV)
QSK19 (115ZV)
QSB5.9 (70ZV)

QSM11 (90ZV)

QSX15 (95ZV)
QSL9 (85ZV)
FAULT
CODE/ DESCRIPTION
LAMP

EG351
Injector Power Supply.
Yellow
EG352
Sensor Supply Voltage #1 Circuit - shorted low.
Yellow
EG378
Fueling Actuator #1 Circuit - open circuit.
Yellow
EG379
Fueling Actuator #1 Circuit - grounded circuit.
Yellow
EG386
Sensor Supply Voltage #1 Circuit - shorted high.
Yellow
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
EG422
Engine Coolant Level Sensor Circuit - data incorrect.
Yellow
EG426
SAE J1939 datalink - cannot transmit.
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
Unswitched Battery Supply Circuit.
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
115ZV EX 62-34
62 Function & Structure Electrical Group
ECM (Engine Controller)

QST30 (135ZV)
QSK19 (115ZV)
QSB5.9 (70ZV)

QSM11 (90ZV)

QSX15 (95ZV)
QSL9 (85ZV)
FAULT
CODE/ DESCRIPTION
LAMP

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
EG466
Turbocharger #1 Wastegate Control Circuit - shorted low.
Yellow
EG482
Fuel Pressure Low - warning.
Yellow
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
EG487
Start Assist Device - canister Empty (Ether Injection).
Yellow
EG488
Intake Manifold Temperature High - warning.
Yellow
EG496
Engine Speed / Position Sensor #2 (Camshaft) Supply Voltage.
Yellow
EG497
Multiple Unit Synchronization Switch Circuit - data incorrect.
Yellow
EG498
Engine Oil Level Sensor Circuit - voltage above normal or shorted high.
Yellow
EG499
Engine Oil Level Sensor Circuit - voltage below normal or shorted low.
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.
EG584
Starter Relay Circuit - shorted high.
Yellow
EG585
Starter Relay Circuit - shorted low.
Yellow
EG595
Turbocharger #1 Speed High - warning level.
Yellow
 115ZV EX 62-35
62 Function & Structure Electrical Group
ECM (Engine Controller)

QST30 (135ZV)
QSK19 (115ZV)
QSB5.9 (70ZV)

QSM11 (90ZV)

QSX15 (95ZV)
QSL9 (85ZV)
FAULT
CODE/ DESCRIPTION
LAMP

EG596
Electrical Charging System Voltage High - warning level.
Yellow
EG597
Electrical Charging System Voltage Low - warning level.
Yellow
EG598
Electrical Charging System Voltage Low - critical level.
Red
EG599
OEM Commanded Dual Output Shutdown.
Red
EG611
Engine Hot Shutdown.
None
EG649
Change Lubricating Oil and Filter.
Yellow
EG687
Turbocharger Speed Sensor - below normal operating range.
Yellow
EG689
Crankshaft Engine Speed Signal Error.
Yellow
EG691 Turbocharger #1 Compressor Inlet Air Temperature Sensor Circuit - voltage above
Yellow normal or shorted high.
EG692 Turbocharger #1 Compressor Inlet Air Temperature Sensor Circuit - voltage below
Yellow normal or shorted low.
EG731
Mechanical Timing Misalignment.
Yellow
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
EG779
Auxiliary Equipment Sensor Input #3 (OEM Switch).
Yellow
EG951
Cylinder Power Imbalance Detected.
None
EG1117
Power Lost with Ignition ON - data erratic, intermittent, or incorrect.
None
EG1119
Engine Coolant Temperature - data valid but above normal operating range.
Yellow
EG1139
Injector Cylinder #1 - mechanical system not responding properly or out of adjustment.
Yellow
EG1141
Injector Cylinder #2 - mechanical system not responding properly or out of adjustment.
Yellow
EG1142
Injector Cylinder #3 - mechanical system not responding properly or out of adjustment.
Yellow
EG1143
Injector Cylinder #4 - mechanical system not responding properly or out of adjustment.
Yellow
EG1144
Injector Cylinder #5 - mechanical system not responding properly or out of adjustment.
Yellow
EG1145
Injector Cylinder #6 - mechanical system not responding properly or out of adjustment.
Yellow
EG1358
Accelerator Pedal Position Sensor 1 Circuit - voltage above normal or shorted high.
Yellow
EG1359
Accelerator Pedal Position Sensor 1 Circuit - voltage below normal or shorted low.
Yellow
EG1361 Remote Accelerator Pedal Position Sensor 1 Circuit - voltage below normal or shorted
Yellow low.
115ZV EX 62-36
62 Function & Structure Electrical Group
ECM (Engine Controller)

QST30 (135ZV)
QSK19 (115ZV)
QSB5.9 (70ZV)

QSM11 (90ZV)

QSX15 (95ZV)
QSL9 (85ZV)
FAULT
CODE/ DESCRIPTION
LAMP

EG1514
Accelerator Pedal Position Sensor 1 Circuit Frequency - abnormal frequency.
Yellow
EG1595 Remote Accelerator Pedal Position Sensor 1 Circuit - voltage above normal or shorted
Yellow high.
EG1911
Injector Metering Rail 1 Pressure - above normal operating range.
Yellow
EG2185
Sensor Supply Voltage #4 Circuit - shorted high.
Yellow
EG2186
Sensor Supply Voltage #4 Circuit - shorted low.
Yellow
EG2215 Fuel Pump Delivery Pressure - data valid but below normal operational range - moder-
Yellow ately severe level.
EG2216 Fuel Pump Delivery Pressure - data valid but above normal operational range - mod-
Yellow erately severe level.
EG2217
ECM Program Memory (RAM) Corruption - condition exists.
Yellow
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
EG2345
Turbocharger speed invalid rate of change detected - abnormal rate of change.
Yellow
EG2346
Exhaust Gas Temperature - data above normal.
Yellow
EG2347
Turbocharger Compressor Outlet Temperature - data above normal.
Yellow
EG2555
Intake Air Heater #1 Circuit - voltage above normal or shorted high.
Yellow
EG2556
Intake Air Heater #1 Circuit - voltage below normal or shorted low.
Yellow
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
 115ZV EX 62-37
62 Function & Structure Electrical Group
ECM (Engine Controller)

Power mode change

<Engine performance curve> <Torque converter performance curve>

Power mode output (No change)
Power mode Torque Normal mode
360 kW (489.5 PS)/2,000 min-1 (rpm) Torque converter
Torque
No load torque curve

Bucket/Boom or
steering system Torque UP
Normal mode is being operated
330 kW (448.7 PS)/2,000 min-1 (rpm)
E/G speed UP

Power mode ON Power mode ON

Rim-pull UP M/C speed UP

Engine speed Engine speed

Power mode Power mode
Normal mode Normal mode
115ZV62051

Engine power mode switch on the instrument panel is

used to give more power to the torque converter.

When this switch is ON during the bucket, boom or

steering system is being operated, it increases the rim-
pull and the machine speed.
115ZV EX 62-38
62 Function & Structure Electrical Group
ECM (Engine Controller)

Accelerator pedal
(S/N 0101~0144, 9001~9010)

Pedal

THROTTLE PEDAL

IDLE SW
4 BrW
YV 35
5
6 BLg
E THROTTLE
OPENING SENSOR
C
OFF IDLE Potentiometer
M 7 GyY

31 BL

8 GyW
IDLE

Circuit diagram

Connector

(0) 6 1 (G)
(V) 5 2 (B)
(Y) 4 3 (R)

View A

K115ZVE62010

Note Pedal Test.

Typical pedal potentiometer resistance at 65ºF.
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-second time frame. unplugged.
Wire colors  at pedal up position  at pedal down position
- Turn "ON" the starter switch. R-G 2,290 685
- Stroke the pedal fully up and down 3 times. R-B 2,340 2,340
- Turn "OFF" the starter switch. Y-O Open 1.8
Y-V 4.5 Open
Potentiometer voltage (V)
Input 5
Lo 0.4~0.7
Hi 3.5~4.05
 115ZV EX 62-39
62 Function & Structure Electrical Group
ECM (Engine Controller)

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
below) is indicated follow these steps within a time
frame of about 5 or 6 seconds to initialize the throttle
Installation Pedal angle
angle pedal with the ECM*.
35
Max. 21º 1. Shut off the engine
Full range
Pedal 2. Turn the key to "ON"
stop
14
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 47 (YV-G) and 49 (BLg-B)
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 3.9 V
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-
0.66 V tle pedal:
0
0 21 - Fault Code 132
Pedal Angle - Fault Code 134 (This may show, but is not relevant
to our application.)
- Fault Codes 287, 288 (These may show, but are not
relevant to our application.)
95ZV62119
- Fault Code 431
- Fault Code 432
- Fault Code 443

If the problem is not corrected contact your Cummins

Engine distributor for assistance.

*Engine Control Module; Computer that controls engine

functions, and monitors engine faults.
115ZV EX 62-40
62 Function & Structure Electrical Group
ECM (Engine Controller)

Accelerator pedal
(S/N 0145~, 9011~)

[ Wire color and signal ] Note

A-Black-APS signal APS: Acceleration Position Signal
B-White-APS ground IVS: Idle Validation Switch
C-Red-APS supply (5 V)
D-Green-Throttle active
E-Blue-Idle active
F-Orange-IVS supply (5 V) Pedal
THROTTLE PEDAL

IDLE SW
BrW
4
YV
Potentiometer
5
6 BLg
E THROTTLE
OPENING SENSOR
C
M OFF IDLE
7 GyY

31 BL
GyW
8
IDLE
35

Circuit diagram

(G) 6 1 (B)
(L) 5 2 (W)
(O) 4 3 (R) Connector

View A

1-Black-APS signal
2-White-APS ground A
3-Red-APS supply (5 V)
4-Orange-IVS supply (5 V)
5-Blue-Idle active
6-Green-Throttle active

K115ZVE62011

Note Pedal Test.

Typical pedal potentiometer resistance at 65ºF.
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.
Wire colors  at pedal up position  at pedal down position
- Turn "ON" the starter switch. R-G 2,205 570
- Stroke the pedal fully up and down 3 times. W-B 356 1,985
- Turn "OFF" the starter switch. R-W 2,530 2,530
G-O Open 1.1
Potentiometer voltage (V)
L-O 0.9 Open
Input 5
Lo 1.3~1.4
Hi 4.9~5.0
 115ZV EX 62-41
62 Function & Structure Electrical Group
ECM (Engine Controller)

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
below) is indicated follow these steps within a time
frame of about 5 or 6 seconds to initialize the throttle
Installation Pedal angle
angle pedal with the ECM*.
35
Pedal stop
Max. 17º 1. Shut off the engine
Full range
2. Turn the key to "ON"
18
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 47 (YV-B) and 49 (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-
0.66 V tle pedal:
0
0 17 - Fault Code 132
Pedal Angle - Fault Code 134 (This may show, but is not relevant
to our application.)
- Fault Codes 287, 288 (These may show, but are not
relevant to our application.)
K90ZV62007
- Fault Code 431
- Fault Code 432
- Fault Code 443

If the problem is not corrected contact your Cummins

Engine distributor for assistance.

*Engine Control Module; Computer that controls engine

functions, and monitors engine faults.
115ZV EX 62-42
62 Function & Structure Electrical Group
Transmission Control Circuit (S/N 0101~0153, 9001~)

Transmission Control Circuit (S/N 0101~0153, 9001~)

Controller

LEDs for input

or output

E1 E2 E3
9 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11 10 18 17 16 15 14 13 12 11 10 9 12 11 10 9 8 7 6
115ZV62061

There are various IC's inside the controller. The IC's

have programs for various functions described later.

IMPORTANT
If the controller malfunctions, be sure to replace the
controller assembly. Do not replace or repair any
parts.

Note
1. The couplers are shown for controller side.
2. Connector symbols correspond to symbols in the
wiring diagram.
 115ZV EX 62-43
62 Function & Structure Electrical Group
Transmission Control Circuit (S/N 0101~0153, 9001~)

LED inspection windows

Connector E2 (Output; lamp, relay)
IN (Input signal) OUT (Output signal)
Sym- Sym- No. Symbol Signal
bol
Signal bol
Signal
1 4R 4 (right) lamp
F Shift lever position F X Controller failure
2 3R 3 (right) lamp
R Shift lever position R RR Back relay ON
3 2R 2 (right) lamp
1 Shift lever position 1 DC Modulator valve 2 ON
2 Shift lever position 2 L Low clutch solenoid valve 4 1R 1 (right) lamp

3 Shift lever position 3 H High clutch solenoid valve 5 4L 4 (left) lamp

Reverse clutch sol. valve 6 3L 3 (left) lamp

A Shift lever position A R
7 2L 2 (left) lamp (-)
M Auto shift cancellation BZ Buzzer
8 1L Emergency steering relay
S Shift switch ON N Neutral relay ON
BR 9 S/1 Emergency steering (input)
Parking switch OFF Auto brake sol. valve ON
P 10 S/2 Spare
(running position) 1 1st clutch sol. valve ON
I Inching switch ON 2 2nd clutch sol. valve ON 11

ES Emergency steering 3 3rd clutch sol. valve ON 12 DD Vibration damper relay (OPT)
13 A Auto lamp
SI1 Spare
14 AB Auto brake lamp
15 N Neutral lamp
Connector E1 (Input) 16 X Controller failure relay
No. Symbol Signal 17 RR Back-up relay
1 I Inching switch (+) 18 NR Neutral relay
2 MC Failure history reset
3 DD Vibration damper (OPT)
4 1 Shift lever 1 (+) Connector E3 (Output, solenoid)
No. Symbol Signal
5 R Shift lever R (+)
1 3 3rd clutch sol. valve
6 EG Engine speed sensor (+)
2 2 2nd clutch sol. valve
7 COM Engine speed machine speed (-)
3 1 1st clutch sol. valve
8 SP Machine speed sensor (+)
9 GND GND 4 PC+ Modulator valve 1 (+)

10 A Shift lever A (+) 5 BZ Buzzer

11 3 Shift lever 3 (+) 6 R Reverse clutch sol. valve

Shift lever 2 (+) 7 H High clutch sol. valve

12 2
8 L Low clutch sol. valve
13 P Parking switch (+)
Shift switch (+) 9 DC Modulator valve 2
14 S
10 BRK Auto brake solenoid valve
15 F Shift lever F (+)
16 MR Failure history call 11 PC- Modulator valve 1 (-)

17 G1 For switch input (-) 12 G2 Solenoid valve (-)

18 SSG Press diff. sensor signal

19 5V Power for press. diff. sensor
20 + +24V
115ZV EX 62-44
62 Function & Structure Electrical Group
Transmission Control Circuit (S/N 0101~0153, 9001~)

Controller connection diagram

CIRCUIT PROTECTOR

E
ACC’

F5 10A (L)
L (L)
CP PARKING
10A SOLENOID
(Lg)
F13

(L) (L)

LR LR (GyB) (GO)
ACC’
L CENTRAL PARKING

MONITOR CONTROLLER
LBr ALARM S/W
LW T/M CONTROLLER SbY [SbY]
BRAKE OIL
H
R N F (SbY) PRESS. (MAIN)
(BY) B BRAKE OIL
LBr PRESS. (DIFF.)
R
(BY)
T/M CLUTCH SOLENOID VALVE
LY
1 1 EP
23A (Gy) Gy E/G OIL PRESS.
LY
LG (GyG) GyG WT E/G WATER TEMP.
2 LG
LO
(GyL) GyL
LO LW
T/M OIL TEMP.
3
T/M (LgL) LgL
SPEED AIR CLEANER
Y
LP
MODULATOR VALVE 2 DC Y (SbO)
SbO [SbR]
T/M OIL FILTER

LB W (Sb) Sb RADIATOR
WATER LEVEL
W BUZZER
MODULATOR VALVE 1 SPPC
LgR
LgB E/G REVO- LgBr WL
LUTION ALTERNATOR
(L) (SbP)
TERMINAL R
NEUTRAL RELAY NR LgBr FUEL LEVEL
CONTROLLER FAILURE RELAY (L) LgW PRESS. DIFF SENSOR
X
SENSOR (YR) YR
YW F 3/4
BACK-UP RELAY RR
(LB)
YGy (YB) YB
3/4 1/2
LB (YL) YL
1/2 1/4
(YBr) YBr
(LP) 1/4 1/8
AUTO
(YG) YG
(GR) E EMPTY
N
(LY) (O) SbR EMERGENCY
1 STEERING
INSTRUMENT
PANEL (LG) (YL)
2
MONITOR QUAD F13
(LO)
LAMP 3 SHIFT S/W (S/N 9021~)
(LW)
4 (BY)

AB
(GY) D FAILURE HISTORY RESET
F13 R FAILURE HISTORY RECALL

(Y)
D
(R)
R
STEERING
PRESS.
S/W REAR PARKING
ON SOLENOID
LgG
(S/N 9021~) CP
(L)
OFF
(Lg) (SbW) ON
F13
OFF
(GO)
PARKING S/W
MONITOR AUTO BRAKE
WO CONTROLLER SOLENOID

(BY)

LLg (LgR)

T/M INCHING S/W

CUT OFF (DECLUTCH)
(Lg) (LgY)
F13

T/M CUT OFF S/W

(LgW) X
CONTROLLER FAILURE

CENTRAL ALARM MONITOR

(GyB) CONTROLLER
E
K115ZVE62009
 115ZV EX 62-45
62 Function & Structure Electrical Group
Transmission Control Circuit (S/N 0101~0153, 9001~)

Controller function
Forward/reverse (F/R) shifting and speed change

From T/C pump

LED (indication: F) F/R clutch solenoid valve

N +Vcc
R F L
+24 V Clutch pressure regulator valve
LED
Shift lever

H Surge
(indication: F)
suppression
(For input R diode
detection) (incorporated
1 in solenoid To solenoid valve bank
A valve)
32 Clutch piston
LED (indication: S) 1

Shift switch

+24 V 2 Drain Clutch control solenoid valve

LED energized clutch engage
(indication: 2)
Speed 3 de-energized clutch disengage
7 segment LED
sensor (Indication:
Character)

Common ground
Engine 7 segment LED
speed (Indication:
Character)
sensor +24 V

AUTO indicator lamp

ON when shift lever in A position

K115ZVE62012

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 com-
noid valve, the clutch oil is fed into the clutch piston mands)
chamber. When the piston operates, the clutch is
engaged. When the current stops flowing through the If both the forward and reverse commands are input at
solenoid valve, the oil is drained from the clutch piston the same time due to a problem, the forward and
chamber, and the clutch is disengaged. reverse clutches will not function. In addition, if two or
more speed commands are input at the same time, all
Input detection speed output command comes to OFF. As a result, no
speed clutches will function.
When the shift lever is set to the F (forward) position,
electric current of input detection signal is sent from the Since two conflicting input LED's will be on at the same
transmission controller to the grounding circuit inside time, troubleshooting is easier.
the transmission controller via shift lever contact F. The
transmission controller, therefore, judges that the shift
lever is set to the F (forward) position. Because the shift
lever contact is not connected to the R (reverse) input
circuit, electric current will not flow. In this status, the
forward (F) indicator lamp will light, and the reverse (R)
indicator lamp will not light.

For the speed change, the transmission controller

judges the set speed position of the shift lever in the
same way as described above.
115ZV EX 62-46
62 Function & Structure Electrical Group
Transmission Control Circuit (S/N 0101~0153, 9001~)

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 (BY)

70ZV62025

1. Bracket assembly Operator controlled shifting from 2  1  2 in either "2"

2. Grip or "A" is done by momentarily depressing the QUAD
3. Connector switch 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 controller will judge that the shift
and reverse operation. lever is at the neutral (N) position.
 115ZV EX 62-47
62 Function & Structure Electrical Group
Transmission Control Circuit (S/N 0101~0153, 9001~)

Operation of solenoid valve

Clutch solenoid valve

(Common to L·H·R·1·2·3)

10 N-m (7 lb-ft)

Negative Positive
side side

59 N-m (43 lb-ft)

95ZV62120

Solenoid valve (with built-in diode)

Rated voltage DC 24 V
Coil resistance value Approx. 24 

When the input signal is transmitted, the output circuit of

the corresponding solenoid valve is connected to the
grounding circuit inside the controller. As a result, power
is supplied to the solenoid valve and the clutch is
engaged. At the same time, the speed indicator lamp in
the cab lights. In addition, the LED indicator of the corre-
sponding output circuit lights on the controller.

Note that when the parking brake or inching brake is

applied, the forward or reverse (F or R) clutch solenoid
valve is turned off and the transmission is set to neutral.
115ZV EX 62-48
62 Function & Structure Electrical Group
Transmission Control Circuit (S/N 0101~0153, 9001~)

Automatic shift 7 segment LED indication

Indication Machine speed (km/h) E/G rev. (rpm)

0 0 16 32 0
1 1 17 160
Shift up
2 2 18 320
Shift down
Speed 3 3 19 480
4 4 4 20 640
5 5 21 800
3 6 6 22 960
7 7 23 1,120
2 8 8 24 1,280
9 9 25 1,440
13 11 0 10 12 16 19 A 10 26 1,600
Reverse Speed km/h Forward b 11 27 1,760
(Approx. speed) C 12 28 1,920
Automatic shift map (standard set value) d 13 29 2,080
E 14 30 2,240
Machine speed LED E/G rev. LED F 15 31 2,400

T/M controller

Displayed font
Machine
speed E/G rev.

115ZV62044

When the shift lever is set to A, the AUTO indicator lamp

in the cab will light and one of the 2nd through 4th
speed solenoid valves will be automatically energized
according to the machine speed. In addition, the speed
indicator lamp will light. The input signal for automatic
shift is controlled by the pulse generated by the speed
sensor. While the speed sensor is transmitting the
pulse, the segment LED indicates in characters accord-
ing to the pulse.
 115ZV EX 62-49
62 Function & Structure Electrical Group
Transmission Control Circuit (S/N 0101~0153, 9001~)

Machine speed sensor/Engine speed sensor

25 0.25 mm
(0.98 0.001 in) 49 N-m (5.0 kgf-m) (36 lb-ft) (Engine speed sensor)
39 N-m (4.0 kgf-m) (29 lb-ft) (Machine speed sensor)

Clearance adjustment
0.98~2.0 mm (0.04~0.08 in)

K115ZV62020

Internal resistance * 2.3±0.2 k (25ºC) (77ºF) Sensor location

* Internal resistance changes greatly with temperature. At lower tem-
perature resistance is lower. At operating temperature the resistance
increases.
If resistance is 0  or   the speed sensor is defective. Machine speed sensor Engine speed sensor

The sensing elements of the sensors are provided adja-

cent to the transmission output gear (for the machine
speed) and the torque converter PTO drive gear (for the
engine revolution). The voltage generated by revolution
of the gear is transmitted in sine wave to the transmis-
sion controller.

The machine speed sensor is used for auto shift and

auto brake. The engine revolution sensor is used for
clutch pressure modulation. Actuation of the sensors
can be confirmed through the LED inspection window in
the transmission controller.

115ZV62020
Note
To prevent electronic "noise" from other sources that
may corrupt signal, "twist" the wire from sensor all the
way to the T/M controller.

IMPORTANT
Make sure to check the adjusted clearance when
replacing the sensor. Shims are available to set clear-
ance as needed.
115ZV EX 62-50
62 Function & Structure Electrical Group
Transmission Control Circuit (S/N 0101~0153, 9001~)

Switching from automatic to manual QUAD (shift) switch operation

QUAD (shift) switch

T/M controller

Dip switch 115ZV62045

The machine has automatic shift cancellation function

for troubleshooting. 80ZVE62017

Turn the controller dip switch No. 6, 7 and 8 to ON posi- The QUAD switch is attached to the boom control lever.
tion.
In any operation mode, pressing the QUAD switch dur-
The "M" input LED indicator of the controller will light ing 2nd speed operation shifts the 2nd speed to 1st
and the mode will be switched from automatic to man- speed. After that, if the QUAD switch is pressed again,
ual. Position "A" of the shift lever, therefore, is fixed to the speed is changed from the 1st to the 2nd, or to
the 4th speed. move the shift lever to neutral or to the opposite direc-
tion, the speed will be changed to the 2nd again.
DIP switch
Note that when the speed is shifted, the "S" LED indica-
This switch is provided on the board for setting proper- tor of the controller will momentarily light (blink).
ties of the T/M controller.
QUAD switch
This switch is not used frequently. This switch is usually
used for settings which rarely change after being set.

When the T/M controller cover is removed, this switch

can be seen in the position shown to right.
YL

BY

70ZV62031

Max. voltage DC 24 V
Allowable value
Current 10 mA

The QUAD switch is of the momentary type. It is spring

loaded to the “OFF” position.
 115ZV EX 62-51
62 Function & Structure Electrical Group
Transmission Control Circuit (S/N 0101~0153, 9001~)

Modulation at clutch switching

Input side Output side

T/M controller

R N
F Output Modulator valve (1)
current

Clutch selection
+ 24 V control
Shift lever No output LED is provided

input signal
1
4 3 2
ON during modulation Modulator valve (2)

+ 24 V Output LED
Press. diff. sensor
(Indication: DC)
E/G speed sensor

Machine speed
sensor
95ZV62043

Press. diff. sensor Modulator valve (2)

Modulator valve (2)
Modulator valve (1)

Press. diff.
sensor

To T/M
clutch

To T/C

Modulator valve (1) From pump

115ZV62064 Modulator valve unit hydraulic circuit 115ZV62065

The rise time of clutch oil pressure is controlled by mod-

ulator valve (1) and modulator valve (2) to shorten the
time lag and reduce shock that occurs when shifting
between forward and reverse, and between gears.
115ZV EX 62-52
62 Function & Structure Electrical Group
Transmission Control Circuit (S/N 0101~0153, 9001~)

Modulator valve (1) [MV1] - Initial charging (t1)

Clutch oil pressure during clutch application is con- The current flow through the coil of MV1 immediately
trolled according to the current passing through the coil after clutch selection is maintained as high as it was
of MV1. before clutch selection (400 mA).
This allows a lot of oil to flow rapidly into the empty
The pressure rises and falls along with the current. clutch piston chamber, reducing the time lag.

- Charging (t2)

On completion of the initial charging, the current

through the coil of MV1 is sharply reduced (170 mA).
Operation of modulator valve (1), (2) and
clutch pressure change.
This reduced current is maintained until the end of
the charging to prevent a sudden pressure rise and
Clutch selection shift shock.

- Completion of the charging

ON
Low clutch sol. OFF The pressure differential sensor of the modulator
valve valve unit sends electrical signal to the transmission
1st clutch sol.
ON controller.
valve When the charging is completed, due to no pressure
Completion of charging difference between the orifices in the line, the trans-
Approx. 400 mA
Modulator valve (1)
mission controller determines it by the signal sent
Current flow from the sensor.
(mA) Approx. Then the transmission controller sends signal to rise
170 mA the current through the MV1 coil gradually.
0
ON - Pressure rise (t3)
Modulator valve (2)
OFF
The clutch oil pressure rises gradually in proportion
to the current rise.
Main pressure
Pressure P2 P3 Note
MPa (psi) P1 - If the MV1 coil is damaged or disconnected, the
0 clutch oil pressure rises only 0.2 to 0.5 MPa (28 to
71 psi) and the pressure value is not enough to
Low clutch engage the clutch.
pressure Pressure - Transmission controller provides the protection pro-
MPa (psi) gram so as to rise the control current again at the
0
time of 0.5 seconds after decreasing the MV1 control
current when the differential pressure sensor is dam-
aged.
t1 t2 t3 t4

95ZV62044
 115ZV EX 62-53
62 Function & Structure Electrical Group
Transmission Control Circuit (S/N 0101~0153, 9001~)

Modulator valve (2) [MV2] Note

Modulator valve (2)
This valve assists MV1 in controlling (lowering) the If MV2 is damaged or disconnected, the machine will
clutch oil pressure. have severe shift shock during clutch engagement. In
this case, the lowest clutch pressure will be only about
Unlike MV1, it performs an ON and OFF operation. 0.7 to 1.0 MPa (100 to 142 psi) during charging. The
highest clutch oil pressure reaches the specified value.
Controlling the clutch oil pressure

Modulator valve (2) is energized simultaneously when

the current in MV1 changes from high to low current
flow. It is de-energized some time after the current in
MV1 returns to a higher level and the clutch oil pressure
reaches the specified value.

Transmission cut off (Declutch) While the transmission cut off switch on the instrument
panel is ON, pressing the brake pedal actuates the
pressure switch (inching switch), turns off the power of
the solenoid valves of the forward/reverse clutches (L,
H, R) by way of the T/M controller, and sets the trans-
mission to the neutral status. At this time, the monitor
lamp and the controller LED (indication: I) light.

When the clutch cut off switch on the instrument panel is

Pressure switch
for declutch
set to OFF, the transmission cut off function is disabled
(with white tape) and the brake pedal is dedicated to braking.

Pressure switch At this time, the monitor lamp on the instrument panel is
for stop lamp no longer illuminated.
(with black tape)

Left brake valve

K115ZV52017

Clutch cut-off switch

(located on operator's LH console)
Transmission controller
Lg Forward/reverse clutch
F13 solenoid valves

Transmission cut-off (Indication: I)

BY
BY
Pressure switch
for inching

95ZV62046
115ZV EX 62-54
62 Function & Structure Electrical Group
Transmission Control Circuit (S/N 0101~0153, 9001~)

Pressure switch for inching (Declutch)

1. Case 10. Terminal
2. Seal film 11. Terminal
(S/N ~0120, ~9010)
3. Packing 12. Base
4. Disc 13. Cover (connector)
5. Inner cover 14. Guide
1 2 3 4 5 6 7 8 9 10 11 12 13 6. Guide pin 15. Stopper
7. Spring 16. Connector terminal
8. Contact 17. Housing seal
16 9. Contact

17
A Pressure switch specifications
View A
Contact Normally open
Voltage (VDC) 24
15 14
Current (A) 2.3 (MAX.)
95ZV62047
Resistance () 10.4
Operating pressure
1.1±0.15 (11±1.5) (159±21)
MPa (kgf/cm2) (psi)
Return pressure MPa (kgf/cm2) (psi) 0.9±0.1 (9.1±1.0) (130±14)

(S/N 0121~, 9011~)

1 2 3 4 5 6 7 8 9 10 11 12 13

14

95ZV52056

1. Case 8. Contact Pressure switch specifications

2. Seal film 9. Contact
3. Packing 10. Terminal Contact Normally open
4. Disc 11. Terminal Voltage (VDC) 24
5. Inner cover 12. Base Current (A) 3.5 (MAX)
6. Guide pin 13. Cover Resistance () 6.9
7. Spring 14. Connector
Operating pressure
0.5 ± 0.1 (5.0 ± 1.0) (71.1 ± 14.2)
MPa (kgf/cm2) (psi)
Return pressure
0.3 ± 0.05 (3.0 ± 0.5) (42.7 ± 7.1)
MPa (kgf/cm2) (psi)
 115ZV EX 62-55
62 Function & Structure Electrical Group
Transmission Control Circuit (S/N 0101~0153, 9001~)

Back-up alarm

+24V

+24V F4 Back-up lights

IN 15A
Circuit
LED protector
+Vcc +24V Back-up relay
R
N
F
(Indication: R) 3 4
Back-up buzzer
Shift lever

1 2

F13
5A
4 1
(A) 3 2
LED
(Indication: RR)
+24V

70ZVE62015

When the shift lever is set to the reverse (R) position,

the coil of the back-up (or reverse) relay will be ener-
gized, and the main contact will be closed. The back-up
lamp, therefore, will light, and the buzzer will sound.

Back-up relay

1 4 LB

Lg
RL

2 3

Chassis side
Body black Elec. circuit coupler

K90ZV62009

Note Shift lever Between Lamp and

Between 1 and 4
This relay is identical to the relays for neutral, horn, position 2 and 3 buzzer
head light, E/G water temperature, E/G oil pressure and R Electric power supply ON ON
machine width lamp relay. F or N No electric power supply OFF OFF

They may be interchanged for testing purposes. Rating DC 24 V

Operation voltage 16 V or less
Reset voltage 2.4 V or more
Coil resistance 320 
115ZV EX 62-56
62 Function & Structure Electrical Group
Transmission Control Circuit (S/N 0101~0153, 9001~)

Parking brake

5A
+ 24V
F13
Monitor
P lamp
Parking S/W

ON Running Parking brake

Parking Oil cylinder
OFF
ON

L
OFF + Vcc

LED H
indication: P P
C.P.
Monitor R
controller
F5 Solenoid valve
10A for parking brake

+24V

115ZV62053

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 oil cylinder. The spring inside the will be fed into the oil cylinder. The oil will depress the
cylinder applies force to make the brake apply (drum spring to release the brake. In addition, the “P” LED
type). In this condition, the input “P” LED indicator is off. indicator will light.
If the transmission shift lever is set to the forward or
reverse (F or R) position, the buzzer will sound and the
clutch will not be engaged.

Parking brake operation

Parking brake solenoid LED indicator of

Parking switch Monitor lamp Buzzer
valve controller
“Parking” position Sounds when shift No electric power Input “P” LED
Parking * P
(pulled up) lever is set to F or R supply indicator: Off
“Running” position Input “P” LED
Running Off No buzzer Electric power supply
(pushed in) indicator: On
*When the parking switch is set to “parking”, the forward or reverse clutch is disengaged and set to neutral.
 115ZV EX 62-57
62 Function & Structure Electrical Group
Transmission Control Circuit (S/N 0101~0153, 9001~)

Parking brake solenoid valve

Oil cylinder (brake actuator)

Solenoid (S/N 0101~0126, 9001~9020)
B Knob
Solenoid (S/N 0127~, 9021~)

Reducing
valve P

Manual release
T (counterclockwise rotation)
Spool
Seat Seat
face A face B Tank B

P T
Hydraulic circuit diagram K90ZV52012

Solenoid valve Solenoid valve specifications

for auto-brake
Voltage DC24 V
Solenoid valve for
parking brake Current 0.69 A
Resistance 34.8 

Front Valve assembly

Transmission

K115ZV52020
115ZV EX 62-58
62 Function & Structure Electrical Group
Transmission Control Circuit (S/N 0101~0153, 9001~)

Auto brake

Input side Output side

T/M controller
Solenoid valve for auto brake

Shift lever position

+24V
LED
selector signal
(Indication: BRK)
Shift lever

Auto brake monitor lamp, buzzer

+24V
Machine speed

Machine speed Solenoid valve for forward/reverse clutch

L
sensor
H

Installation position of solenoid valve for auto brake.

Refer to the description on the solenoid valve for parking brake.

95ZV62053

61 To rear To front
service brake service brake
31 When the traveling direction is switched over between
A
forward and reverse at a machine speed of 12 km/h (7.5
C mph) or more, the auto brake is applied to protect the
B
transmission clutches.
When the machine speed is too high, the auto brake is
23 24
applied also to prevent troubles caused by excess
AR Ap
Pi AF
speed in the engine and the transmission.
When the auto brake signal enters from the T/M control-
ler to the solenoid valve for auto brake (27) and the
PR T PF Tp Pp
solenoid valve (27) is energized and magnetized, the
pilot oil from the reducing valve enters the pilot port of
the left brake valve (23) through the shuttle valve (31),
1.0
and actuates the pilot piston and the spool of the brake
valve.
1.0
When the spool is switched over, the high-pressure oil
coming from the pump through the unloader valve and
B
37 the reducing valve enters the front and rear brake piston
From unloader
valve (Pump) chambers to apply the service brake.

At this time, the BRK LED and the monitor lamp on the
T/M controller 27
signal
P T instrument panel light, and buzzer sounds.
While the auto brake is applied, the forward/reverse
From reducing clutches of the transmission are disengaged and kept in
valve (Pump)
the neutral status until the actual machine speed
Shown in the "released" position K115ZV52021 decreases and reaches the set value.
 115ZV EX 62-59
62 Function & Structure Electrical Group
Transmission Control Circuit (S/N 0101~0153, 9001~)

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 3 km/h 2 km/h
forward and reverse (1.9 mph) (1.25 mph)
ON
Speed clutch
Machine
solenoid valve
speed

Brake solenoid
valve
ON
F solenoid valve OFF
Monitor lamp
OFF

T/M in neutral ON Service brake operating 115ZV62067

OFF
R solenoid valve
When the machine speed reaches or exceeds the set
Brake solenoid ON value, the service brake is applied as in the above case.
valve When the machine speed drops below the specified
OFF OFF
Monitor lamp value, the service brake is released.

During service brake application, the transmission is

Service brake operating placed in neutral.

115ZV62066
Speed range Set value
1st Approximately 15 km/h (9.3 mph)
2nd Approximately 22 km/h (13.7 mph)
When the traveling direction is switched over between
3rd
forward and reverse while the shift lever is in the posi- Approximately 36 km/h (22.4 mph)
4th/A
tion A, the power of the solenoid valve for auto brake
turns on and the service brake is applied until the
machine speed is reduced to 3 km/h (1.9 mph). At the
same time, the power of all solenoid valves for forward/
reverse clutches is turned off, and the transmission is
set to the neutral position.

When the machine speed reaches 3 km/h, the power of

the solenoid valve for auto brake turns off and the clutch
for the opposite direction is engaged. (However, the
brake remains applied until the machine speed
becomes approximately 2 km/h (1.25 mph) because oil
discharge is delayed.)

While the shift lever is not in the position A, the auto

brake function is disabled even if the traveling direction
is switched over between forward and reverse.
115ZV EX 62-60
62 Function & Structure Electrical Group
Transmission Control Circuit (S/N 0101~0153, 9001~)

Auto brake solenoid valve

Brake valve (shuttle valve)

B Spool

P
Reducing
valve

(S/N ~0126, ~9020)

(S/N 0127~, 9021~)

T
Tank
Seat face A Seat face B

B Solenoid

P T
Hydraulic circuit diagram
K115ZV52016

Solenoid valve
for auto-brake

Solenoid valve
for parking brake

Front Valve assembly

Transmission

K115ZV52020

Solenoid specifications

Rated voltage DC24 V

Rated current 0.69 A
Resistance 34.8 
 115ZV EX 62-61
62 Function & Structure Electrical Group
Transmission Control Circuit (S/N 0101~0153, 9001~)

Transmission controller failure warning Controller fault relay

Should the transmission controller stop working due to

any of the following causes, a dash mounted monitor
lamp lights up to give warning.

T/M controller failure monitor lamp

If a warning is given as a result of self-diagnosis of

the transmission controller
Body blue
The transmission controller has a self-diagnosis func-
tion incorporated in it, and if the computer program
becomes abnormal due to abuse or defect, a dangerous
condition may occur, the monitor lamp lights up and all
the outputs from the controller are turned OFF. In this
1 4

LgW
case, the Led on the output circuit side of the controller

L
will not be lit. Some input Led may still be operating
(ON).

LgW
B
2 3
If the circuit protector (CP) is turned OFF
Elec. circuit Chassis side
If the circuit protector is automatically turned OFF due to (normally closed) coupler
a short circuit, etc., in the output circuit, the monitor
lamp lights up and all the outputs from the controller are
turned OFF. In this case, the none of the LEDs on the K90ZV62010

controller will be lit.

Rating DC 24 V
Operation voltage 16 V or less
Replacement of the transmission controller Reset voltage 2.4 V or more
Coil resistance 320 
If the monitor lamp lights up under the cause 1 above, it
is an indication that the transmission controller's pro-
gram has malfunctioned and the transmission controller
assembly must be replaced.

If the monitor lamp lights up under the cause 2 above,

the cause is NOT the transmission controller.

Once the cause is removed, the controller may be reset

and continue to be used.

To reset simply turn the circuit protector switch to "ON".

115ZV EX 62-62
62 Function & Structure Electrical Group
Transmission Control Circuit (S/N 0101~0153, 9001~)

Emergency steering function (for Europe spec only)

When the steering hydraulic pressure goes down while Ground
the engine is running, the pressure switch is turned on.
Then the input signal is sent to the transmission control-
ler.

As a result, the emergency steering relay turns on, and To monitor

the emergency steering motor and pump is driven. controller

Then it is ready to steer the machine.

To operation
stand
Pressure switch (B contact) preset value
Steering hydraulic pressure
ON: at 0.4 MPa (4 kgf/cm2) (58 psi) or lower

Pressure
switch
Monitor controller
Input Output
+ + D P BO EP WT TF EL 1/2 1/8 ES EA B EP WT TF F 1/2 1/8 W TR

R BM TR TT AC WL 3/4 1/4 EMP BL TT AC WL ES 3/4 1/4 EMP BZ

B B R SbY GyL LgL Sb YR YL YG GyL LgL Sb O YB YBr YG LgBr

E402 H648 H620 H606 H662 H619 H647 H604 A401 A402 A404 A509 A515 A513 A512 G802

L L Y GO B Gy GyG SbO B YB YBr SbR WL SbY Gy GyG SbO YR YL GyB

D003 D002 E403 B303 F202 F102 H605 H633 H661 H635 H603 A406 A407 A408 A519 A516 A514 G601

13 1 11 1
E5 E6

Monitor controller
L B L R
B
Pressure switch
(Pump side)
Instrument panel

+ ES DD EG2 EG1 EG3 SS WTM TTM

(+) TF F 3/4 1/2 1/4 EMP GND

RB SbO YR YB YL YBr YG B
C211 E607 E605 E616 E604 E615 E614

Lg O O BrB BrW BrR YB YSb

Emergency
D103 E617 B902 H630 H602 H616 H607 H621
steering pilot
10 1 lamp
A5
B9 O
A508 K115ZV62011
1
K115ZVE62006

Monitor controller
Refer to "Monitor controller (S/N 0101~0153, 9001~)"
page 62-71.
 115ZV EX 62-63
62 Function & Structure Electrical Group
Transmission Control Circuit (S/N 0154~)

Transmission Control Circuit (S/N 0154~)

Machine control unit (MCU)

To S1 To S2 To S3 To S4 To S5

85V2E62041
115ZV EX 62-64
62 Function & Structure Electrical Group
Transmission Control Circuit (S/N 0154~)

Connector

MCU

To S1 To S2 To S3 To S4 To S5

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.SS_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.FR_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

To S1 To S2 To S3 To S4 To S5

Connector details
85V2U62009
 115ZV EX 62-65
62 Function & Structure Electrical Group
Transmission Control Circuit (S/N 0154~)

Machine control unit (MCU) connection diagram (S/N 0154~0222)

ACC’
E
F5 L/L(L) (L)
PARKING
10A
F10 G S/W

L
E17

B13 LR F SOLENOID
ACC’ LR VALVE E
D11
LBr
D04 B01 LW H SOLENOID VALVE
F N R

SHIFT LEVER
B04 LBr R SOLENOID VALVE

A18 LY 1ST SPEED SOLENOID VALVE

1
23A A02 LG 2ND SPEED SOLENOID VALVE
LW
D12 A05 LO
LO 3RD SPEED SOLENOID VALVE
D05
LG
D03 A17 LP
LY D SOLENOID VALVE
D10

E (YL) WR AUTO BRAKE

SHIFT S/W D14 B14
SOLENOID VALVE
ON (SbW) (Lg)
F13 GO
PARKING D01 A04 YV RIDE CONTROL
OFF GO F5
SOL. LgG ON LLg
SOLENOID VALVE
(L) D21 LgR LgR
OFF B05 MODULATION VALVE
(GyW) 1A
RIDE CONTROL S/W C33

A BrB
AUTO / MANUAL SELECTION D02
M B18 (SbP) (L)
NEUTRAL RELAY

BrY
LLg T/M MODE SELECTION C04
CONTROLLER
B12 LgW (L)
FAILURE RELAY
MODEL SELECTION 1 C10 (Lg)
F13
(LgR) MODEL SELECTION 2 C11
MODEL SELECTION 3 C12 B11 (LB) BACK LAMP RELAY
DECLUTCH DECLUTCH MODEL SELECTION 4 C13
S/W (LgY) (Lg)
F13 BrW
FR23 SELECTION C22
BrR
F34 SELECTION C23 A21 (LgR) AUTO SHIFT INDICATOR
E LAMP
A29 (GR) NEUTRAL INDICATOR LAMP
[SbY] SbY
BRAKE OIL PRESS. C02
A20 (GY) AUTO BRAKE LAMP
BRAKE OIL PRESS. DIFF. S/W C09
A14 (GyB) CENTRAL WARNING LAMP
E/G OIL LEVEL S/W C03
A28 (LgY) BRAKE OIL PRESS.
Gy
E/G OIL PRESS. S/W C16 WARNING LAMP
GyG
E/G COOLANT TEMP. S/W C07
(Gy)
A19 E/G OIL PRESS. WARNING LAMP
GyL
T/M OIL TEMP. S/W C05 E/G COOLANT TEMP.
A15 (GyG)
[SbR] SbO WARNING LAMP
T/M OIL FILTER S/W C14
A16 (GyL) T/M OIL TEMP. WARNING LAMP
LgL
AIR CLEANER CLOGGING S/W C06
A26 (SbO) T/M OIL FILTER WARNING LAMP
Sb
RADIATOR WATER LEVEL S/W C15
A27 (LgB) AIR CLEANER WARNING LAMP
W
STEERING OIL PRESS. S/W C08
A13 (Sb) RADIATOR WATER LEVEL
YR WARNING LAMP
FUEL LEVEL F C17
(O)
YB A12 STEERING OIL PRESS. WARNING LAMP
FUEL LEVEL 3/4 C28
YL (LY)
FUEL LEVEL 1/2 C20 A24 1ST SPEED INDICATION LAMP
YBr
FUEL LEVEL 1/4 C29 A25 (LG) 2ND SPEED INDICATION LAMP
YG
FUEL LEVEL 1/8 C21
A30 (LO) 3RD SPEED INDICATION LAMP
YW E09
T/M PRESS. DIFF. SENSOR
YGy
C19 A34 (LW) 4TH SPEED INDICATION LAMP
W
ECM (11) E15 A11 (YR) FUEL LEVEL F
Y
E16 A33 (YB) FUEL LEVEL 3/4
MACHINE SPEED SENSOR Y (YL)
E08 A22 FUEL LEVEL 1/2
WL
ALTERNATOR E24 A31 (YBr) FUEL LEVEL 1/4
F13
Note A23 (YG) FUEL LEVEL E
(Lg)
(GL)
CAN_H
Refer to Section 92 for the MODM CAN_L
(GW)
E29
E20
B09 (LgBr) BUZZER
detailed electrical connection E

diagram for the controller TXD

GR
GL
B22
RS-232C RXD B16
(MCU) including modification GND
(BY)
E7 B24 (WL)
TACHOMETER
information. MCU
115ZVE62062
115ZV EX 62-66
62 Function & Structure Electrical Group
Transmission Control Circuit (S/N 0154~)

Machine control unit (MCU) connection diagram (S/N 0223~)

 
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 115ZV EX 62-67
62 Function & Structure Electrical Group
Transmission Control Circuit (S/N 0154~)

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 3

LgW
MCU are turned OFF.

L
LgW
MCU replacement

B
2 4

If the monitor lamp lights up under the cause above, it is

Chassis side
an indication that the MCUÅfs program has malfunc- Elec. circuit coupler
tioned and the MCU assembly must be replaced.
K95ZV62016
When installing a new MCU on the machine, all specifi-
cations must be registered into the MCU through the
MODM. MCU fault relay (Normally closed)

Rating DC 24 V
Operation voltage 16 V or less
Reset voltage 2.4 V or more
Coil resistance 320 
115ZV EX 62-68
62 Function & Structure Electrical Group
Monitor Circuit

Monitor Circuit
If a problem of a unit is detected while the engine is run- When the starter switch is set to ON, all of the monitor
ning, a monitor lamp lights to inform the operator. lamps are lit for 3 seconds and buzzer sounds to check
For some problems, the buzzer sounds also, and the whether the monitor lamps are normal (not burn out).
central alarm lamp flashes also.

Items to be monitored and operation condition

No. Item to be monitored Monitor lamp Operation condition Buzzer Lamp test Remarks

Defective controller (CPU)

1 Controller —
Control Processor Unit

Unloader valve accumulator port oil pressure

2 Brake oil pressure
3.9 ± 0.5 MPa (40±5 kgf/cm2) (569 ± 71 psi)

600 0.1 (1.1)

While engine running 800 0.13 (1.3)
3 Engine oil pressure min-1/MPa (kgf/cm2) or 1,500 0.17 (1.7)
less 2,100
0.2 (2.1)
2,400

101 ± 2ºC or more

4 Engine water temperature —
(214 ± 4ºF or more)

Torque converter oil 120 ± 5ºC or more

5 —
(transmission) temperature (248 ± 9ºF or more)

Filter resistance:
6 Clogged air cleaner 635 ± 58 mmAq or more —
(25 inches H2O)
Pressure difference at 50 ± 2ºF (122 ± 4ºF) or
Clogged transmission oil more
7 —
filter 0.3 MPa (3.15±0.28 kgf/cm2) (45 ± 4 psi) or
more

When operates steering under the steering

8 Steering oil pressure (option)
pressure less than 0.4 MPa (57 psi)

When E/G water level drops

9 Engine water level —
(before start up only)

10 Auto brake operation When auto-brake works

11 Centralized alarm For items 1-8 — Flashing type

 115ZV EX 62-69
62 Function & Structure Electrical Group
Monitor Circuit

12 Engine protection lamp —

(orange)

Any fault in engine detected by ECM

13 Engine warning lamp —
(Engine controller)
(yellow) (2 sec.)

14 Engine stop lamp —

(red)
115ZV EX 62-70
62 Function & Structure Electrical Group
Monitor Circuit

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

When transmission cut off switch is set

2 Transmission cut off Green For declutch
to ON

When working light (rear) switch is set

3 Working light Green
to ON

4 Turn signal indicator (left) Green When turn signal lever (left) is actuated

When turn signal lever (right) is

5 Turn signal indicator (right) Green
actuated

6 High beam Blue When head lamp is set to high beam

When transmission shift lever is set to

7 Auto shift Green
automatic position

When transmission shift lever is set to

8 Neutral Green
neutral position

When transmission shift lever is set to

9 Transmission status Yellow
corresponding gear (1~4)

When vibration damper switch is set to

10 Vibration damper Green (OPT)
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
 115ZV EX 62-71
62 Function & Structure Electrical Group
Monitor Circuit

Monitor controller (S/N 0101~0153,

Connector (E5) (Input) Connector (E6) (Output)
9001~)
No Sym Signal No Sym Signal
bol bol

1 EA Alternator voltage Fan 2-step relief

1 TR
solenoid valve
Steering oil pressure
2 ES
switch 2 W Central alarm sw.
3 1/8 Fuel level (1/8) 3 1/8 Fuel level lamp (1/8)
4 1/2 Fuel level (1/2) 4 1/2 Fuel level lamp (1/2)
5 EL — 5 F Fuel level lamp (F)
Connector
Connector pin layout 6 TF T/M oil filter switch 6 —
E5 E6
E/G water tempera- T/M oil filter alarm
7 WT 7 TF
13 12 11 10 9 8 7 6 5 4 3 2 1 11 10 9 8 7 6 5 4 3 2 1 ture switch lamp
26 25 24 23 22 21 20 19 18 17 16 15 14 22 21 20 19 18 17 16 15 14 13 12
E/G oil pressure Water temperature
*The couplers shown are the controller side. 95ZV62058 8 EP 8 WT
switch alarm lamp

9 BD — E/G oil pressure

There are various IC's inside the controller. The IC's 9 EP
10 P Parking switch alarm lamp
have programs for various functions described later.
11 D Memory call Brake oil pressure
10 B
alarm lamp
IMPORTANT 12 + DC24V

If the controller malfunctions, be sure to replace the 13 + DC24V 11 —

controller assembly. Do not replace or repair any 14 — 12 —
parts. 15 — 13 BZ Buzzer
16 EM Fuel level (E) 14 EM Fuel level lamp (E)

17 1/4 Fuel level (1/4) 15 1/4 Fuel level lamp (1/4)

18 3/4 Fuel level (3/4) 16 3/4 Fuel level lamp (3/4)
19 WL E/G water level sw. Emergency steering
17 ES
20 AC Air cleaner sensor lamp

T/M oil temperature E/G water level alarm

21 TT 18 WL
switch lamp

Fan 2-step relief Air cleaner alarm

22 TR 19 AC
solenoid valve lamp

Brake oil pressure T/M oil temperature

23 BM 20 TT
(Main) switch alarm lamp

24 R Memory reset 21 —
25 — GND 22 —
26 — GND
115ZV EX 62-72
62 Function & Structure Electrical Group
Monitor Circuit

(S/N 0101~0153, 9001~)

ACC’ (BR) E

F5 10A
L (L) PARKING
CP
10A SOLENOID
(Lg)
F13

(L)

CENTRAL
(GyB) (GO)
ALARM PARKING S/W
ACC’ (158)

MONITOR CONTROLLER
SbY [SbY]
BRAKE OIL
(SbY) PRESS. (MAIN)

INSTRUMENT PANEL (Gy) Gy EP

MONITOR LAMP E/G OIL PRESS.
(GyG) GyG
E/G WATER TEMP.
(GyL) GyL
T/M OIL TEMP.
(LgL) LgL

(SbO) SbO [SbR]

T/M OIL FILTER
(Sb) Sb
RADIATOR
BUZZER WATER LEVEL
LgBr WL ALTERNATOR
TERMINAL R
TO T/M FUEL LEVEL
CONTROLLER SENSOR
(YR) YR
F 3/4
(YB) YB
3/4 1/2
FUEL LEVEL (YL) YL
1/2 1/4
INDICATOR LAMPS
(YBr) YBr
1/4 1/8
(YG) YG EMPTY
E

SbR
EMERGENCY STEERING
(FOR EUROPE)
F13

(S/N 9021~)
D FAILURE HISTORY RECALL

R FAILURE HISTORY RESET

(Y)
TO T/M
CONTROLLER (R)

K115ZVE62007
 115ZV EX 62-73
62 Function & Structure Electrical Group
Monitor Circuit

Monitoring sensor and switch Engine water temperature alarm sensor

Set value 102±2ºC (214±4ºF) or more

Air cleaner clogging switch Continuity established across terminals C and NO

Transmission oil temperature alarm switch

Indicator
Set value 120±5ºC (248±9ºF) or more
Continuity established across terminal and body

Transmission oil temperature switch

Air cleaner
Set value 50±2ºC (122±4ºF) or more
Continuity established across both terminals

K115ZV62012 Engine water level alarm sensor

Set value Full radiator water level

Set value Resistance: 635±58 mmAq or more
No continuity established across terminal and body
Continuity established across terminals

Refer to "Sensor Mount" page 62-10 for the location of

T/M oil filter clogging switch these switches and sensors.

(S/N ~0120,
~9010) Torque converter

Indicator

Transmission
K115ZV62013

(S/N 0121~, 9011~)

Torque converter
Indicator

Transmission
K115ZV62014

Set value 0.3 MPa (45±4 psi) or more

Continuity established across terminal and body
115ZV EX 62-74
62 Function & Structure Electrical Group
Instrument Panel and Switch

Instrument Panel and Switch

Instrument panel
(S/N 0101~0222, 9001~)

1 24 23 20 5 22 6 21 2 26 4 11 12

13

37 33

38 34

POWER 35
40 14
15
39
16
17
STOP

18
19

28 29 30 31 32 25 9 8 7 3

K115ZVE62008

1. Tachometer 21. Turn signal indicator lamp (right)

2. Engine coolant temperature gauge 22. High beam indicator lamp
3. Torque converter oil temperature gauge 23. Auto shift indicator lamp
4. Fuel gauge 24. Neutral indicator lamp
5. Central warning lamp 25. Transmission status monitor
6. Parking brake indicator lamp 26. Hour meter
7. Auto brake indicator lamp 27. —
8. Transmission cut-off (declutch) selection 28. Engine stop lamp
indicator lamp 29. Engine warning lamp
9. Working light indicator lamp (rear) 30. Engine protection lamp
10. — 31. Ride control selector indicator lamp (option)
11. Controller warning lamp 32. Steering circuit error warning lamp
12. Brake oil circuit warning lamp 33. Working light switch (front)
13. Engine oil pressure warning lamp 34. Working light switch (rear)
14. Engine coolant temperature warning lamp 35. Engine power mode switch
15. Torque converter oil temperature warning lamp 36. —
16. Air cleaner clogging warning lamp 37. Emergency flasher indicator lamp switch
17. Charge warning lamp 38. Transmission cut-off (declutch) selector switch
18. Transmission oil filter clogging monitor lamp 39. Ride control switch (option)
19. Engine coolant level warning monitor lamp 40. Cold starter switch
20. Turn signal indicator lamp (left)
 115ZV EX 62-75
62 Function & Structure Electrical Group
Instrument Panel and Switch

(S/N 0223~)

25 24 23 20 22 6 5 7 8 9 21 2
1
13 12 11

37 33

38 34

40
POWER
35

39

32 31 26 3 14 15 16 17 18 19 28 29 30 4

115ZVE62065

1. Tachometer 21. Turn signal indicator lamp (right)

2. Engine coolant temperature gauge 22. High beam indicator lamp
3. Torque converter oil temperature gauge 23. Auto shift indicator lamp
4. Fuel gauge 24. Neutral indicator lamp
5. Central warning lamp 25. Transmission status monitor
6. Parking brake indicator lamp 26. Hour meter
7. Auto brake indicator lamp 27. —
8. Transmission cut-off (declutch) selection 28. Engine stop lamp
indicator lamp 29. Engine warning lamp
9. Working light indicator lamp (rear) 30. Engine protection lamp
10. — 31. Ride control selector indicator lamp (option)
11. Controller warning lamp 32. Steering circuit error warning lamp
12. Brake oil circuit warning lamp 33. Working light switch (front)
13. Engine oil pressure warning lamp 34. Working light switch (rear)
14. Engine coolant temperature warning lamp 35. Engine power mode switch
15. Torque converter oil temperature warning lamp 36. —
16. Air cleaner clogging warning lamp 37. Emergency flasher indicator lamp switch
17. Charge warning lamp 38. Transmission cut-off (declutch) selector switch
18. Transmission oil filter clogging monitor lamp 39. Ride control switch (option)
19. Engine coolant level warning monitor lamp 40. Cold starter switch
20. Turn signal indicator lamp (left)
115ZV EX 62-76
62 Function & Structure Electrical Group
Instrument Panel and Switch

Instrument panel rear surface

(S/N 0101~0222, 9001~)

CN4
CN1 L13 CN3
1 4 L11 29 48
L12
8P L20 12P 16P
L1 58 57
5 8 L14 L10 35 56
L2 Hour L10 L10
L10 meter L15 S
L21
L3
L16 E V
L4 S S
L17 L10
L5 E V E V
Engine water
temperature sensor L18 Tachometer
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)

A5 A6 A7 A8 A9
CN1(8P) CN2(20P) CN3(12P/16P) CN4(2P)
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 57
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 85V2E62052

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/C oil temperature alarm L5 24 Fuel level lamp (3/4) — 44 Converter (–) —
5 Engine coolant temp. alarm L4 25 Fuel level lamp (1/2) — 45 — —
6 Engine oil pressure alarm L3 26 Fuel level lamp (1/4) — 46 T/M cut-off (declutch) lamp L17
7 Brake oil pressure alarm L2 27 Fuel level lamp (E) — 47 — L19
8 Controller 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 Emergency steering L22 30 — — 50 GND (–) —
11 Vibration damper (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 Engine coolant temp. gauge — 36 1st speed indication — 56 — —
17 T/C 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
 115ZV EX 62-77
62 Function & Structure Electrical Group
Instrument Panel and Switch

(S/N 0223~)

CN1 12 1

24 13

E E

S S
V
V
18 1
CN2
36 19

E E

S S

V V

CN1(24P) CN2(36P)
12 11 10 9 8 7 6 5 4 3 2 1 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 13 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 80Z562010

Pin Lamp Pin Lamp Pin Lamp

CN1-Signal CN2-Signal CN2-Signal
No. No. No. No. No. No.
1 Secondary steering (option) 32 1 — — 19 Fuel level 3/4 4
2 — — 2 Ride control (option) 31 20 — —
3 — — 3 — — 21 T/C (T/M) oil temperature gauge 3
4 — — 4 — — 22 — —
5 — — 5 — — 23 Engine water level warning lamp 19
6 4th speed indication 25 6 Declutch lamp 8 24 Charge lamp 17
7 3rd speed indication 25 7 AUTO brake 7 25 Air cleaner clogging alarm 16
8 2nd speed indication 25 8 Central alarm lamp 5 26 T/C (T/M) oil temperature alarm 15
9 1st speed indication 25 9 Neutral indication 24 27 Engine water temperature alarm 14
10 GND (–) — 10 Turn signal (left) lamp 20 28 Engine oil pressure alarm 13
11 Backup battery — 11 AUTO lamp 23 29 — —
12 +24 V power supply — 12 T/M oil filter clogging alarm 18 30 Brake circuit warning lamp 12
13 Tacho meter 1 13 Instrument panel illumination — 31 — —
14 Parking brake lamp 6 14 High-beam lamp 22 32 — —
15 — — 15 Work lamp 9 33 E/G stop lamp 28
16 — — 16 Turn signal (right) lamp 21 34 E/G warning lamp 29
17 — — 17 Fuel level F 4 35 E/G protection lamp 30
18 — — 18 Controller failure alarm 11 36 — —
19 — —
20 Hour meter 26
21 Fuel level E 4
22 Fuel level 1/2 4
23 Fuel level 1/4 4
24 Engine water temperature gauge 2
115ZV EX 62-78
62 Function & Structure Electrical Group
Instrument Panel and Switch

Gauge circuit Sensors detect the temperature respectively, and con-

vert them into electric signals. The signals are transmit-
(S/N 0101~0222, 9001~) ted to the corresponding gauges that indicate the
transmitted values.

Controller
Note
If a gauge is removed from the panel, the resistance
between the terminals will differ from the standard value
shown in the table.
Grounding S Power supply
24V

E V 15V

Viewed from rear surface of instrument panel

K90ZV62016

Gauge Engine water temperature T/C, T/M oil temperature

110ºC(230ºF)
97ºC(206ºF) 100ºC(212ºF)
100ºC(212ºF) 120ºC(248ºF)
35ºC(95ºF) 103ºC(217ºF)
50ºC(122ºF)
125ºC(257ºF)

Indication

White Red White Red

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 ()

(S/N 0223~)
Gauge Engine water temperature T/C, T/M oil temperature

67C° 125C°
(152.6°F) 56C°
102C° (257°F)
50C° (132.8°F)
(215.6°F)
(122°F)

Indication

White
Red White
Red

Resistance
80~95 80~95
between S and E ()
Resistance
26~30 26~30
between S and V ()
Resistance
106~126 106~126
between E and V ()
 115ZV EX 62-79
62 Function & Structure Electrical Group
Instrument Panel and Switch

Temperature sensor
(For engine coolant temperature and torque con-
verter oil temperature)
(S/N 0101~0222, 9001~)

Flat terminal
Thermistor

95ZV62066

Temperature of 60 80 100 120

detection part (ºC) [140ºF] [176ºF] [212ºF] [248ºF]
Resistance ()
between terminal 56.3 29.5 16.5 10
and body

(S/N 0223~0224) For torque converter oil temperature

K95ZV62020

Temperature of 50 60 70 80 90 100 110 120 130

detection part (ºC) [122ºF] [140ºF] [158ºF] [176ºF] [194ºF] [212ºF] [230ºF] [248ºF] [266ºF]
Resistance ()
between terminal 4.40 3.19 2.34 1.75 1.33 1.02 0.79 0.62 0.49
and body

(S/N 0223~) For engine coolant temperature

Temperature of 50 70 105 115

detection part (ºC) [122ºF] [158ºF] [221ºF] [239ºF]
Resistance ()
between terminal 99.5 44.2±5 15.5±0.5 12.4
and body

(S/N 0225~) For torque converter oil temperature

Temperature of 56 70 90 125
detection part (ºC) [132.8ºF] [158ºF] [194ºF] [257ºF]
Resistance ()
70Z42E62003 between terminal 68.2±6.8 41.6 22.7 8.4±0.7
and body
115ZV EX 62-80
62 Function & Structure Electrical Group
Instrument Panel and Switch

Fuel gauge circuit The level sensor provided inside the fuel tank is
equipped with five float switches.

1/2 When the oil level becomes low, the contact of the cor-
3/4 responding float switches turns on.
B
E 1/4
The float switch signals are transmitted to the monitor
1/8
controller, electrically processed, then only one lamp
View A corresponding to the gauge level lights on the instru-
A ment panel as in the table below.
(brown)
SW3
SW1 (1/4) SW5
(3/4) (E)
(white) (green) Float switch switching and indicator lamp lighting status
Indicator lamp
Float switch
O: Lit : Flashing
O: ON X: OFF
– : Extinguished
E 1/8 1/4 1/2 3/4 E 1/4 1/2 3/4 F
SW4 (yellow)
SW2 (1/8) 3/4 or more X X X X X – – – – O
(1/2) SW1
Actual fuel level

(3/4) From 3/4 to 1/2 X X X X O – – – O –

(blue)
From 1/2 to 1/4 X X X O O – – O – –
View B
From 1/4 to 1/8 X X O O O – O – – –

SW2 From 1/8 to E X O O O O O – – – –

(1/2) E or less O O O O O  – – – –
Any other pattern – – – – –
Example of failure:
When the wire of the "1/4" float switch is broken, the indicator lamps
for "1/8" and "E" do not light even if the fuel amount becomes 1/2 or
SW3 less.
(1/4)

Float switch

SW4
(1/8)

OFF Liquid surface SW5

(E)
ON

K115ZV62016

Indicator lamps Fuel level sensors

Monitor
controller
+24 V
(YR) YR
3/4
(YB) YB
1/2
(YL) YL
1/4
(YBr) YBr
1/8
(YG) YG
E
GND

Fuel level circuit K115ZV62017

 115ZV EX 62-81
62 Function & Structure Electrical Group
Instrument Panel and Switch

Tachometer circuit

E Tacho
Converter

meter
C 24 V
M 0
0.3 V
Number of rotations of
engine x 12 pulses

90ZV62015

The Cummins ECM transmits the engine speed signal

(square wave) to the converter. And the converter
transmits the square wave signal to the tachometer.

Tachometer

Its pointer moves in proportion to the input frequency.

Input frequency (Hz) Instructed number of rotations (min-1)

66.67 500 ± 50

200 1,500 ± 45

333.33 2,500 ± 125

115ZV EX 62-82
62 Function & Structure Electrical Group
Electrical Detent Circuit

Electrical Detent Circuit

Bucket leveler After dumping, if the control lever is set to the "roll back"
position, the bucket control lever will be held at that
position until the bucket is tilted to the set angle. This is
because the detent magnet in the pilot valve is ener-
Detent solenoid
(Pilot valve Detent solenoid gized so that the holding plate connected to the spool is
S/N 0141~, (Pilot valve held by the magnetic force.
9021~) S/N ~0140,
~9020)
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 coil of the pilot valve is de-
energized and de-magnetized. The bucket 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.

The bucket digging angle can be arbitrarily adjusted by

loosening bolts and moving a plate equipped with the
Multiple control valve K90ZV62011 proximity switch.

Bucket digging angle Dimension A

-7º 6 mm (15/64 in)
0º 69 mm (2 23/32 in)
+7º 134 mm (5 9/32 in)

Bucket cylinder

When installing the proximity switch

- Clearance between the proximity switch and the rod

(detecting element):
5 ± 2 mm (1/8 ~ 9/32 in)
A
Indicator lamp
- Attach the proximity switch so that the indicator lamp
Proximity switch Cover
(LED) comes to the bottom side so that the lamp sta-
Adjusting plate Rod tus can be visually checked.
(detected object)
- :
Proximity switch: 19.6 N-m (2 kgf-m) (13 lb-ft)
5 2 mm

Clearance between rod

and proximity switch
K115ZV62018
 115ZV EX 62-83
62 Function & Structure Electrical Group
Electrical Detent Circuit

Boom kick-out (option) Float

When the boom control lever is set to the “boom float”

Bolt position, it is held in that position.
Plate position when
Boom Highest position of hoist operating the machine
with the boom
elevation angle at 0º
The boom control lever can be released manually.
Plate

Cover
41.2

Proximity
switch
Proximity switch
115ZV62029

While the boom is being raised, the boom control lever

is held in the “boom raise” position. When the boom
reaches the preset height, the boom control lever is
automatically returned to the neutral position.

The detent function and its release method are the

same as those of the bucket positioner.

The boom elevation angle can be arbitrarily adjusted in

the range from 43.6º to 0º by loosening bolts and sliding
a plate.

Installation of proximity switch

- Clearance between the proximity switch and the

plate (**) = 7 ± 1 mm (15/64 ~ 5/16 in)

- Clearance between the cover and the plate (*) =

5 mm (13/64 in)

- Attach the indicator lamp (LED) so that the it can be

checked from the bottom of the machine.
: 19.6 N-m (2 kgf-m) (13 lb-ft)
115ZV EX 62-84
62 Function & Structure Electrical Group
Electrical Detent Circuit

Proximity switch

Adjusting the clearance

Proximity switch +24V

LED Br 1
Switch main Coil for detent
circuit
B2 inside pilot valve
L
3
+24V

Detection part
Operation indicator lamp (LED) 1(Br)

Detected object
Z
3(L) 2(B)

5±2 mm (0.197±0.079 in) View Z

K90ZV62012

Adjust the clearance between the sensor and the

adjusting plate to 5 ± 2 mm (1/8 ~ 9/32 in).
In this condition, the operation indicator lamp (LED)
turns on, and the circuit between the switches (2) and
(3) is on.

Detent solenoid
Three detent solenoids are installed in the pilot valve.
One detent solenoid, for the bucket leveler, is installed
in the pilot valve bucket side.
Two detent solenoids, for the boom kick-out and float,
are installed in the pilot valve boom side. (S/N 0141~, 9021~)

(S/N 0101~0140, 9001~9020)

Solenoid Steel ball for detent

Plate
Push rod

Detent solenoid

Fixing disc

Lock nut
95ZV42014
Disc
K90ZV62013

Voltage DC 24 V
Coil resistance 238±10 
Voltage DC 24 V
Coil resistance 62±3 
 115ZV EX 62-85
62 Function & Structure Electrical Group
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
70ZV62051
is not absorbed. This damages electrical parts.)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
115ZV EX 62-86
62 Function & Structure Electrical Group
Diode

Diode check method Caution for diode check method

Continuity check mode

When checking the continuity by continuity check mode

of volt-ohm-ammeter, only in case that the resistance is
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 (2) (3)
B AC
R2 C 5A
(2)(3) Diode unit
BATTERY
F14

RELAY
5A

Suppression diode

Charge circuit R1
B
Monitor circuit

Neutral relay From alternator

K85ZV62004

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
 115ZV EX 62-87
62 Function & Structure Electrical Group
Diode

Resistance check mode

Analog type tester

R1>0 R2=
0 0

Forward check Backward check

Digital type tester

R1>0 R2=

R1

Forward check Backward check

Forward check Backward check Judgement

R  (0<R<)  Normal
  Open circuit
0 0 Short-circuit
115ZV EX 62-88
62 Function & Structure Electrical Group
Diode

Surge voltage and surge suppres- Fig. 3

sion diodes
Surge suppression
Fig. 1 diode

Electromagnetic field forms Coil

when switch closes.
Current direction

Coil
Voltage
Battery

Current Switch or
transistor
Current [A]
Voltage [V]

K70V2J62006

Time [sec]

When the surge voltage was generated, it causes to

Load increase wear on the switch points.
115ZVE62032

During the coil is being activated by the transistor, when

Some electrical parts such as solenoid valves are the excruciating high voltage is loaded on the transistor,
equipped with a coil. the transistor may be broken.

When a coil is energized, an electromagnetic field is In order to absorb this surge voltage, connect the diode
formed. See fig. 1. parallel to the coil in the reverse direction against the
power supply.
Fig. 2
When the switch is off, the same amount of electric cur-
When the switch opens, the rent, that was flown till now, flows through the diode.
field collapses across the coil
windings. This electric current is attenuated gradually and finally it
Coil
Voltage reaches zero. That means no surge voltage is gener-
Battery

Current ated in the circuit.

Current [A]
Voltage [V]

This diode is called as flywheel diode.

ON OFF
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.)
 115ZV EX 62-89
62 Function & Structure Electrical Group
Diagnostic System (S/N 0101~0153, 9001~)

Diagnostic System (S/N 0101~0153, 9001~)

Transmission controller
Diagnostic system flow

Starter switch ON (Engine stops.)

Year, month and day are

indicated in this order for
Date display
1 second each.
(3 seconds) YExample: 01.06.16 (or June 16, 2001)

Diagnosis ON
switch (momentarily)

OFF

Current
There is failure.
conditions

Corresponding warning
lamp lights
There is no failure. (transmission controller).

Speed and engine

rotation are indicated. Failure history indication
Failure code flashes Failure codes are lit one by
(to indicate current one at every 2 seconds.
failure).

Reset switch

If more than one failure code is stored

Remains ON for approx.
in the memory, each of them is
3 seconds while engine is
indicated for 2 seconds from the
stopped, then turns off
newest one.
momentarily.
If no failure code is stored, "FF" is
indicated for 2 seconds.

Stored failure history is cleared.

(Buzzer sounds for 0.5 second.) While the indication switch is pressed
and held, codes are kept indicated.

115ZV62047
115ZV EX 62-90
62 Function & Structure Electrical Group
Diagnostic System (S/N 0101~0153, 9001~)

Failure code (T/M controller)

The failure code is displayed on the failure code indica-

tion window on the T/M controller.

Code Failure Detection condition

11 Shift lever F and R contact ON at the same time In case the failure continues for more than “3 seconds“
25 QUAD switch malfunction In case the switch is ON for more than “10 seconds“
26 Inching (Declutch) switch malfunction In case the switch is ON for more than “3 minutes“
38 Up-shift switch malfunction In case the switch is ON for more than “10 seconds“
39 Down-shift switch malfunction In case the switch is ON for more than “10 seconds“
51 1st solenoid coil or wiring circuit is open or disconnected In case the failure continues for more than “1 second“
52 2nd solenoid coil or wiring circuit is open or disconnected The same as the above
53 3rd solenoid coil or wiring circuit is open or disconnected The same as the above
54 H solenoid coil or wiring circuit is open or disconnected The same as the above
55 L solenoid coil or wiring circuit is open or disconnected The same as the above
56 R solenoid coil or wiring circuit is open or disconnected The same as the above
Modulator valve (2) solenoid coil or wiring circuit is open or
57 The same as the above
disconnected
Auto-brake solenoid coil or wiring circuit is open or discon-
58 The same as the above
nected
Modulator valve (1) solenoid coil or wiring circuit is open or In case the current value less than “5 mA” continues for more than “10
59
disconnected seconds”
Pressure difference sensor malfunction (1)
- The problem may be an electrical malfunction of the sen- E/G revolution is more than “1,500 min-1 (rpm)” and the shift lever is
60 sor or wiring. changed more than “10 times”, however the sensor voltage never
- The problem may be a mechanical malfunction (sticking) reaches more than “2 V”
of the switch.
Pressure difference sensor malfunction (2)
In case the signal voltage is more than ”3 V” and it continues for more
61 - The problem is probably a mechanical malfunction
than “10 seconds”
(sticking) of the switch.
In case the E/G revolution detection value is more than “3,000 min-1
71 E/G speed sensor malfunction
(rpm)”
In case all the machine speed detection value is more than “50 km/h (31
72 Machine speed sensor malfunction
mph)”
E1 EPROM write frequency limitation In case the write frequency is more than “80 thousands”
FF No failure record memorized
 115ZV EX 62-91
62 Function & Structure Electrical Group
Diagnostic System (S/N 0101~0153, 9001~)

Diagnostic (T/M controller) failure code 6. Solenoid open circuit codes (codes 51~58):
detection condition
If the transmission solenoid coil is internally open,
has high resistance (more than 35 ), or a broken
1. Failure code indication for current failure:
wire between the controller and the solenoid coil.
The machine will not move in the gear that has the
If more than one failure code is stored in memory
open circuit (malfunction codes 51~56). The symp-
the newest one is displayed first. To review older
tom may be the same as 2 above. Read the mal-
failure codes switch ON the diagnostic switch.
function code to determine which malfunction has
actually occurred.
2. Shift lever failure detection code (code 11):
If the modulator valve 2 (MV2) is disconnected
(malfunction code 57) harsh shifting will occur.
Code 11 indicates a short circuit in either the shift
If the auto-brake solenoid coil is defective or dis-
lever or the wiring.
connected the auto-brake feature will not work.
3. QUAD switch malfunction code (code 25):
7. Modulator Valve 1 (MV1) open circuit codes (codes
59):
Normally the switch is not pushed for more than 10
seconds. If the switch stays ON (contacts closed)
The normal current value is about 450 milli-Amps
for more than 10 seconds the controller considers it
(mA) through MV1 coil. When the current value
to be a short circuit in the switch or its wiring.
through the MV1 coil is less than 5 mA for more
than 10 seconds the controller senses an open cir-
4. Inching (declutch) switch malfunction code (code
cuit in the coil or its wiring. In this case the trans-
26):
mission pressure will be very low and may not
move.
When using the inching (also called declutch or
clutch-cutout) switch it is normal for it to be ON
8. Pressure differential sensor malfunction #1 (code
(contacts closed) while the brake pedal is
60):
depressed. However, if the switch remains ON for
more than 3 minutes the controller considers that
When this code is indicated the sensor itself is
there is a short in the switch or its wiring. Should
defective. However, the internal spool may be stuck
the operator keep the pedal depressed more than 3
rather than an electrical defect.
minutes the malfunction code will be stored in the
controller but the machine will continue to operate
9. Pressure differential sensor malfunction #2 (code
normally.
61):
5. Shift switch malfunction codes (code 38, 39):
This code indicates the signal from the sensor is
not correct. While the sensor may be electrically or
In the normal use, the shift switch is not pressed
mechanically (stuck spool) defective there is the
and held continuously. Accordingly, if it remains ON
possibility that internal leakage in the clutch pack
for 10 seconds or more, the controller considers it
seal (s). Replacement to the sensor will not correct
to be malfunction in the shift switch itself (such as
the problem if the seal is defective.
sticking of contact) or short-circuit to the body in the
wiring between the shift switch and the transmis-
sion controller.
115ZV EX 62-92
62 Function & Structure Electrical Group
Diagnostic System (S/N 0101~0153, 9001~)

10. Engine speed sensor malfunction (code 71): Fault diagnostic result storage condition
This code occurs when the signal from the engine 1. Faults are stored in the time series (from the oldest
speed sensor is extremely high (over 3,000 min-1 one to the latest one).
(rpm)).
While this could occur from an engine over speed 2. Thirty two faults can be stored.
situation it can also occur from electronic "noise"
from other sources. Be sure the wiring from the 3. If the code was recorded past and it was not
sensor to the controller is twisted through the har- deleted, the same code is not recorded newly.
ness. Twisting the wire prevents it from acting like Therefore when the cause of the fault was
an antenna and picking up the electronic noise gen- removed, delete the code once recorded.
erated from other sources.

Note
If the speed sensor is defective or disconnected no
LED characters will be displayed when the engine
is running (refer to the controller display).

11. Machine speed sensor malfunction (code 72):

This code occurs when the signal from the engine

speed sensor is extremely high (over 50 km/H).
While this could occur from an engine over speed
situation it can also occur from electronic "noise"
from other sources. Be sure the wiring from the
sensor to the controller is twisted through the har-
ness. Twisting the wire prevents it from acting like
an antenna and picking up the electronic noise gen-
erated from other sources.

Note
If the speed sensor is defective or disconnected no
LED characters will be displayed when the engine
is running (refer to the controller display).

12. EPROM write frequency limitation (code E1):

The EPROM is designed to have enough capacity

to outlast the life of the machine and should never
be displayed.

13. No malfunction code recorded (code FF):

If the diagnostic switch is installed and pressed and

there are no malfunction codes stored in memory
the display will be show "FF". If the machine will not
move and "FF" is displayed check the input LED's
to be sure there are no open circuit from the lever.
 115ZV EX 62-93
62 Function & Structure Electrical Group
Diagnostic System (S/N 0101~0153, 9001~)

Monitor controller
Diagnostic system flow

Starter SW ON (Engine OFF)

Current
Abnormal
condition

Normal Warning lamp ON

2 seconds ON: Release switch to the "off"

position when the screen goes blank.
Diagnostic (Timing is critical.)
SW

Failure history indication

Warning lamp flashes on
and off every 3 seconds.

Reset SW
If the failure code memorized is more
than one the newer failure code
flashes on and off first in order.
3 seconds ON: Release switch to the "off" In case no failure code memorized, all
position when the screen goes blank. warning lamps come on for 1.5
(Timing is critical.) seconds.

Failure history memorized is

deleted completely
(Buzzer sounds 0.5 seconds)

70ZV62056
115ZV EX 62-94
62 Function & Structure Electrical Group
Diagnostic System (S/N 0101~0153, 9001~)

Alarm monitor actuation and data storage

Alarm monitor control

Central alarm lamp Fuel level

Brake oil pressure

Engine oil pressure
Engine water temperature

T/M oil temperature

Air cleaner

T/M oil filter

Engine water level

Emergency steering 95ZV62077

1. Lamp test 4. Abnormal engine oil pressure.

When the power is turned on, monitor lamps (cen- After the lamp test is finished, if there is something
tral alarm, brake oil pressure warning, engine oil abnormal in the engine oil pressure while the
pressure warning, T/M oil temperature warning, engine is running (that is, while a signal is input
engine water temperature warning, air cleaner clog- from the alternator), the central alarm lamp flashes
ging, T/M oil filter clogging, engine water level and the engine oil pressure warning monitor lamp
warning and emergency steering (option)) are lit for lights. In addition, buzzer sounds, and the alarm
3 seconds and buzzer sounds for 3 seconds. item (engine oil pressure) is stored in memory.

2. Check before operation (engine water level). 5. Abnormal brake oil pressure.

After the lamp test is finished, if there is something After the lamp test is finished, if there is something
abnormal in the engine water level while the engine abnormal in the brake oil pressure (main pressure),
is stopped (that is, while no signal is input from the the central alarm lamp flashes and buzzer sounds.
alternator), the engine water level warning monitor In addition, the alarm item (brake oil accumulator
lamp lights and the alarm item (engine water level) pressure) is stored in memory.
is stored in memory.
When the engine starts (that is, when a signal is
input from the alternator), the engine water level
warning monitor lamp turns OFF.

3. Abnormal T/M oil temperature, engine water tem-

perature, air cleaner or T/M oil filter.

If there is something abnormal in the T/M oil tem-

perature, engine water temperature, air cleaner or
T/M oil filter, the central alarm lamp flashes and a
corresponding warning monitor lamp lights. In addi-
tion, the corresponding alarm item is stored in
memory.
 115ZV EX 62-95
62 Function & Structure Electrical Group
Diagnostic System (S/N 0101~0153, 9001~)

6. Emergency steering alarm Fault diagnostic result storage condition

After the lamp test is finished, if there is something 1. Faults are stored in the time series (from the oldest
abnormal in the steering oil pressure, the emer- one to the latest one).
gency steering monitor lamp lights.
After the lamp test is finished, if there is something 2. Sixty three faults can be stored.
abnormal in the steering oil pressure while the
engine is running (that is, while a signal is input 3. If the result of the sensor check performed at first
from the alternator), the central alarm lamp flashes after the power is turned on is equivalent to the lat-
and the emergency steering monitor lamp lights. In est stored fault, it is not stored.
addition, buzzer sounds, and the alarm item (steer-
ing oil pressure) is stored in memory. 4. When an error of the same combination occurs
intermittently (that is, when the cause of the fault is
Fuel level indication not removed)

1. Lamp test - Alarm monitor control

An error of the same combination is stored
When the power is turned on, all of the fuel level up to three times, and ignored after that.
indicators are lit for 3 seconds. - Fuel indication
An error of the same combination is not
2. Fuel level indication stored.

If the displacement status continues for 4 seconds 5. When the memory is full, the stored data is deleted
or more, the fuel level lamps change as shown in from the oldest one.
the table below.
After the lamp test is finished, if there is something
abnormal in the input (that is, if the “Except the
above” status shown in the table below remains for
4 seconds or more), the input signal status at that
time is stored in the memory.

Input Output
E 1/8 1/4 1/2 3/4 E 1/4 1/2 3/4 F
X X X X X – – – – O
X X X X O – – – O –
X X X O O – – O – –
X X O O O – O – – –
X O O O O O – – – –
O O O O O Fl – – – –
Except the above – – – – –
LED indication
Fuel level sensor switch
O : ON
O: Input signal (Yes)
– : OFF
X: Input signal (No)
Fl: ON and OFF (flash)

: :

95ZV62078
115ZV EX 62-96
62 Function & Structure Electrical Group
Diagnostic System (S/N 0101~0153, 9001~)

Diagnostic failure history indica-

tion and deletion
Failure history indication

When the starter switch is set to ON (without starting the

engine) and the diagnostic switch is pressed and held
for 2 seconds or more, all monitor lamps and fuel level
lamps are lit for 1.5 seconds. And each of stored alarm
monitor items is indicated (a corresponding monitor
lamp lights) in the reverse order of the time series (that
is, from the latest one to the oldest one) 3 times respec-
tively in the 1-second cycle. (Between two items, all
lamps are extinguished for 1.5 seconds.)

After that, the fuel level lamps light, become extin-

guished or flash to indicate the input status at that time.

After all stored alarms are indicated, the history indica-

tion is finished and the machine returns to the normal
mode.

Diagnostic switch - Starter switch ON (E/G OFF)

2 sec

ON

OFF
Diag. SW
1.5 sec
Newest 1 sec
failure ON

OFF
Warning lamp 1

1.5 sec
ON

OFF
Warning lamp 2

1.5 sec
ON

OFF
Fuel level lamp

ON
Oldest
failure OFF
Buzzer

Finish
95ZV62079
 115ZV EX 62-97
62 Function & Structure Electrical Group
Diagnostic System (S/N 0101~0153, 9001~)

Failure history deletion

When the starter switch is set to ON (without starting the

engine) and the reset switch is pushed for more than 3
seconds, all failure history memorized is deleted com-
pletely. At that time the buzzer sounds 0.5 second.

Reset switch - Starter switch ON (E/G OFF)

3 sec

Reset SW

0.5 sec

Buzzer
Failure history memorized is deleted completely.
95ZV62131

Note
1. If the memory call switch is pressed and held for 2
seconds or more while the stored fault data is indi-
cated, the fault data is indicated from the first fault.
2. If the revolution signal is input or the starter switch
is set to OFF while the stored fault data is indicated,
fault data indication stops.

CAUTION
When the engine is stopped (starter switch ON) and
the reset switch is being pushed for more than 3 sec-
onds, both the failure history for the transmission
controller and the monitor controller are deleted at
the same time.
115ZV EX 62-98
62 Function & Structure Electrical Group
Diagnostic System (S/N 0101~0153, 9001~)

Diagnostic switch

Diagnostic switch Reset switch

OFF
ON

OFF
(A)
ON

G R

Y B

B
Y R

Y R
B

To T/M controller (machine body harness)

95ZV62081

When performing the diagnostic procedure, connect the

diagnostic switch coupler to the controller as shown
below.

Necessary parts

1. Diagnostic switch assembly (A)

Part Number
35020-20510
- Diagnostic sw
- Reset sw
- Harness assembly
 115ZV EX 62-99
62 Function & Structure Electrical Group
MODM (S/N 0154~)

MODM (S/N 0154~)

(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 machine information
The MODM has the following functions: screen displays information relative to the machine
function.
- Information monitor

Displays machine speed and engine speed and volt- Changing display from one function to next
age.
Press both the [ (step back)] button and [ (step
- Replacement monitor forward)] button at the same time to change over the
monitor mode in sequence "Information monitor 
Not used. Replacement monitor  Fault log monitor  Input/Out-
put monitor  Parameter setting monitor  Specifica-
- Fault log monitor tion setting monitor Information monitor".

Allows check of previous errors, and displays active However the monitor mode can not be changed in
errors. reverse such as "Information monitor  Specification
setting monitor  Parameter setting monitor ....."
- Input/Output monitor
The display will not be changed to the next monitor
- Parameter setting monitor when you hold the buttons.

Allows check and change of the calendar setting

only.

- Specification setting monitor

Allows check of the program number only.

 !"   # $%   &' ( $ & %$ ) %
115ZV EX 62-100

MODM (S/N 0154~)

  
  

    - *

$*
#  ' ($
62 Function & Structure Electrical Group

    

$ * .  $
+ ,*

    

- *
  

     $*

!    

    

 


 Information Monitor

Hour Meter

Outside Temperature
(Information Menu Initial Screen)
(Not used) 3 sec

Language Selection

2 sec Change
No Change

Active Error
Machine Speed / Engine Speed
Unit Conversion
Active Error
Odometer
Press any button

Engine Coolant Temperature Cycle

(Not used) (Not used)

Transmission Oil Temperature Hydraulic System Oil Pressure

Specification Setting
(Not used) (Not used)
Monitor

Hydraulic Oil Temperature Voltage

(Not used) Replace Monitor

Odometer / Trip Meter Hour Meter Press any button:

( , , or )
(Not used) (Not used)

Cycle Outside Temperature

95ZVE62076
MODM (S/N 0154~)
115ZV EX 62-101
62 Function & Structure Electrical Group
 Fault Log Monitor
2 sec
115ZV EX 62-102

Machine Fault Log Engine Fault Log

MODM (S/N 0154~)

2 sec
Active Fault

Machine Fault Log Maximum

Active Fault

Machine Fault Log 1 Press any button

(Initial Screen for Machine Fault Log) 2 sec

Clear Fault Log

62 Function & Structure Electrical Group

2 seconds or more: Return after clear

Return without clear

Machine Fault Log 2 2 sec

Clear Fault Log

Replace Monitor
2 seconds or more: Return after clear
Return without clear

Machine Fault Log 3 2 sec

Clear Fault Log (Not used)

Input/Output Monitor
2 seconds or more: Return after clear
Return without clear
Clear Fault Log
Press any button

( , , or )

Maximum Machine Fault Log 2 sec

Clear Fault Log

2 seconds or more: Return after clear

Return without clear

Machine Fault Log 1

95ZVE62077
 115ZV EX 62-103
62 Function & Structure Electrical Group
MODM (S/N 0154~)

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 1•2•3•A contact ON at the same time
CN122 Shift lever 1•2•3•A switch malfunction (1)
Failure continues for more than 3 seconds
CN123 Shift lever 1•2•3•A switch malfunction (2) All 1•2•3•A signal OFF continues for more than 3 seconds
CN145 Kick-down switch malfunction Switch is ON for more than 10 seconds
CN152 T/M Press. diff sensor malfunction T/M Press. diff sensor voltage is larger than 3V for more than 10 seconds
CN161 Machine speed sensor malfunction (1) Input circuit is disconnected for more than 3 seconds
CN162 Machine speed sensor malfunction (2) Input value is over 70 km/h (44 mile/h) for more than 3 seconds
No E/G speed sensor input for more than 3 seconds when E/G speed
CN163 E/G speed sensor 1 (ECM output) malfunction (1)
sensor 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
CN165
(1) sensor 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) Switch is ON for more than 180 seconds
Steering oil pressure switch is ON for more than 1 second during engine
CN254 Low secondary steering oil pressure
running
CN381 Fuel level sensor malfunction Input signal corresponds to "any other pattern" in fuel level indication table
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 difference switch is in abnormal condition for more than
CN414 Abnormal brake oil pressure difference
1 second
Engine oil amount switch is OFF for more than 2 seconds when no engine
CN420 Abnormal engine oil amount
running
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
CN451 Abnormal T/M oil temperature (1) T/M oil temperature switch is ON for 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.
CN912 Abnormal MCU voltage (1) Voltage is larger than 30±1 V
Voltage is lower than 22±0.5 V for more than 10 seconds during engine
CN913 Abnormal MCU voltage (2)
running
115ZV EX 62-104
62 Function & Structure Electrical Group
MODM (S/N 0154~)

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 the 95/115/135ZV-2 units.

Failure code (Output side)

Code Failure Detection condition

CN512 F solenoid valve malfunction F solenoid valve is short-circuited or disconnected
CN514 R solenoid valve malfunction R solenoid valve is short-circuited or disconnected
CN516 1st solenoid valve malfunction 1st solenoid valve is short-circuited or disconnected
CN518 2nd solenoid valve malfunction 2nd solenoid valve is short-circuited or disconnected
CN521 3rd solenoid valve malfunction 3rd solenoid valve is short-circuited or disconnected
CN526 D solenoid valve malfunction D solenoid valve is short-circuited or disconnected
CN528 H solenoid valve malfunction H solenoid valve is short-circuited or disconnected
CN534 Auto brake solenoid valve malfunction Auto brake solenoid valve is short-circuited or disconnected
Speed change control solenoid valve malfunction
CN537 Speed change control solenoid valve is disconnected
(2)
 Input/Output Monitor
2 sec 2 sec 2 sec 2 sec 2 sec

Other Output Input Signal Analogue Input Output Signal Other Output Input Signal

2 sec 2 sec 2 sec 2 sec 2 sec

Active Error

DI Port 7 DO Port 6
Active Error

Press any button

DI Port 1
(Initial Screen for I/O Monitor) DO Port 1

DI Port 2 DO Port 2

Fault Log Monitor

DI Port 3 DO Port 3

Parameter Setting
Monitor

Press any button

( , , or )

DI Port 7 DO Port 6

DI Port 1 DO Port 1

Input Signal Screen Input Sensor Screen Output Signal Screen Cooling Fan Current Output

95ZVE62081
MODM (S/N 0154~)
115ZV EX 62-105
62 Function & Structure Electrical Group
 0 1 2 3 4 5 6 7
115ZV EX 62-106

MODM (S/N 0154~)

INPUT 1 Shift lever F Shift lever R Shift lever 1 Shift lever 2 Shift lever 3 Shift lever A Shift-up Shift-down

Engine speed sensor

A/M selection
INPUT 2 Kick-down Declutch switch Parking switch selection (ECM
output/sensor output)
(automatic/manual)

Stick steering (K-Lever)

INPUT 3 arm rest switch

Machine speed Machine speed

INPUT 4 Ride control switch Model selection 4
selection 2 selection 1
62 Function & Structure Electrical Group

Alternator neutral Brake oil pressure

INPUT 5 Model selection 3 Model selection 1 Model selection 2 E/G oil level switch
point voltage switch

Brake differential Steering oil pressure Engine oil pressure Engine coolant Transmission oil Axle oil temperature Air cleaner clogging Abnormal brake
INPUT 6 pressure switch switch switch temperature switch temperature switch switch switch switch

INPUT 7 Fuel level 3/4 Fuel level 1/2 Fuel level 1/4 Fuel level 1/8 Fuel level F

0 1 2 3 4 5 6 7

1st speed solenoid 2nd speed solenoid 3rd speed solenoid 4th speed solenoid
OUTPUT 1 F solenoid valve R solenoid valve H solenoid valve Brake solenoid valve
valve valve valve valve

Ride control solenoid Reverse fan solenoid

OUTPUT 2 D solenoid valve
valve valve
Engine coolant Transmission oil
1st speed indicator Brake oil pressure Engine oil pressure Axle oil temperature Air cleaner warning
OUTPUT 3 temperature warning temperature warning
lamp warning lamp warning lamp lamp lamp
warning lamp lamp

4th speed indicator Emergency steering

OUTPUT 4 Neutral relay MCU failure relay Back lamp relay
lamp motor relay

3rd speed indicator Auto shift indicator Neutral indicator Auto brake indicator Radiator water level Steering oil pressure
OUTPUT 5 Central warning lamp Fuel level F
lamp lamp lamp lamp warning lamp warning lamp

2nd speed indicator E/G oil level warning

OUTPUT 6 Fuel level 3/4 Fuel level 1/2 Fuel level 1/4 Fuel level E Buzzer
lamp lamp
MODM: Input/output monitor - Input/output signal correspondence table
 Parameter Setting Monitor

Calendar Power Control (Vni) Setting 2

Deceleration Prevention Setting 1

(Initial Screen for Parameter Setting) Lower Kick Out

(Not used) (Not used) Input/Output Monitor

Deceleration Prevention Setting 2 Lift Kick Out

(Not used) (Not used) Specification

Selection Monitor

Ride Control Setting 1 Calendar 2 sec

(Not used) Parameter Setting

2 sec Change
No Change

Ride Control Setting 2

Deceleration Prevention Setting 1
(Not used)

Parameter Setting
Speed Meter Divide Setting 1

(Not used)

The cursor flashes in a 1-second cycle.

(lights for 0.5 second and lights off for 0.5 second).

- SPEED METER DIV2 - TRACTION CONTROL F1 The cursor moves rightward.

- TACHOGRAPH DIV1 - TRACTION CONTROL DSsc (upper right lower left lower right upper left)
- TACHOGRAPH DIV2 - TRACTION CONTROL Isc
- EMG STEERING ON - TRACTION CONTROL ti The cursor skips (digits/column) which can not be changed.
- EMG STEERING OFF - TRACTION CONTROL SCv Adding 1 to the value where the cursor is
- K-LEVER V1 - TRACTION CONTROL SCeg (Not used)
- K-LEVER V2 - TRACTION CONTROL SCi (0 1 2 9 0)
- K-LEVER Vmax - TRACTION CONTROL SCt
Subtraciting 1 to the value where the cursor is.
- K-LEVER i1 - T/M CUT OFF IS
- K-LEVER i2 - 2 STAGE DSon (9 8 7 0 9)
- K-LEVER imax - POWER CONTROL TWni

Power Control (Vni) Setting 2

95ZVE62083
MODM (S/N 0154~)
115ZV EX 62-107
62 Function & Structure Electrical Group
 Specification Setting Monitor
Program No.
(Initial Screen for Specification)
115ZV EX 62-108

MODM (S/N 0154~)

62 Function & Structure Electrical Group

MODM Display
Parameter Setting
Model Model Program Date Program Date Monitor

95 ZV 01
yymmdd yymmdd
Information
115 ZV 02 Monitor

: Space
yy : Year (last 2 digits)
mm : Month
dd : Date

95ZVE62084
 115ZV EX 63-1
63 Check & Adjustment Electrical Group

63 Check & Adjustment

Electrical Group

Cautions Regarding Electric Circuit Check ...........................63-2

Electrical Transmission Control System Troubleshooting
Flowchart (S/N 0101~0153, 9001~) ......................................63-5
Transmission Controller Abnormal Operation Judgment
(S/N 0101~0153, 9001~).......................................................63-6
Electrical Circuit Check (S/N 0101~0153, 9001~)...............63-10
115ZV EX 63-2
63 Check & Adjustment Electrical Group
Cautions Regarding Electric Circuit Check

Cautions Regarding Electric Circuit Check

Disconnecting or reinstalling con-

nector

Inserting waterproof round connector

80ZV63006

Removing square connector

80ZV63003

80ZV63007

1. Before disconnecting or reinstalling the connector,

Removing waterproof round connector be sure to turn the power off (turn the starter switch
80ZV63004
to OFF).

2. To disconnect a connector, firmly grab the connec-

tor, and press and hold the stopper claw. While
holding down the claw, pull out the connector in the
straight direction. Do not pull the electric cable or
wires. They may be damaged. Do not twist the con-
nector or the female terminal cover may be dam-
aged to cause poor contact.

3. When reconnecting, insert it until the stopper claw

clicks.
If the connector is not completely connected, it may
cause poor contact.
Inserting square connector
80ZV63005
 115ZV EX 63-3
63 Check & Adjustment Electrical Group
Cautions Regarding Electric Circuit Check

Note
In corrosive environments (such as salt air, phosphate
plants, or fertilizers) the square type connectors will
require special coatings to prevent or minimize electrical
problems. Use only an approved sealant like Dow Corn-
ing 738 or Loctite "Ultra Blue".
Other silicone sealants may contain acetic acid which
may corrode the wiring.
(Hint: If the silicon has a vinegar type odor it has acetic
acid and should not be used.)
Use only a very small amount of di-electric grease if
needed.
115ZV EX 63-4
63 Check & Adjustment Electrical Group
Cautions Regarding Electric Circuit Check

How to attach the probes of the

circuit tester

How to attach the probes of the circuit tester

to the square connector.
80ZV63008

How to attach the probes of the circuit tester

to the waterproof round connector. 80ZV63009

When checking the conductivity or the voltage, follow

the procedure below:

1. Square connector

Insert the probes for the tester to the wire side of

the connector. Do not insert the probes into the
open side of the connector. The damaged connec-
tor may cause poor contact.

2. Waterproof round connector

For the waterproof round connector, do not attach

the probes of the tester to the wire side because
the wire side is waterproofed. Attach the probes to
the open connector side. Do not force the probes
into the female side. The damaged connector may
cause poor contact.
 115ZV EX 63-5
63 Check & Adjustment Electrical Group
Electrical Transmission Control System Troubleshooting Flowchart (S/N 0101~0153, 9001~)

Electrical Transmission Control System Troubleshooting

Flowchart (S/N 0101~0153, 9001~)
For a problem regarding transmission control, check the To check the electric control system, determine the
electric control system first, and then check the cause of the problem while referring to the flowchart
mechanical system. below, and then solve the problem.

Standard troubleshooting flowchart

Cause of problem

Is the "controller
failure" monitor On - The transmission controller
lamp on? failure. If the circuit protector in
the controller is off, the power
supply or output circuit is
off shortcircuited. Check for
damaged solenoid coils or their
wiring.

Check the other

monitor lamps.* Abnormal - The input circuit or one of the
input units is defective.
* Check that the monitor lamps are properly
turned on and off according to operation of the
Normal respective unit, such as shift lever and parking
switch.

Check the on/off

statuses of the
transmission Abnormal - The input circuit or one of the input
controller LED units is defective.
indicators.* - The transmission controller is
* Refer to the table "Transmission controller defective. (The defective controller
LED indicator". Also check for logged fault judgment standard is described on
Normal codes. the next page.)

Check operation of
the output circuit Problem detected
- The output circuit or one of the
and output units.* (disconnection, etc.)
output units is defective.
* Measure the resistance of the output circuit
No problem and output units (solenoid valve, etc.) while
operating the input units.

Check mechanical
operation of the Problem detected - An output unit is defective.
output units.*
* Disassemble the output units
(solenoid valve, etc.), and check
No problem them for sticking.
Check the drive line and
the transmission for
mechanical problems.

70ZVE63009
115ZV EX 63-6
63 Check & Adjustment Electrical Group
Transmission Controller Abnormal Operation Judgment (S/N 0101~0153, 9001~)

Transmission Controller Abnormal Operation Judgment

(S/N 0101~0153, 9001~)

Transmission controller check When the output units (solenoid valve, etc.)
do not operate properly:
To judge whether the transmission controller operates
properly, follow the procedure below: Remove connector E2, E3 from the output side. Oper-
ate the shift lever, parking switch, etc., and check the
on/off statuses of the transmission controller LED indi-
IMPORTANT cator.
When performing test 3, be careful not to arc across
to other terminals. Damage to controller can result. ON/OFF Input side No LED Normal LED Normal LED
status of
Use plug in connector pig-tail wires to do this with. LED Output side No LED Normal LED No LED
Judgment for
Normal Abnormal
controller
Defective Defective
Defective
Cause input unit or transmission
When the "controller failure" monitor lamp output unit
circuit controller
lights: Check the Check the Replace the
input units output units transmission
Solution
and the and the controller
Under the condition, check the position of the circuit circuit circuit assembly
protector switch (on or off). (After turning the starter
switch to the OFF position, turn on the circuit protector
switch.)

Circuit protector OFF ON

Judgment for Normal Abnormal

controller
Defective transmission
Power supply or output
Cause controller
circuit shortcircuited
(IC self-diagnosis)
Check the power sup- Replace the transmis-
Solution
ply and output circuits sion controller assembly
 115ZV EX 63-7
63 Check & Adjustment Electrical Group
Transmission Controller Abnormal Operation Judgment (S/N 0101~0153, 9001~)

If the input units or circuit are not defective Directly inputting input signal

Shortcircuit (connect) the terminals of connector E1

using the probes of the tester or a jumper wire.

Input signal Terminals to be connected Inlet LED

LED's for F 15-17 F

shift lever position

inputs or
R 5-17 R

Comparable
outputs
1 4-17 1
2 12-17 2
3 11-17 3
A 10-17 A
Parking 13-17 P
Inching (Declutch) 1-17 I
E1 E2 E3
9 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11 10 18 17 16 15 14 13 12 11 10 9 12 11 10 9 8 7 6

Note
The couplers shown are for controller side.
95ZV62083

There is a strong possibility that the transmission con-

troller is defective. To check the transmission controller,
directly input the input signal, and then check the on/off
statuses of the transmission controller LED indicator. If
a LED indicator is not on, judge that the transmission
controller is defective. Replace it.

Set-up

Remove all the controller connectors, and then supply

power to connector E1 (terminal 20: +24V/Terminal 9 or
17: Grounding).
115ZV EX 63-8
63 Check & Adjustment Electrical Group
Transmission Controller Abnormal Operation Judgment (S/N 0101~0153, 9001~)

Transmission controller LED indi-

cator
The transmission controller LED indicator should be on
as shown below if the transmission controller is operat-
ing normally and inputs are correct.

In running status

Only the LED's related to the transmission circuit are

shown.

Automatic shift

Speed change

QUAD switch
During auto-
Normal running

switching
condition
Machine

braking
Inching
(“A” shows automatic
LED on shift position) cancel
- - Related LED on
Remarks
(depending on
Forward Backward
machine speed)
F F F F R R R R F R F1 F1 F F F2 F2 R2 R2
position
lever
Shift

• • • • • • • • • •   • •    
1 2 3 A 1 2 3 A 4 3 F2 R2 2 2 F1 R1
F Shift lever position • F

R Shift lever position • R
1 Shift lever position • 1

2 Shift lever position • 2
Input side LED window

3 Shift lever position • 3

A Shift lever position • A
M Automatic shift cancel
S Shift switch ON
P Parking switch OFF (running status) LED ON: In running status
I Inching switch ON
Machine speed Indicates in character according to the engine revolution.
Engine revolution Indicates in character according to the machine speed.
X T/M controller (when working properly: ON)

RR Back-up relay ON
DC Modulator valve 2 ON LED ON: During clutch change only
Output side LED window

L Low clutch sol. valve ON

H High clutch sol. valve ON
R Reverse clutch sol. valve ON
BZ Buzzer
N Neutral relay ON
BRK Auto brake sol. valve ON
1 1st clutch sol. valve ON
    
2 2nd clutch sol. valve ON
3 3rd clutch sol. valve ON
 115ZV EX 63-9
63 Check & Adjustment Electrical Group
Transmission Controller Abnormal Operation Judgment (S/N 0101~0153, 9001~)

In parking status
(During engine operation)
Circuit protector on when
controller failure alarm is
Usual parking
Circuit protector OFF
condition
Machine

LED on
- - Related LED on
on

(depending on
machine speed)
position
Neutral
lever
Shift

F Shift lever position • F

R Shift lever position • R
1 Shift lever position • 1
2 Shift lever position • 2
Input side LED window

3 Shift lever position • 3

A Shift lever position • A
M Automatic shift cancel
S Shift switch ON
P Parking switch OFF (running status)

I Inching switch ON
Machine speed
Engine revolution Related Character: ON

X T/M controller (when working properly: ON)

RR Back-up relay ON
DC Modulator valve 2 ON
Output side LED window

L Low clutch sol. valve ON

H High clutch sol. valve ON
R Reverse clutch sol. valve ON
BZ Buzzer
N Neutral relay ON
BRK Auto brake sol. valve ON
1 1st clutch sol. valve ON
2 2nd clutch sol. valve ON
3 3rd clutch sol. valve ON
115ZV EX 63-10
63 Check & Adjustment Electrical Group
Electrical Circuit Check (S/N 0101~0153, 9001~)

Electrical Circuit Check (S/N 0101~0153, 9001~)

Shift lever input electrical circuit Disconnection check:

check Shift lever Check
position Terminals to be checked Judgment
result
Between terminals F and F/R
F
common grounding (BY)
Between terminals R and F/R
R
common grounding (BY)
Between terminals 1 and speed Conduc-
1
change common grounding (B) tive
Normal
Between terminals 2 and speed (Resis-
2 tance 0 )
change common grounding (B)
Between terminals 3 and speed
3
change common grounding (B)
Between terminals A and speed
A
change common grounding (B)

If the line is not conductive, judge that the switch or wire

is damaged or defective.

Shortcircuit check:

Shift lever Check

position Terminals to be checked Judgment
Connector B4 result
Grounding for speed Between terminals R and F/R
change side (B) F
common grounding (BY)

1st speed (GW) 2nd speed (GL) Between terminals F and F/R
R
common grounding (BY)
Auto (G) 3rd speed (GY)
Between terminals 1 and speed Non
1
F (GR) Unused change terminal other than 1 conductive
Normal
Between terminals 2 and speed (Resistance
R (GB) Grounding for 2
change terminal other than 2  )
F/R side (BY) 70ZV63002
Between terminals 3 and speed
3
change terminal other than 3
Check that the LED indicator corresponding to the shift Between terminals A and speed
lever position is on. A
change terminal other than A

LED Judgment If a section is conductive, judge that the switch is stick-

Corresponding LED indicator is on Normal ing.
Corresponding LED indicator is off Disconnection
Abnormal
Wrong LED indicator is on Shortcircuit In this case two or more signals would be sent at the
same time (e.g. forward and reverse; 1st and 3rd)
If the judgment is abnormal, follow the check procedure
below: <Solution>

<Step 1> Shift lever conductivity test If disconnection or shortcircuit is detected, replace the
shift lever assembly. The shift lever has no serviceable
Set the starter switch to the OFF position, and then dis- parts and must be replaced. If the conductivity check
connect connector B4 so that the shift lever assembly is reveals that the shift lever is not defective, go to step 2.
disconnected. Perform conductivity test using a tester
(circuit tester).
 115ZV EX 63-11
63 Check & Adjustment Electrical Group
Electrical Circuit Check (S/N 0101~0153, 9001~)

<Step 2> Checking conductivity of shift lever input

circuit cable Shift lever Check
position Terminals to be checked Judgment
result
F LR-BY (E117 to E119)
R LBr-BY (E105 to E119)
1 LY-BY (E104 to E119)
Conductive Normal
2 LG-BY (E114 to E119)
3 LO-BY (E113 to E119)
Shift lever circuit A LW-BY (E112 to E119)

If a line is not conductive, judge that the cable is defec-

tive. Also check that only the above terminals are con-
ductive. Otherwise there could be a short circuit in the
Transmission controller wiring.

<Solution>

Repair or replace the defective cable.

LED’s for
inputs or
outputs GW GL GY

G B

GR GB BY

3 1
LR LBr BY
E117 E105 E119

LW BY
E112 E119

LY LG LO
E104 E114 E113

T/M CONTROLLER B4

INPUT

GND SP COM EG R 1 DD MC I

+ 5V SSG G1 MR F S P 2 3 A

B401 L YW YGy BY Y LR YL GO LG LO LW
B405 D001 H710 H709 E403 B403 G201 B303 B408 B407 B406
C701
G202 B Y Y/W W LBr LY R LLg
H613 H612 H627 B402 B409 E402 A202
H626
11 1

E1

115ZVE62020

Connect connector B4 to the shift lever, and disconnect

connector E1 from the transmission controller. Check
the conductivity of the cable connector terminals.
115ZV EX 63-12
63 Check & Adjustment Electrical Group
Electrical Circuit Check (S/N 0101~0153, 9001~)

Inching (Declutch) input electrical

Input LED "I"

Transmission
cut-off switch
circuit check Brake pedal
Judgment Remarks
Pressed
Released
down
Transmission cut-off monitor lamp DECLUTCH
T/M CUT S/W
— Normal
2
1
— — Disconnect Inching impossible

Abnormal
3
5
4 ON
6 Defective Machine stays in
SW or short- the inching
7 4 5 6 circuit (declutch) mode
8 1 2 3
Inching function
— — Normal
Inching (declutch) switch
LgY
A703
B
OFF cancel
(S/N 0101~0120, LLg LgR
E101 C702 Abnormal Defective wiring
9001~9010) 4 A2 1 On
2
LgR BY
1
— Off
A201 E119
C7

<Step 1> Checking inching switch

Inching (declutch) switch
(S/N 0121~, 9011~)
2
LgR BY
1
C7 Check the conductivity between the cable terminals of
A201 E119
each switches and the controller.
T/M controller INPUT
(see “abbreviation chart” page 62-43) <Solution>
GND SP COM EG R 1 DD MC I
Repair or replace the defective cable.
+ 5V SSG G1 MR F S P 2 3 A

B401 L YW YGy BY Y LR YL GO LG LO LW
B405 D001 H710 H709
C701
G202
E403 B403 G201 B303 B408 B407 B406
Inching switch specification
B Y Y/W W LBr LY R LLg
H613 H612 H627 B402 B409 E402 A202
H626
11 1 (S/N 0101~0120, 9001~9010)
E1
Operating pressure MPa 1.1 ± 0.15
(kgf/cm2) (psi) (11.2 ± 1.5) (159 ± 21)
K115ZVE63001
Return pressure MPa 0.9 ± 0.1
(kgf/cm2) (psi) (9.2 ± 1.0) (131 ± 14)
Turn the transmission cut-off (Declutch) switch on the Resistance () 10.4
instrument panel "ON". Note that the transmission cut-
off monitor lamp will light if the lamp circuit is not defec- (S/N 0121~, 9011~)
tive. Press down the left brake pedal, and check the on/ Operating pressure MPa 0.5 ± 0.1
(kgf/cm2) (psi) (5.0 ± 1.0) (71.1 ± 14.2)
off status of the transmission controller "I" LED indicator.
Return pressure MPa 0.3 ± 0.05
(kgf/cm2) (psi) (3.0 ± 0.5) (42.7 ± 7.1)
WARNING Resistance () 6.9

Unexpected movement of the machine may cause an

accident resulting in injury or death.
Be sure to observe the following items before starting
work.
- Position the machine on level ground, and lower
the bucket onto the ground.
- Block the tires with chocks to prevent them from
moving
 115ZV EX 63-13
63 Check & Adjustment Electrical Group
Electrical Circuit Check (S/N 0101~0153, 9001~)

<Step 2> Checking transmission cut-off switch

assembly

ON OFF

Transmission cut-off
switch

7 4 5 6
8 1 2 3

LgY B
A703 Cable side connector
LLg LgR
E101 C702

4 1

A2
95ZV62087

Disconnect the A2 connector of the transmission cut-off

switch assembly from the instrument panel.

Perform conductivity test using a tester.

Conductivity test
Terminals to be checked Switch position Judgment
ON OFF
0  Normal
Between terminals 5 and
6 (Transmission control- Discon-
 
Abnormal

ler input) nect

Between terminals 2 and
Short-
3 (Lamp circuit)  0  (other than 
circuit

<Step 3> Checking cable

When no trouble found on both inching switch and

transmission cut-off switch, the cable or the connector is
defective.

<Solution>

Repair or replace the defective cable.

115ZV EX 63-14
63 Check & Adjustment Electrical Group
Electrical Circuit Check (S/N 0101~0153, 9001~)

QUAD switch input electrical cir- If the "S" indicator does not light:
Checking QUAD switch:
cuit check
Disconnect the switch E1 connector. Check that the ter-
minal line between 1 and 2 is conductive when the
switch is depressed.

<Solution>

If the switch is defective (non-conductive), replace it. If

the switch is not defective, judge that the cable or con-
nector between the control box and switch is defective.
Repair or replace the defective unit.
BY
YL
E116

E119

G2

T/M controller INPUT

(see “abbreviation chart” page 62-43)
GND SP COM EG R 1 DD MC I

+ 5V SSG G1 MR F S P 2 3 A

L YW Ygy BY Y LR YL GO LG LO LW
B401 D001 H710 H709 E403 B403 G201 B303 B408 B407 B406
B405
C701 B Y Y/W W LBr LY R LLg
G202 H613 H612 H627 B402 B409 E402 A202
H626
11 1

E1 K115ZVE63002

[While traveling at the 2nd speed, turn on the QUAD

switch, and the speed will be shifted to the 1st speed.
(For both manual and automatic modes)] Turn the
switch ON again and the transmission should be shifted
back to the 2nd speed.

The QUAD switch does not shift the speed

[Checking transmission controller input LED indicator]

Check that the transmission controller “S” LED indicator

lights instantaneously when the QUAD switch is turned
ON.

LED Judgment
ON Normal
OFF Abnormal Disconnect
 115ZV EX 63-15
63 Check & Adjustment Electrical Group
Electrical Circuit Check (S/N 0101~0153, 9001~)

Machine speed sensor input elec- <Step 1> Checking sensor

trical circuit check Installation adjustment:

Adjust the clearance between the sensor and gear to

0.98~2.0 mm (0.04~0.08 in).

Checking sensor for disconnection:

Clearance adjustment Disconnect the sensor connector, and then measure the
0.98~2.0 mm (0.04~0.08 in) resistance between the terminals.

Resistance Judgement
Approx. 2.3 k (25ºC) (77ºF)* Normal
Shims are available to set
clearance as needed.  (Disconnection) 0  (Short) Abnormal
33190–20970 is 0.04" thick.
33190–21660 is 0.02" thick.
*Note
The speed sensor resistance varies greatly with temper-
1 2
ature.
Y Y
H613 H612
A hot sensor will have higher resistance, cold will
reduce the resistance.
M6

T/M controller INPUT <Solution>

(see “abbreviation chart” page 62-43) H6

GND SP COM EG R 1 DD MC I If the sensor is defective, replace it. If the sensor is not
+ 5V SSG G1 MR F S P 2 3 A defective, the cable or connector between the sensor
L YW
B401 D001 H710
YGy
H709
BY Y LR YL GO LG LO LW
E403 B403 G201 B303 B408 B407 B406
and the transmission controller is defective.
B405
C701 B Y Y/W W LBr LY R LLg
G202 H613 H612 H627 B402 B409 E402 A202

11
H626
1
Repair or replace the defective unit.
E1
K115ZVE63003

Note
- Problem The machine speed sensor is the same type as the
The automatic shift function is not working. engine speed sensor.
Therefore, to check the machine speed sensor, replace
The automatic shift function needs a speed signal. the machine speed sensor with the engine speed sen-
sor for easy troubleshooting.
[Transmission controller input LED indicator]
Sensor location
Checking conditions
Machine speed sensor Engine speed sensor
1. Select an open site away from people, other equip-
ment and buildings.

2. Watch the segment LED indicator while the

machine is moving at 1~5 km/h.

LED [SS] Judgement

Flashes according to the speed Normal
Does not light (flash) Abnormal

Note
To prevent electronic "noise" from external sources that
may corrupt the signal, "twist" the wire from the sensor
all the way to the T/M controller.
Installation position 115ZV62020
115ZV EX 63-16
63 Check & Adjustment Electrical Group
Electrical Circuit Check (S/N 0101~0153, 9001~)

Clutch solenoid valve output elec- - Check valve for sticking

trical circuit check
WARNING
- Problem Unexpected movement of the machine may cause an
A clutch will not engage. accident resulting in injury or death. Be sure to
observe the following items before starting work.
Set the shift lever to the problem position. If the cor- - Position the machine on level ground, and lower
responding transmission controller input/output LED the bucket onto the ground.
indicator is properly turned on and off, judge that the - Block the tires with chocks to prevent them from
coil of the corresponding solenoid valve is discon- moving.
nected, or the valve is sticking, or the cable of the
output circuit is disconnected or poorly connected. Note
The solenoid valve for L, H, R, 1, 2 and 3 are the same.
- Problem Therefore, to check the 1st speed solenoid, for exam-
The circuit protector is turned off. ple, replace the 1st speed solenoid with one of these
solenoids.
The cable (power supply side) between the trans-
mission controller and the solenoid valve is short cir- Be sure engine is off before checking.
cuited or the solenoid valve coil is internally
defective. Push the manual operation knob to the ON position by
hand, and then check that the spool operates smoothly.
- Problem If it does not operate smoothly, judge that the valve is
The machine can run at only one shift lever position. sticking.

The machine runs at a certain shift lever position, <Solution>

though it does not run or runs too slow at any other
position. In this case, judge that the cable (negative) If the coil is disconnected or the valve is sticking,
of the solenoid valve is short-circuited, or the valve is replace the defective unit as an assembly.
sticking.
Manual operation knob
<Step 1> Checking solenoid valve
10 N-m (1 kgf-m)(7.2 lb-ft)
- Measuring coil resistance

Disconnect the connector from the solenoid valve,

and then measure the coil resistance using a tester.
Note that a diode is incorporated in the coil. Negative Positive
side side
Coil resistance Judgment
Approx. 24  Normal
Disconnect short 0 Abnormal 59 N-m (6 kgf-m)(43 lb-ft)

To check the coil and the diode:

Use an analog (needle type) Volt-Ohm Meter (VOM)
with an Rx1  setting. Adjust the meter's zero setting.
Measure the resistance through the coil in both direc- 95ZV62132
tions by reversing the test probes. The meter reading
will be different for each measurement if the diode is
good. If the diode is defective the meter will read the
same in both directions. If the diode is defective replace
the solenoid valve assembly. A defective diode can
cause a controller failure over time.
 115ZV EX 63-17
63 Check & Adjustment Electrical Group
Electrical Circuit Check (S/N 0101~0153, 9001~)

<Step 2> Checking output circuit and cable Disconnect the connector from the problem solenoid
valve, and then set the starter switch to the ON position
(engine OFF; shift lever set to problem speed; parking
brake OFF). Measure the voltage of the connector ter-
T/M controller OUTPUT (sol) minal on the cable side using a tester.
(see “abbreviation chart” page 62-43)
BZ PC+ 1 2 3
Example
G2 PC- BRK DC L H R
Measure the voltage between terminals LY and LB to
LB LgB WO LP LR LW LBr
H711 H707 H651 H712 H706 H705 H704 check the connector of the 1st speed solenoid valve.
LgBr LgR LY LG LO
G802 H708 H703 H702 H701

7 E3 1 Note
6 1
Power is supplied to a solenoid valve only when the shift
E310 E309 E308 E303 E302 E301
LR LW LBr LY LG LO lever is set to the corresponding position. (When the
E311 E314 E121 E120 E306 E313
LP LB YW YGy LgR LgB output LED is on) To check the 4th speed connector, be
J102
~702
J902
H7 sure to cancel the automatic shift function.
LP LB YW YGy LgR LgB
J701 J903 J901 J801 J802
LR LW LBr LY LG LO

T/M solenoid 6
J101 J201 J301 J401 J501 J601

1
IMPORTANT
valve
LR LB
When measuring voltage, do not short-circuit two ter-
J1
L - + H706 H711
minals of a connector. This is because the electronic
1 2
parts inside the controller may be damaged.
LW LB J2
H - + H705 H711

1 2
Checking positive cable
LBr LB J3
R - + H704 H711

1 2
Terminals to be checked Voltage Judgment
Between terminals LY and Approx. 24 V Normal
1 - +
LY LB
H703 H711
J4 body grounding
(For 1st speed solenoid) Approx. 0 V Abnormal
1 2

LG LB J5
2 - + H702 H711 Checking negative cable
1 2

LO LB J6 Terminals to be checked Voltage Judgment

3 - + H701 H711

1 2 Between terminals LB and Approx. 1 V Normal

body grounding Approx. 24 V Abnormal
Modulator valve (2) D - +
LP LB
H712 H711
J7

1 2
<Solution>
Modulator valve (1) SPPC
LgR LgB
H708 H707
J8

1 2 If the voltage is abnormal, the cable may be broken. In

YW
this case, check H7 and E3 in turn in the connector in
R H710
Pressure diff. YGy LB
J9 the same way, find a defective part, then repair or
sensor B W H709 H711
1 2 replace it.

Colors of output circuit cables

(+) ( )
L LR
H LW
R LBr
LB
1 LY
2 LG
3 LO

115ZV62035
115ZV EX 63-18
63 Check & Adjustment Electrical Group
Electrical Circuit Check (S/N 0101~0153, 9001~)

Modulator valve output electrical - Clutch oil pressure and symptoms in case of modu-
lator valve (1) or (2) sticking or shorted at full stroke
circuit check position.

Clutch oil pressure MPa (kgf/cm2)

Stuck under Remarks
ON condition During (PL) After (PO) (symptoms)
charging selection
Normal modulation at clutch selection At 1st speed, At 1st speed,
Modulator approx. 2.0 (20) approx. 2.5 (25) Harsh
ON valve (1) At other position, At other position, engagement
approx. 2.8 (29) approx. 2.9 (30)
OFF Modulator valve (2)
Modulator 0.2~0.5 2.3~2.5 Slightly
400 mA valve (2) (2~5) (23~26) sluggish
Modulator valve (1)
H H
L Po
Electrical problem or faulty clutch?
170 mA Approx. 3.0 MPa
(Approx. 30 kgf/cm2)
If all the clutches have similar symptoms in regard to
Approx. 2.3~2.5 MPa
Clutch
(Approx. 23~26 kgf/cm2)
time lag, jolt, clutch oil pressure, the electrical circuit,
oil and modulator valves (1) and (2) should be suspected.
pressure

PL

Approx.0.2~0.5 MPa (Approx. 2~5 kgf/cm2)

Time
PL = Pressure low
PO = Pressure operating

115ZV62048

Inspection and remedy of output circuits of modulator

valve (1) and (2)

- Symptoms and clutch oil pressure in the case of a

broken wire in output circuit wiring of modulator
valve (1) or (2):

Broken wire Clutch oil pressure MPa (kgf/cm2)

Remarks
or stuck under During (PL) After (PO) (symptoms)
OFF condition charging selection
Modulator 0.2~0.5 Approx. 1.0 Sluggish and
valve (1) (2~5) (10) apt to slip
At 1st speed,
Modulator Approx. 1.0 approx. 2.5 (25) Harsh
valve (2) (10) At other position, engagement
approx. 2.9 (30)
 115ZV EX 63-19
63 Check & Adjustment Electrical Group
Electrical Circuit Check (S/N 0101~0153, 9001~)

<Step 1> Check output circuit wiring <Step 2> Check modulator valve (1) or (2)

Using a tester volt-ohm meter, measure resistance

T/M controller OUTPUT (sol)
(see “abbreviation chart” page 62-43)
between both terminals of the connector.
BZ PC+ 1 2 3
Decision Resistance of modulator valve (1) or (2)*
G2 PC- BRK DC L H R
Normal About 24 Ohms
LB LgB WO LP LR LW LBr


H711 H707 H651 H712 H706 H705 H704
Abnormal (Broken wire)
LgBr LgR LY LG LO
G802 H708 H703 H702 H701

7 E3 1

6 1
- Check for sticking
E310 E309 E308 E303 E302 E301
If necessary, disassemble the valve and inspect.
LR LW LBr LY LG LO
E311 E314 E121 E120 E306 E313
LP LB YW YGy LgR LgB

J102
<Solution>
~702 H7
J902
LP LB YW YGy LgR LgB
J701
LR LW LBr
J903 J901 J801 J802
LY LG LO
If a broken wire or sticking valve is found, replace the
J101 J201 J301 J401 J501 J601
entire modulator valve assembly.
6 1

MV2 resistance check:

To check the coil and the diode:
LP LB J7
Modulator valve (2) D - + H712 H711

1 2 Use an analog (needle type) Volt-Ohm Meter (VOM)

with an Rx1  setting. Adjust the meter's zero setting.
LgR LgB J8
Modulator valve (1) SPPC H708 H707
Measure the resistance through the coil in both direc-
1 2
tions by reversing the test probes. The meter reading
will be different for each measurement if the diode is
good. If the diode is defective the meter will read the
115ZV62036
same in both directions. If the diode is defective replace
Disconnect the connector of modulator valve (1) or (2) the solenoid valve assembly. A defective diode can
and measure voltage between both terminals of the wir- cause controller failure over time.
ing connector.

Decision Voltage
14 V ~ 18 V (MV1)
Normal
Approx. 24 V (MV2)
Abnormal (Broken wire) 0 V if broken wire

- Voltage for modulator valve (2) can be measured

only during clutch selection.

<Solution>

If a wire is broken, check at the next connector to locate

the faulty spot, and repair or replace the wiring or con-
nector. To find the faulty spot use a VOM (Volt-Ohm
Meter) and measure the resistance through each wire
until a high resistance is found.
115ZV EX 63-20
63 Check & Adjustment Electrical Group
Electrical Circuit Check (S/N 0101~0153, 9001~)

Neutral relay electrical circuit <Step 1> Checking cable of output circuit
check 1. Disconnect connector F6 from the neutral relay,
and then set the starter switch to the ON position.
Set the shift lever to the neutral (N) position, and
Neutral relay
then measure the voltage of the connector terminal
on the cable side.

2. Checking positive cable

RL SbP
+ +
H610 E220
Terminals to be checked Voltage Judgment
G L
D102 D002
Between terminals L and Approx. 24 V Normal
2 1
(Black) body grounding Approx. 0 V Abnormal
F7

3. Checking negative cable

G - From fuse F14 (starter switch terminal C)
Terminals to be checked Voltage Judgment
RL - To magnetic switch terminal
Between terminals SbP and Approx. 24 V Normal
SbP - to T/M controller E220 body grounding Approx. 1 V Abnormal
L - To T/M circuit protector for T/M controller
95ZV63002 <Solution>

- Problem If the voltage is abnormal, judge that the cable is discon-

Engine does not start with the shift lever in neutral nected or short-circuited. Repair or replace the cable.
position.
<Step 2> Checking neutral relay individually
Though the transmission controller "N" LED indicator
is on, the engine will not start, judge that the neutral The neutral relay is the same type as the back-up lamp
relay contact is not closed. relay, horn relay, etc. Therefore, to check the neutral
relay, replace it with one of these relays, then detect
- Problem which one between the neutral relay and the wiring is
The engine will start at the shift lever forward or the cause of the fault.
reverse position.
<Solution>
If the engine starts though the transmission control-
ler "N" LED indicator is off, judge that the neutral If the relay is defective, replace it.
relay contact is sticking, or the transmission control-
ler is defective.
 115ZV EX 63-21
63 Check & Adjustment Electrical Group
Electrical Circuit Check (S/N 0101~0153, 9001~)

Parking brake electrical circuit

check WARNING
Unexpected movement of the machine may cause an
accident resulting in injury or death.
To prevent such an accident, observe the following
items before checking the parking brake circuit:
- Park the machine on level ground.
- Block the tires with chocks to prevent wheels from
Parking brake S/W moving.
L
G
R Y
B

B Y R
L G

L LgG
D003 H665

GO SbW B
E115 A607
E510
3 1

B3

H6

M2 (24V) (0~1V)
1 2
B LgG
H665

B W

[Step 1]
W
Parking brake switch OFF

B
(35 )

[Step 2]
Parking solenoid Coil resistance

115ZV62038

- Problem
The parking brake cannot be applied or cannot be
released.

The parking switch is interlocked to the parking lamp

of the instrument panel. It turns on and off the park-
ing lamp. If the lamp turns on when the switch is
pulled up and goes off when it is pushed in the
switch is working properly. If the lamp does not work
the switch, lamp or wiring is defective. If the lamp
works with the switch, check the parking brake sole-
noid or its wiring.
115ZV EX 63-22
63 Check & Adjustment Electrical Group
Electrical Circuit Check (S/N 0101~0153, 9001~)

<Step 1> Checking cable of output circuit <Step 2> Checking solenoid valve

Disconnect the connector from the solenoid valve, and Solenoid valve
then measure the voltage of the connector terminal on for auto-brake
the cable side using a tester. Note that the starter switch Solenoid valve
should be "ON", engine "OFF" and parking switch for park brake
should be at the OFF position.

Checking positive cable

Terminals to be checked Voltage Judgment

Front Valve assembly
Between terminals LgG and Approx. 24 V Normal
body grounding Approx. 0 V Abnormal

Transmission
Checking negative cable

Terminals to be checked Voltage Judgment

Between terminals L and 0V Normal
body grounding Other than 0 V Abnormal K115ZV52020

<Solution> - Measuring coil resistance

If a cable is disconnected or a wire broken, measure the Disconnect the connector from the solenoid valves,
voltage of the next connector in the same way. Find the and then measure the resistance of the coil using an
defective cable, and then repair or replace the cable. analog meter.

Coil resistance Judgement

Approx. 35  Normal
Disconnect or short-circuited 0 Abnormal

Note
The diode is incorporated in the coil.

- Checking sticking of solenoid valve

Run engine and charge the brake accumulator,

move the manual operation knob on the solenoid
valve, then check whether the parking brake can be
turned on and off. If the parking brake cannot be
turned on and off, the solenoid valve is stuck.

<Solution>

If wire breakage or a sticking valve is detected in the

coil, replace the valve assembly.
 115ZV EX 63-23
63 Check & Adjustment Electrical Group
Electrical Circuit Check (S/N 0101~0153, 9001~)

Auto brake electrical circuit check - If auto-braking does not occur

61 To rear To front Possible causes include a broken wire in the auto

service brake service brake braking solenoid valve output circuit, a broken coil in
31
A the solenoid valve, or a sticking valve.
C

B
WARNING
23 24
Unexpected movement of the machine may cause an
Pi AR AF Ap
accident resulting in injury or death.
To prevent such an accident, observe the following
items before checking the auto brake circuit.
PR T PF Tp Pp - Park the machine on level ground.
- Block the tires with chocks to prevent wheels from
moving.
1.0

1.0 <Step 1> Checking solenoid valve

B - Measuring coil resistance

From unloader 37
valve (Pump)
Disconnect the connector from the solenoid valve,
and then measure the resistance of the coil using a
T/M controller P T 27 tester.
signal

From reducing Coil resistance Judgment

valve (Pump) Approx. 35  Normal
Shown in the "released" position K115ZV52021 Disconnect or short-circuited 0 Abnormal

- Checking sticking of solenoid valve

T/M controller OUTPUT (sol)
(see “abbreviation chart” page 62-43)
M1
Run engine and charge the brake accumulator, push
BZ PC+ 1 2 3
H6
1 2
in the manual operation button (diameter: approxi-
G2 PC- BRK DC L H R

LB LgB WO LP LR LW LBr
B WO
H651 mately 4 mm) on the solenoid valve, then check
H711 H707 H651 H712 H706 H705 H704
whether the brake can be turned on and off. If the
LgBr LgR LY LG LO B W
G802 H708 H703 H702 H701
brake cannot be turned on and off, the solenoid
7

E3
1
valve is stuck.
B

<Solution>
W

If wire breakage or a sticking valve is detected in the

coil, replace the valve assembly.

Auto brake
solenoid
115ZV62039
115ZV EX 63-24
63 Check & Adjustment Electrical Group
Electrical Circuit Check (S/N 0101~0153, 9001~)

<Step 2> Checking wiring in output circuit

Check continuity of the wiring from the controller to the

solenoid valve. If continuity is not detected, the wiring is
broken. In this case, check continuity between each
connector, detect a defective part, then repair or replace
the wiring.

If any defective part is not detected in the steps 1 and 2

above and something is still wrong with the auto brake,
the controller may be defective. In this case, replace the
controller assembly.

Before replacement of the controller assembly, confirm

that the input circuit is normal. (Refer to the description
on the inspection of the speed sensor input circuit.)
 115ZV EX 63-25
63 Check & Adjustment Electrical Group
Electrical Circuit Check (S/N 0101~0153, 9001~)

Gauge circuit electrical circuit Torque converter oil temperature and engine water
temperature
check
Temperature of 60 80 100 120
INSTRUMENT PANEL detection area (ºC) (140 ºF) (176 ºF) (212 ºF) (248 ºF)
(see “abbreviation chart” page 92-26)
+ ES DD EG2 EG1 EG3 SS WTM TTM
(+) TF F 3/4 1/2 1/4 EMP GND
Resistance between
56.3 29.5 16.5 10
RB SbO YR YB YL YBr YG B terminal and body ()
C211 E607 E605 E616 E604 E615 E614

Lg O O BrB BrW BrR YB YSb

D103 E617 B902 H630 H602 H616 H607 H621

10 1
A5

H6

N4 L9
YSb H621

YB
H607

E/G coolant T/C oil temp.

temp. sensor sensor

K115ZVE63004

The sensors detect the torque converter oil temperature

and engine water temperature and then convert them
into electric signals. The electric signals are then fed to
the respective gauges and indicated on the gauges. If a
gauge indicates wrong values, either the sensor, gauge
or wiring will be defective. Determine the defective unit
by using the following procedure.

<Step 1> Checking sensor signal

Disconnect the connector A5 from the instrument panel,

or disconnect the connector from the corresponding
sensor. Measure the resistance between the sensor sig-
nal terminal and the ground terminal. If the measure-
ment value is acceptable compared with the standard
value shown below, the sensor is not defective. If the
measurement value is abnormal, check the wire in addi-
tion to the sensor because the cable may be defective
(corroded, broken, or high resistance).
115ZV EX 63-26
63 Check & Adjustment Electrical Group
Electrical Circuit Check (S/N 0101~0153, 9001~)

<Step 2> Checking gauge Resistance between gauge terminals ()

Engine water T/C, T/M oil
Gauge
temperature temperature
Between S and E 120~125 75~80
Between S and V 120~125 85~90
Controller
Between E and V 170~190 130~150

Remove the instrument panel, and then disconnect the

Grounding S Power supply connector from the panel. Measure the resistance
24V
between the screw terminals on the rear surface of the
E V 15V panel. Judge whether the resistance value is accept-
able.

Viewed from rear surface of instrument panel Note

K90ZV62016
If a gauge is removed from the panel, the resistance
between the terminals will differ from the standard value
shown in the table. Please see table at bottom of page.
Instrument panel (back side view)

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/G water E V
temperature gauge L18
Tachometer
L6 L10 L10
L19
L7 S
CN2
L8 9 18 L22 L23 L24 L25 L26 L27
E V 20P
L9 T/C oil temperature gauge
19 28

115ZV63002

Resistance between gauge terminals ()

Between S and E 160
Between S and V 150
Between E and V 310

S
Note
E V When the ground of the gauge is defective such as con-
tact failure and derailment, the pointer scales out.
Before replacing the gauge, check the ground circuit.
Viewed from rear surface of gauge

70ZV63014
 115ZV EX 63-27
63 Check & Adjustment Electrical Group
Electrical Circuit Check (S/N 0101~0153, 9001~)

Fuel level gauge electrical circuit <Step 1> Checking level sensor
check

Indicator lamps Fuel level sensors Fuel level sensor

Monitor
controller
+24 V
(YR) YR
3/4
(YB) YB
1/2 X
(YL) YL
1/4 M5
(YBr) YBr
1/8
Float switch (5 positions)
(YG) YG
E
Unused
GND

Fuel level circuit K115ZV62017 (Brown) 1/4

(White) 3/4
(Green) E
Float switch switching and indicator lamp lighting status
Indicator lamp
Float switch
O : Lit : Flashing Unused (Yellow) 1/8
O: ON X: OFF
– : Extinguished
(Blue) 1/2
E 1/8 1/4 1/2 3/4 E 1/4 1/2 3/4 F
3/4 or more X X X X X – – – – O View from X
Actual fuel level

From 3/4 to 1/2 X X X X O – – – O –

From 1/2 to 1/4 X X X O O – – O – –
From 1/4 to 1/8 X X O O O – O – – –
From 1/8 to E X O O O O O – – – –
E or less O O O O O  – – – –
Any other pattern – – – – – INSTRUMENT PANEL
Example of failure:
When the wire of the "1/4" float switch is broken, the indicator lamps +
(+)
ES
TF
DD EG2 EG1 EG3
F 3/4
SS
1/2
WTM TTM
1/4 EMP GND
for "1/8" and "E" do not light even if the fuel amount becomes 1/4 or
less. RB SbO
C211 E607
YR YB YL YBr YG
E605 E616 E604 E615 E614
B

Lg O O BrB BrW BrR YB YSb

D103 E617 B902 H630 H602 H616 H607 H621
Only a fuel level lamp corresponding to the actual oil 10 1

level lights. A5

If no fuel level lamp lights, it should be judged which one

between the fuel level sensor and the fuel level lamps is
defective. K115ZVE63005

The level sensor has five float switches. When a float

Disconnect the connector M5 of the level sensor, and
moves down, a corresponding switch contact is closed.
perform conductivity test between the terminals and
body using tester (circuit tester).
When the fuel tank becomes empty, the contact of all
float switches is closed and the lamp “E” flashes on the
Float position Check result Judgment
fuel level gauge.
Conductive Abnormal
At the top end
When the fuel tank becomes full, the contact of all float Non-conductive Normal
switches is open and the lamp “F” lights on the fuel level At the bottom Conductive Normal
gauge. end Non-conductive Abnormal
115ZV EX 63-28
63 Check & Adjustment Electrical Group
Electrical Circuit Check (S/N 0101~0153, 9001~)

<Solution>

If disconnection or short-circuit is detected, replace the

level sensor assembly.

<Step 2> Checking level gauge

Disconnect the connector A5 of the back side of the

instrument panel. Turn the starter switch to the ON posi-
tion (engine OFF) and connect each terminal (E~3/4) of
the connector A5 (gauge side) to ground respectively. If
the related level lamp does not light up, the switch is
defective and replace fuel gauge assembly.

<Step 3> Checking cable

If no defective on the level sensor and the fuel gauge is

found, check the conductivity of the wires between level
sensor, monitor controller and the instrument panel.
 115ZV EX 63-29
63 Check & Adjustment Electrical Group
Electrical Circuit Check (S/N 0101~0153, 9001~)

Bucket positioner electrical cir- <Step 1> Checking proximity switch

cuit check Supply +24 V to pin 1 (Br) and pin 2 (B), and connect
the ground to pin 3 (L).

Detection part
If the operation indicator lamp (LED) does not light,
Operation indicator lamp (LED) 1(Br) judge that the proximity switch is defective.
Detected View Z
object <Solution>
3(L) 2(B)
Replace the proximity switch.

Proximity switch +24V

LED Br 1
Switch Coil for detent
main. B 2 inside pilot <Step 2> Checking cable at chassis side
circuit L valve
3
+24V
90ZV63009 Check the cable from the proximity switch to the pilot
valve detent magnet solenoid in order. If wire discon-
nection is found, repair it.
Though the clearance between the proximity switch and
the rod (detecting element) is 5±2 mm (0.197±0.079
in.), the operation indicator lamp (LED) is not lit, judge
that the proximity switch is defective, or the cable at the
chassis side is disconnected or a wire broken.
115ZV EX 63-30
63 Check & Adjustment Electrical Group
Electrical Circuit Check (S/N 0101~0153, 9001~)

<Step 3> Checking detent magnet solenoid

(S/N 0101~0140, 9001~9020) (S/N 0141~, 9021~)

Detent magnet
solenoid

Push rod

Detent solenoid

Fixing disc

Coupler To
tank port
K90ZV62013

From
pump
port

To / from MCV oil packs

70ZV63016

Check the continuity between coupler pins for the pilot

valve detent magnet solenoid.

If wire breakage is detected, repair it.

Detent coil specification

Coupler
(blue, female)
Rated voltage DC 24 V
Resistance 238 
T

K90ZV63001

Voltage DC 24 V
Coil resistance 62±3 
 115ZV EX 72-1
72 Function & Structure Operator Station Group

72 Function & Structure

Operator Station Group

Cabin .....................................................................................72-2
Operator Seat......................................................................72-10
Steering and Transmission Shift Lever................................72-11
Air Conditioner ....................................................................72-14
115ZV EX 72-2
72 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
 115ZV EX 72-3
72 Function & Structure Operator Station Group
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
115ZV EX 72-4
72 Function & Structure Operator Station Group
Cabin

Glass

70V2E72001

1. Front glass
2. Front side glass
3. Rear glass
 115ZV EX 72-5
72 Function & Structure Operator Station Group
Cabin

1. Part number 32011-21690 2. Part number 32011-21700

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
R2

R3
953

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.
115ZV EX 72-6
72 Function & Structure Operator Station Group
Cabin

3. Part number 32011-21500

(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.
 115ZV EX 72-7
72 Function & Structure Operator Station Group
Cabin

Wiper mount
Front wiper

714 (Along surface)

Wipin
g angle
56º

2
ace)
ng surf

1
lo
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

3
50
R5

450

2 106

97ZV72005

1. Wiper motor 3. Wiper blade

2. Wiper arm 4. Washer jet nozzle
115ZV EX 72-8
72 Function & Structure Operator Station Group
Cabin

Wiper motor
Front

Cabin

(Automatic stop position)

12

159200 589
24V

100
3 4 5 6
80
(B

ø5 the
115

re
a

70
rh

60
ol
e)
.2

(3º 10')
±0
5.6
R8

Wipin
g angl
e 56º 22
Ro
tati
ng
d irec
tion

(-1) AVS0.85 W
(-2) AVS0.85 L

(+) AVS0.85 R
(S) AVS0.85 Y

( L1~L3=3.7µH
C1~C3=0.2µF )
(+) 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 46±4 min-1
5. Cap 1.0 N-m (0.1 kgf-m) High 68±7 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
 115ZV EX 72-9
72 Function & Structure Operator Station Group
Cabin

Rear

Wiping angle: 106º±3º

Automatic stop
position

L(+)
LB (+1) Y(S)

Cabin

AVS0.85 LB
(+1)

AVS0.85 L
(+)

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 38±5 min-1
6. Nut 0.6 N-m (0.6 kgf-m) Current 2 A or less
Rotating speed Speed 40±5 min-1
No load Current 1 A or less
Starting voltage 16 V or less
Locked rotor current 7 A or less
115ZV EX 72-10
72 Function & Structure Operator Station Group
Operator Seat

Operator Seat
Armrests

Rotate control knob (3) to select desired angle. Pivot up

and parallel with backrest when not in use.

Combined height and weight adjuster

3
1. Sit on the seat.

2. Turn handle (4) to adjust seat height.

Clockwise to raise seat.
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 the handwheel (6)

clockwise to raise the seat unseated, rotate it counter-
1. Reclining adjustment lever
clockwise 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.
 115ZV EX 72-11
72 Function & Structure Operator Station Group
Steering and Transmission Shift Lever

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 70 mm upward and downward
5. Gas spring
6. Column shaft assembly Note
7. Lower column shaft - Install the gas spring (5) with its rod side facing
8. Orbitrol® downward as shown in the figure above.
- Install the lower column shaft (7), together with the
The tilt case (1) ~ (6) can select the optimal position in Orbitrol®, from the underside of the operator stand.
the following range:
115ZV EX 72-12
72 Function & Structure Operator Station Group
Steering and Transmission Shift Lever

Tilt case

1
1

4 Lock 6
release
position
2 7
2
quantity

5
Slide

70

4
Operator
stand

5 9
Operator
270 (355 when slid)

stand
11

Lock position
10 3

K65ZV72001

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 (tapered mounting : (10) (inside): 31.9 N-m (3.3 kgf-m)
hole) : (10) (outside): 89.1 N-m (9.1 kgf-m)
5. Bolt (left-hand double-start thread)
6. Nut (left-hand double-start thread, tapered in lever Note
mounting area) - Apply grease at the slider of bracket (3) (shaded
7. Nut (left-hand double-start thread) part).
8. Nut - When mounting tilt lock lever, install nut (6) to bolt (5)
9. Bushing first, fix lever (4) with nut (7) while holding nut (6).
10. Nut Adjust lever (4) to tilt at an angle of 5º against col-
11. Bolt (flanged bolt is not applicable) umn shaft (1). The control force at the end of lever
(4) is 130~150 N (13~15 kgf).
 115ZV EX 72-13
72 Function & Structure Operator Station Group
Steering and Transmission Shift Lever

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)

115ZV EX 72-14
72 Function & Structure Operator Station Group
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
Cooler performance
3. Air filter
4. Control panel
Cooling capacity 4.65 kw ± 10 %
5. Condenser assembly
Air quantity 550 m3/h ± 10 %
6. Compressor assembly
Rated voltage DC 24 V
7. Receiver dryer
8. Receiver holder Power consumption 345 W ± 10 %
9. Joint
10. Drain hose Heater performance
11. Relay
12. Thermistor (inside air sensor) Heat radiation quantity 5.2 kw ± 10 %
13. Thermistor (outside air sensor) Air quantity 380 m3/h ± 10 %
14. Solar sensor (insolation sensor) Rated voltage DC 24 V
Power consumption 170 W ± 10 %
(Difference in temperature: 65ºC, water flow rate: 6 L/min)
 115ZV EX 72-15
72 Function & Structure Operator Station Group
Air Conditioner

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
115ZV EX 72-16
72 Function & Structure Operator Station Group
Air Conditioner

1. Cooling unit case (rear) 20. — 39. —

2. Cooling unit case (front) 21. — 40. —
3. — 22. — 41. —
4. Evaporator 23. Power IC assembly 42. —
5. Heater core 24. Servo motor (A/M, air mixing) 43. —
6. Expansion valve 25. Servo motor (mode) 44. —
7. — 26. — 45. —
8. Tube 27. — 46. —
9. Thermistor 28. — 47. —
10. — 29. — 48. —
11. Door (upper) 30. — 49. Lever (face, front)
12. Door (lower) 31. — 50. Control lever (face, front)
13. Door (foot) 32. — 51. Door (S/A) (face, front)
14. Damper (vent) 33. — 52. —
15. Pressure switch (triple) 34. — 53. —
16. Liquid tube 35. — 54. —
17. Suction tube 36. — 55. —
18. — 37. Lever (face, door) 56. —
19. — 38. Lever (foot, door) 57. Thermo sensor (water temperature)
 115ZV EX 72-17
72 Function & Structure Operator Station Group
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 (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
115ZV EX 72-18
72 Function & Structure Operator Station Group
Air Conditioner

Air compressor (with magnetic clutch)

2-1

2 2-2

2-3

2-6
5~7

97ZV72025

1. Compressor 3. —
2. Magnetic clutch assembly 4. —
2-1 Magnetic stator 5. Plate washer
2-2 Magnetic clutch rotor 6. Plate washer
2-3 Clutch hub 7. Plate washer
2-6 Plate washer

Condenser unit

7
3

10
4

12 97ZV72026

1. Condenser core 7. Cover

2. Blower assembly 8. —
3. Condenser bracket 9. —
4. Condenser bracket 10. Wire harness
5. — 11. —
6. — 12. Resistor
 115ZV EX 72-19
72 Function & Structure Operator Station Group
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
115ZV EX 72-20
72 Function & Structure Operator Station Group
Air Conditioner

Cooling mechanism Refrigerant

Principle of cooling An object which circulates inside the cooling circuit and
transmits heat is called "refrigerant". The refrigerant
changes repeatedly its state, from "liquid --> gas --> liq-
Expansion uid --> gas ...", and carries heat from the low tempera-
Indoor valve ture side (inside the cabin) to the high temperature side
(outside the cabin) while changing its status.
Evaporator Expansion Condenser
Evaporation Releases There are many types of refrigerants. This air condi-
Condensation heat to the tioner adopts refrigerant R134a which does not contain
outside. chlorine and does not destroy the ozone layer.
Deprives heat
Compression Refrigerant
of the adjacent
area.
IMPORTANT
Compressor
Make sure to use the specified refrigerant (Freon
Basic cooling cycle
97ZV72029
R134a). If any other refrigerant is used, the following
problems may occur:
- The air does not become cool enough.
When alcohol is applied on your skin, you feel cool. - The equipment may be damaged.
And never mix Freon R134a with any other refriger-
When the garden is watered in summer, you feel cool ant.
also. It is because alcohol or water deprives heat (which
is called "latent heat") of its adjacent area when evapo-
Chemical formula CH2FCF3
rated.
Molecular weight 102.03

These phenomena clearly show the principle of cooling. Boiling point -26.19ºC
Critical temperature 101.14ºC
Cooling offers coldness and coolness by utilizing such Critical pressure 4.1 MPa (41.45 kgf/cm2)
natural phenomena. Critical density 511 kg/m3
Density of saturated liquid (at 25ºC) 1,206 kg/m3
Generally, a cooler seals the liquid, which evaporates Specific volume of saturated vapor
0.0310 m3/kg
easily and is called "refrigerant", inside its circuit, and (at 25ºC)
makes the refrigerant vaporized and liquefied repeat- Latent heat of evaporation (at 0ºC)
197.54 KJ/kg
edly while circulating it. The figure on the right shows (47.19 kcal/kg)
the basic cooling cycle. Combustibility Incombustible
Ozone decomposition modulus 0
 115ZV EX 72-21
72 Function & Structure Operator Station Group
Air Conditioner

Refrigerant characteristics Generally, the fluid (which is the generic name for gas
and liquid) has the following properties.

100
1. When the temperature of gas at a certain pressure
decreases, the gas starts to condense and change
into liquid at a certain temperature. For each sub-
Refrigerant temperature (ºC)

80

stance (liquid), this temperature is fixed if the pres-

60
sure is determined. This temperature determined
40
by the pressure is called the "saturated tempera-
35 ture".
20
15
2. On the contrary to (1), when the temperature is
0 determined, the pressure at which liquefaction
starts is fixed. This pressure is called "saturated
20

30
pressure".
The figure on the left shows the relationship
30 40 (kgf/cm )
2
0 3.6 5 8 10 15 20 25 35
353 490 785 981 1,471 1,961 2,452 2,942 3,432 3,923 (kPa) 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 (= on
and saturated temperature of R134a 97ZV72030
the lower right side of) the curve, the refrigerant is
liquid.
At the temperature and the pressure above (= on
the upper left side of) the curve, the refrigerant is
gas.

Suppose that the air conditioner is used in mid summer.

When evaporated, the refrigerant absorbs the heat of
evaporation from the air inside the cabin.

Accordingly, in order to cool down the air inside the

cabin to approximately 25ºC, the refrigerant should
change (be evaporated) from liquid into gas at a tem-
perature lower than 25ºC. From the figure, it can be
seen that the refrigerant R134a can sufficiently cool
down the air inside the cabin at a pressure above the
atmospheric pressure. (If used refrigerant requires a
pressure below the atmospheric pressure to cool down
the air to the necessary temperature, air enters into the
circuit and the ability of the cooler is deteriorated.)

In the process in which the vaporized refrigerant is

returned to liquid, the refrigerant is cooled down by the
outside air of 35ºC or more so that it condenses.

Accordingly, as is seen from the figure, the refrigerant

can be liquefied at the pressure of 785 kPa (8.0 kgf/
cm2G) or more.
115ZV EX 72-22
72 Function & Structure Operator Station Group
Air Conditioner

Cooling circuit The figure on the left shows the cooling circuit of the air
conditioner.

In this circuit diagram, the area which cools down the air
inside the cabin 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 cabin. The
Inside cabin area where the refrigerant is evaporated is the evapora-
Pressure bulb
tor. 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
Evaporator Expansion valve
refrigerant (wet evaporation refrigerant with low degree
Blower of dryness) is supplied into the evaporator.

Inside engine room

For example, in order to cool down the air to 15ºC, the
refrigerant can absorb the latent heat of evaporation
from the air only when it is evaporated at a temperature
Compressor Cooling fan lower than 15ºC. It can be seen from the figure in the
previous page that the pressure of the refrigerant inside
the evaporator should be 353 kPa (3.6 kgf/cm2G) or
less to realize it. And in order to keep sufficient cooling
Receiver dryer effect, the supplied refrigerant quantity should be
adjusted so that the refrigerant supplied to the evapora-
Condenser tor is completely evaporated inside the evaporator into
dry vapor or gas.
Structure of cooling circuit
Accordingly, the cooling circuit should be constructed to
95ZVE72017
reduce the pressure inside the evaporator and supply
proper quantity of refrigerant into the evaporator so that
the evaporator can cool down the air sufficiently.

The supplied refrigerant quantity can be adjusted by the

expansion valve. The pressure inside the evaporator is
kept at a low value by the closing action of the 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.
 115ZV EX 72-23
72 Function & Structure Operator Station Group
Air Conditioner

Electrical circuit
Control schematic drawing

Outside
air sensor Input signals Input signals
Set temperature, room temperature,
water temperature, Insolation sensor
air temperature after evaporator Outside air sensor

Insolation e = Inside air temperature - Set temperature Set temperature

sensor correction
Frost sensor

Water temperature
sensor
Blower voltage/temperature control/blow-off servo motor position determination
Inside air
Blower

Water temperature (ºC)

Warm-up control
sensor 55
voltage

BLC
Temperature 25
control
servo HOT

Blower motor COOL

Blow-off
Temperature servo FACE
control servo B/I
FOOR
Y value
Blow-off servo

Compressor ON-OFF
ON

3 4
Frost sensor temperature (ºC)

95ZVE72018
115ZV EX 72-24
72 Function & Structure Operator Station Group
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 the OFF switch (1) is pressed, the set temper- The air flow quantity is displayed on the LCD unit.
ature and the air blow quantity displayed on the LCD When the switch is pressed, the air flow quantity
unit (7) as well as the indicator lamps above the increases.
AUTO switch (5) and the air conditioner ON/OFF When the switch is pressed, the air flow quantity
switch (8) are extinguished, and the operation is decreases.
stopped. 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 "weak"

Air quantity "medium 1"

Air quantity "medium 2"

Air quantity "medium 3"

Air quantity "medium 4"

Air quantity "strong"

 115ZV EX 72-25
72 Function & Structure Operator Station Group
Air Conditioner

- (3) Temperature setting switches

These switches set the temperature inside the cabin

in the range from 18.0 to 32.0ºC.
When the switch is pressed, the set temperature
increases.
When the switch is pressed, the set temperature
decreases.
Usually, set the set temperature to 25.0ºC.

Display on the LCD unit and the function

Display on LCD unit Set temperature

18.0 Maximum cooling
Temperature inside cabin is controlled so that
18.5~31.5
set temperature is realized.
32.0 Maximum heating

- (4) Vent mode selector switch

This switch changes over the vent mode.

When the vent mode selector switch (4) is pressed,
the vent mode displayed on the LCD unit (7) is
changed over, and air is blown from the displayed
vent positions.
In the automatic mode, the vent mode is 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 flow 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 the AUTO
accordance with the set temperature. switch (5) is extinguished. In the manual mode, the
When the AUTO switch (5) is pressed, the indicator air flow 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 the temperature setting switches (3), and use
the air conditioner in the automatic mode.
115ZV EX 72-26
72 Function & Structure Operator Station Group
Air Conditioner

- (6) Inside/outside air selector switches

These switches change over inside air circulation

and outside air introduction.
When an either switch is pressed, the indicator lamp
above it lights to indicate the selected air flow status.
In the automatic mode, outside air introduction and
inside air circulation are automatically changed over.

Inside air circulation The outside air is shut down, and the air
inside the cabin is circulated.
Press this switch to rapidly cool or heat the
air inside the cabin or when the outside air
is dirty.
Outside air introduction
The outside air is introduced into the cabin.
Press this switch to introduce clean air into
the cabin or defog the windows.

- (7) Liquid crystal display (LCD) unit

This LCD unit indicates the set temperature, the air

flow quantity and the vent mode during operation.
When the OFF switch (1) is pressed, the set temper-
ature 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.)
 115ZV EX 72-27
72 Function & Structure Operator Station Group
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 the OFF switch (1). Then, the set temperature
and the air blow quantity displayed on the LCD unit are
97ZV72040
extinguished, the indicator lamps above the AUTO
switch (5) and the air conditioner ON/OFF switch (8) are
(a) Set the AUTO switch (5) to ON. Confirm that the set extinguished, and the operation is stopped.
temperature and the air flow quantity are displayed
on the LCD unit, and that the indicator lamps above
the AUTO switch (5) and the air conditioner ON/
OFF switch (8) are lit.

(b) Adjust the temperature setting switches (3), and set

arbitrary temperature.
The air conditioner automatically changes over the
air flow quantity, the vent mode and the inside/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.
115ZV EX 72-28
72 Function & Structure Operator Station Group
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 the blower switches (2), and adjust the air Press the OFF switch (1). Then, the set temperature
flow quantity. and the air flow quantity displayed on the LCD unit are
Confirm that the set temperature and the air flow extinguished, the indicator lamps above the AUTO
quantity are displayed on the LCD unit. switch (5) and the air conditioner ON/OFF switch (8) are
extinguished, and the operation is stopped.
(b) Set to ON the air conditioner ON/OFF switch (8).
Confirm that the indicator lamp above the switch
lights.

(c) Adjust the temperature setting switches (3), and set

arbitrary temperature.

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

(e) Press an either inside/outside air selector switch (6)

to select inside air circulation or outside air intro-
duction.
 115ZV EX 72-29
72 Function & Structure Operator Station Group
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 the blower switches (2), and adjust the air
flow quantity.
(a) Press the blower switches (2), and adjust the air Confirm that the set temperature and the air flow
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 the vent mode selector switch (4), and dis-
play the vent mode or on the LCD
(b) Press the vent mode selector switch (4), and dis- unit.
play the vent mode on the LCD unit.
(c) Set the outside air introduction selector switch (6).
(c) Set to ON the air conditioner ON/OFF switch (8).
Confirm that the indicator lamp above the switch (d) Press the temperature setting switches (3), and dis-
lights. play the set temperature "32.0" (maximum heating
status) on the LCD unit.
(d) Arbitrarily set the blower switches (2), the tempera-
ture setting switches (3) and the inside/outside air Adjust the louver at each vent position so that air flow
selector 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 cabin in rainy season, set the air conditioner
blown to the feet. ON/OFF switch (8) to ON.
115ZV EX 72-30
72 Function & Structure Operator Station Group
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 fail to do it, the failure codes memorized in the
computer continue to display on the LCD whenever
diagnosing. To delete the failure codes, press and
hold both air intake control switches (6) for 3 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 flow 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 changed over in turn by pressing perature display
either temperature setting switch (3) " " or " ".
While the blower is operating, press and hold the both
(b) Press the OFF switch (1) again to finish the self temperature setting switches (3) " " and " "
diagnosis function and return to the normal display. together for 5 seconds or more to change over the unit
of the displayed value between Celsius and Fahrenheit.
However, the unit itself is not displayed.

Only the set value is displayed.

Value displayed on LCD unit

Celsius (ºC) 18.0~32.0
Fahrenheit (ºF) 63~91
 115ZV EX 72-31
72 Function & Structure Operator Station Group
Air Conditioner

Air conditioner unit Air mixing damper

[In the case of maximum cooling]

Air mixing damper A (completely opened)
Heater radiator

Evaporator Cold air

Co
ld
air

Air mixing damper B (completely closed)

[In the case of maximum heating]

Air mixing damper A (completely closed)

Blower motor
Co
ld

ir
a ir

ta
Ho
Inside/outside air selection damper
Air mixing damper A Inside
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 cabin, and consists of an evaporator which
cools down the air, a heater radiator which warms the
air and a blower motor which blows the air.

The temperature in the vent position is adjusted when

the opening/closing position of the air mixing damper is
so controlled that the cooled air while passing through
the evaporator and the warmed air while passing
through the heater radiator are mixed.

The air mixing damper is controlled by the servo motor

for air mixing assembled in the unit.
115ZV EX 72-32
72 Function & Structure Operator Station Group
Air Conditioner

Evaporator The evaporator is an important heat exchanger which

evaporates liquid refrigerant set to low temperature and
low pressure by an expansion valve, utilizes its latent
heat, and absorbs heat from air (target) inside the cabin.
Accordingly, heat should be smoothly transmitted
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.)
 115ZV EX 72-33
72 Function & Structure Operator Station Group
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 (that is, when the cooling load is small)
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 cabin high (that is, when the cooling load is large)
(cooling 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.
115ZV EX 72-34
72 Function & Structure Operator Station Group
Air Conditioner

Troubleshooting the expansion valve

Item Symptom Cause Action

Blocked expansion Both high pressure and low pressure are low,
valve or defective and air bubbles cannot be seen through sight - 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.
 115ZV EX 72-35
72 Function & Structure Operator Station Group
Air Conditioner

Heater radiator

Fin

Heater core

97ZV72051

The heater radiator utilizes the engine cooling water as

the heat source. When going through the heater 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

Item Symptom Cause Action

- 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 cabin does not become warm. - Blockage inside heater radiator - Replacement
Blockage in fins Air quantity is small. - Blockage in fins - Cleaning
115ZV EX 72-36
72 Function & Structure Operator Station Group
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 the terminal
(6) or (7) of the servomotor. (The rotating direction is
determined by the terminal on which the power is
applied.)

A variable resistor is provided inside the servo motor.

As the motor rotates, the resistance of this resistor

changes accordingly.

When the 5 V voltage is supplied from the control panel

to this variable resistor, the control panel detects the
variable resistor position based on the electric potential
difference. When the variable resistor reaches the 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

Item Symptom Cause Action

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.
 115ZV EX 72-37
72 Function & Structure Operator Station Group
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±10 %
Fan outer diameter ø150

Air
Air
97ZV72053

The blower motor assembly consists of a DC motor

and a fan, and blows air.

Troubleshooting the blower motor

Item Symptom Cause Action

- Blower motor
Blower motor operation is defective. Air is not blown at all. - Repair/replacement
- Control unit

BLC (blower linear control)

97ZV72054

This resistor changes over the air quantity of the blower

motor.

Troubleshooting the blower linear control

Item Symptom Cause Action

- 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
115ZV EX 72-38
72 Function & Structure Operator Station Group
Air Conditioner

Thermistor Evaporator

De-icing sensor (Thermistor (or thermal resistor))

Appearance of thermistor

8,000

7,000 Thermistor
6,000
Resistance ()

Heater radiator 97ZV72056

5,000

4,000

3,000
The thermistor mounted on the blowoff port side of the
2,000
evaporator detects the temperature of the air cooled by
the evaporator, and transmits it as a signal to the control
1,000
amplifier.
0
10 5 0 5 10 15 20 25 30
Temperature (ºC)
Characteristics curve between temperature
If the air at the vent is 3ºC or less, the control amplifier
and resistance of thermistor 97ZV72055 turns off the compressor clutch relay. If the air at the
blowoff port becomes 4ºC or more, the control amplifier
The thermistor, a kind of semi-conductor, offers the turns on the compressor clutch relay again to restart
characteristics as shown in the curve on the above. 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

Item Symptom Cause Action

Cable in thermistor is broken. Compressor clutch does not work.
- Thermistor - Replacement
Thermistor is short-circuited. Air not blow g.
 115ZV EX 72-39
72 Function & Structure Operator Station Group
Air Conditioner

Water temperature sensor Foot/defroster selection box

Air conditioner unit

Foot

Def
97ZV72057 97ZV72059

This sensor detects the temperature of the engine 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
-30ºC 91.4 k
25ºC 5 k
100ºC 0.321 

Inside air sensor

97ZV72058

This sensor detects the air temperature inside the cabin,

and feeds it back to the control panel.

This sensor is installed in the inside are suction port,

and can be taken out when the clamp is removed.

Temperature Resistance value

0ºC 16.45 k
25ºC 5 k
115ZV EX 72-40
72 Function & Structure Operator Station Group
Air Conditioner

Compressor and magnetic clutch Compressor specifications

Compressor
Piston
Discharge valve

6 1 Discharge valve

74

3
10

5 Suction valve
Suction valve
Diagonal plate
8
Suction/compression action 97ZV72061

Model 10S150
2 9 Cylinder diameter ø32
11
Stroke 20.8 mm

97ZV72060
Number of cylinders 10
Cylinder capacity 167.3 cm3
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
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 sucks
and compresses the gaseous refrigerant at low temper-
ature and low pressure which deprived heat of the air
inside the cabin in the evaporator and was vaporized to
make the gaseous refrigerant be at high temperature
and high pressure, then feeds it to the circuit on the high
pressure side again. Five pairs of pistons (with ten 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 suction 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 is seized by oil shortage. 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.
 115ZV EX 72-41
72 Function & Structure Operator Station Group
Air Conditioner

Magnetic clutch Magnet clutch specifications

Model L50T
S
Voltage DC 24 V
Suction Power consumption 40 W
force
Stator Drive belt V-ribbed belt (six ribs)
Switch Air gap 0.5±0.15 mm
Iron piece
(rotor)
Power
supply
Magnetic
force
N

Principle of magnetic clutch 97ZV72062

The magnetic clutch controls mechanical connection

between the engine and the compressor. When the
engine is rotating and the air conditioner ON/OFF switch
is ON, if the temperature inside the cabin reaches or
exceeds the temperature set by the temperature setting
switches, the magnetic clutch stops or drives the 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.
115ZV EX 72-42
72 Function & Structure Operator Station Group
Air Conditioner

Troubleshooting the compressor and magnetic

clutch

Item Symptom Cause Action

- 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 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
- Abnormal sounds are made while clutch is - Inside - Repair/replacement
defective.
turned on.
V belt is slack. - V belt - Adjustment/replacement
 115ZV EX 72-43
72 Function & Structure Operator Station Group
Air Conditioner

Condenser unit Condenser fan motor

The condenser fan motor used to cool down the con-

Cover denser is mounted on the condenser together with a fan
Condenser shroud.

Condenser specifications

Voltage DC 24 V
Power consumption 80 W x 10 %
Air quantity 1,750±10 m3/Hr
Number of rotations of motor 2,200 min-1

Blower assembly
Fan motor
Resistor
97ZV72064

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 (70ºC, 1,618 kPa (16.5 kgf/cm2)) sent from the
compressor, and change it into liquid refrigerant during
passing tubes.
115ZV EX 72-44
72 Function & Structure Operator Station Group
Air Conditioner

Resistor

The resistor controls rotation of the condenser fan motor

in two steps in accordance with a command given by
the fan control pressure switch (medium pressure
switch).

Resistor specifications

Resistance 4.0 

Troubleshooting the condenser unit

Item Symptom Cause Action

Heat radiation quantity is
- Blockage or crushed fins - Cleaning or replacement
insufficient due to blockage. Both high pressure and low pressure are
abnormally high, and air does not become cool
Rotation of condenser fan enough. - Fan motor - Repair or replacement
motor is defective.
High pressure is abnormally high, low pressure
is abnormally low, and air does not become
Blockage in circuit - Inside - Cleaning or replacement
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.
 115ZV EX 72-45
72 Function & Structure Operator Station Group
Air Conditioner

Receiver dryer Desiccant

If moisture is present inside the cooling circuit, the com-

pressor valve and oil may deteriorate, metal constituting
the circuit may corrode, or moisture may be frozen
Refrigerant inlet inside the expansion valve and the circuit may be
Refrigerant outlet clogged. To prevent such failure, synthetic zeolite is
accommodated inside the air conditioner as the 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. In such a case, replace the receiver
Desiccant Strainer
dryer.

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 excessive 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.
115ZV EX 72-46
72 Function & Structure Operator Station Group
Air Conditioner

Strainers

If dusts enter the circuit, the expansion valve may be

clogged, the compressor may be damaged, and the
cooling function may be deteriorated.

The strainers are provided to prevent dusts flowing with

the refrigerant from flowing forward.

The strainers cannot be cleaned. When they are consid-

erably clogged (In this case, the high pressure becomes
high and the low pressure becomes low.), the entire
receiver dryer should be replaced.

Troubleshooting the receiver tank

Item Symptom Cause Action

- 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.
 115ZV EX 72-47
72 Function & Structure Operator Station Group
Air Conditioner

Sight glass Pressure switches

Sight glass Terminal

Receiver Contact area

joint

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-

sure type, medium pressure type and low pressure
type, which function as shown in the table below.

Switching pressure Switch operation Causes of abnormal

Switch Function
kPa (kgf/cm2) confirmation method pressure

Pressure switch coupler

A
When pressure between com- 2,550 3,136
pressor and expansion valve (26) (32) Heat radiation of condenser
High
becomes abnormally high, this ON C D is insufficient due to clogging
pressure
switch shuts down power sup- in condenser or defective
switch
plied to compressor magnetic rotation of condenser fan.
clutch to protect circuit. OFF B
Check conductivity
between A and B.

When detecting fluctuation of

pressure between compressor
and expansion valve, this 1,519
switch gives a signal to control (15.5)
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.

When pressure between com-

pressor and expansion valve 226
becomes abnormally low due (2.3)
to refrigerant leak, this switch ON
Low Check conductivity between A and B
shuts down power supplied to Refrigerant leak from a part
pressure in pressure switch coupler shown
compressor magnetic clutch to of circuit.
switch above.
prevent seizure of compressor OFF
caused by insufficient com- 196
pressor oil which decreased (2.0)
together with refrigerant.
115ZV EX 72-48
72 Function & Structure Operator Station Group
Air Conditioner

Troubleshooting the pressure switch

Item Symptom Cause Action

- 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))
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 abnormal high pressure occurs while the high pressure switch is nonconforming, the equipment in the cooling circuit may be damaged.
The pressure relief valve releases the refrigerant to the atmosphere in order to prevent damages of the equipment.

Pressure relief valve

Flow rate
(L/min)
113

Gas discharge route while valve

is operating
97ZV72071

This valve mounted on the high pressure side of the

compressor service valve releases the refrigerant to the
Pressure atmosphere when abnormal high pressure occurs.
28.1 35.0 42.4 (kgf/cm2 )
2,756 3,430 4,158 (kPa)

IMPORTANT
Characteristics drawing of When the refrigerant quantity inside the cooling cir-
relief valve operation cuit is correct, the pressure switch always remains
97ZV72069
ON even if the compressor is stopped because the
refrigerant pressure is approximately 588 kPa (6.0
kgf/cm2) as far as the outside air temperature is
around 25ºC.
When the outside air temperature becomes 0ºC or
less, the pressure switch for low pressure detection
turns off even if the refrigerant quantity is proper
because the refrigerant pressure becomes 196 kPa
(2.0 kgf/cm2) or less. As a result, the compressor
does not work.
It means that the pressure switch for low pressure
detection functions also as a thermostat which
detects the outside air temperature.

Pressure relief valve 97ZV72070

 115ZV EX 72-49
72 Function & Structure Operator Station Group
Air Conditioner

Relay A Relay B
(Condenser fan, condenser fan high, compressor (Evaporator fan motor, low/high)
clutch)

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

Item Symptom Cause Action

- 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
115ZV EX 72-50
72 Function & Structure Operator Station Group
Air Conditioner

Refrigerant hose

Outer layer

Reinforcing layer

Mouth ring

Inner layer
Intermediate layer
97ZV72073

White line and "R134a" indication

97ZV72074

As shown in the figure on the above, the refrigerant

hose consists of the outer layer, the reinforcing layer,
the intermediate layer and the inner layer, and the
mouth ring is crimped.

Region Material
Outer layer Ethylene propylene rubber
Reinforcing layer Polyester
Intermediate layer Chlorinated butyl rubber
Inner layer Nylon

The mouth ring of this hose is changed and the symbol

"R134a" is indicated on this hose as shown in the figure
on the right.

IMPORTANT
Never use any other hose or any other refrigerant.
Otherwise, refrigerant may leak.
 115ZV EX 72-51
72 Function & Structure Operator Station Group
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 40ºC 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 cabin (including trunk), the air
ature (approximately -30ºC). If it splashes on your temperature may rise considerably due to solar
skin, you may suffer from frostbite. Pay close heat, etc., and may become dangerously tempera-
attention when handling it. ture even in winter if the closed cabin is exposed to
- If the refrigerant (Refrigerant R134a) touches a hot direct sunlight. Never put the can inside the cab.
object (approximately +400ºC 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 40ºC or less (temperature - If the compressor oil (ND-OIL 8) adheres to the
at which you feel warm when putting your hand painting face or the resin area, the painting may
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.
115ZV EX 72-52
72 Function & Structure Operator Station Group
Air Conditioner

Work procedure Gas charging process

The refrigerant charging process is mainly divided into The "gas charging process" charges the refrigerant to
"air evacuation process" and "gas charging process" as the circuit in the vacuum status. The gas charging pro-
shown in the chart below. cess not only affects the cooling ability of the air condi-
tioner but also affects the life time of parts constructing
the circuit. If the refrigerant is charged too much, the
Air evacuation process pressure inside the circuit may become extremely high
and the cooling ability may deteriorate. If the refrigerant
The "air evacuation process" eliminates the moisture quantity is too small, the lubricating oil for the compres-
present inside the cooling circuit. If the moisture sor may not circulate smoothly and the sliding area of
remains inside the circuit, it may cause varied problems the compressor may seize.
even if its quantity is extremely small: The moisture may
be frozen inside the expansion valve during operation, Because the gas charging process involves high pres-
and may block the circuit or generate oxidation. To pre- sure gas, it is extremely dangerous if it is performed
vent such problems, the air inside the cooling circuit with the wrong procedure.
should be evacuated, and the moisture inside the circuit
should be boiled and evaporated so that the moisture is Observe the work procedure shown below and the cau-
eliminated before the refrigerant is charged into the cir- tions, and charge the refrigerant correctly.
cuit.

Work chart

Start air evacuation. -750 mmHg or less

20~30 min
Air
evacuation Stop air evacuation. Check and repair connection area.
process
Leave for 5 min.

Check air tightness. When gage indicates an abnormal value

When gage indicates a normal value

Charge refrigerant. Charge gaseous refrigerant until gauge pressure

reaches 98 kPa (1 kgf/cm2).

Check for gas leak.

Gas
charging
process
Charge refrigerant.

Check for gas leak.

Performance test
95ZVE72042
 115ZV EX 72-53
72 Function & Structure Operator Station Group
Air Conditioner

Refrigerant charging tools Charging hose and quick joints

Vacuum pump

Vacuum pump adapter

Gauge manifold

Low pressure
Vacuum pump charging hose High pressure
(blue) charging hose
97ZV72076
(red)

Quick joint (Lo)

A vacuum pump should be used to eliminate the mois-
ture inside the circuit.

Center charging
hose (green)
Quick joint (Hi)

97ZV72077

These three hose of three colors are used to evacuate

the air and charge the gas. (The colors may be different
depending on the manufacturer.)

Red hose
Connects the high pressure valve of the gauge manifold
and the high pressure charging valve (with "H" mark on
its cap) of compressor outlet hose.

Blue hose
Connects the low pressure valve of the gauge manifold
and the low pressure charging valve (with "L" mark on
its cap) of the compressor inlet hose.

Green hose
Connects the center valve of the gauge manifold and
the vacuum pump (or the service can valve).
115ZV EX 72-54
72 Function & Structure Operator Station Group
Air Conditioner

Gauge manifold Service can valve

Low pressure High pressure

gauge gauge

Center charging hose Service can valve

Gauge manifold

Low pressure
valve High pressure
valve Service can T joint
Low pressure
charging hose Center valve High pressure
mounting nipple Center charging charging hose
hose mounting mounting nipple
nipple 97ZV72078 97ZV72079

It is used to evacuate the air and charge the gas, and This valve is attached to a service can when gas is
equipped with a high pressure gauge, a low pressure charged, and used to open the service can, supply the
gage, many valves and hose mounting nipples as gas and stop supply of the gas.
shown in the figure on the above.
In order to open the service can or stop supply of the
gas, tighten the handle clockwise completely. In order to
supply the gas, loosen the handle counterclockwise
completely.
 115ZV EX 72-55
72 Function & Structure Operator Station Group
Air Conditioner

Cautions on handling of quick joint and charg- 2. Disconnecting the quick joint
ing valve

When discharging the refrigerant, use a quick joint.

Sleeve "Click" sound (OK)
1. Connecting the quick joint
(A)

Sleeve "Click" sound (OK) (B)

(A)

97ZV72081

Charging valve

Quick joint

97ZV72080

Slide the sleeve upward, push the quick joint

against the charging valve, press and hold securely
part (A) until a click is heard, then slide the sleeve
Screwdriver, etc.
downward.
Valve pin
IMPORTANT
Spring
- Push the quick joint against the charging valve ver-
tically.
- If refrigerant remains inside the charging hose, the
quick joint may not be easily connected. Release Charging valve
the refrigerant from the hose. 97ZV72082

While pressing and holding the part (A) of the quick

joint, slide the sleeve upward to disconnect the
quick joint.

IMPORTANT
If you push the valve pin with a considerable force
[294 kPa (3 kgf/cm2)] with a screwdriver, etc., the
spring may come off and the refrigerant may leak.
Never do this.
115ZV EX 72-56
72 Function & Structure Operator Station Group
Air Conditioner

Refrigerant charging procedure 1. Connecting the gauge manifold

Air evacuation work
Valve setting
WARNING Lo Hi
If hoses are connected incorrectly, serious accidents Closed Closed
may occur. High pressure valve
Observe the following contents.
- Never confuse connection of hose to the high pres-
Low pressure valve
sure side and the low pressure side of the gauge
manifold.
(red)
(blue)
IMPORTANT (green)

A depression pin is provided on the L-shape end of

the hose. Attach a quick joint to this end. (Hi)

(Lo)

Charging valve
on high pressure
side (located on
receiver dryer)
Vacuum pump (stopped)
Compressor (stopped)

95ZVE72045

(a) Close both the high pressure (Hi) valve and the low
pressure (Lo) valve of the gauge manifold.

(b) Connect the charging hose.

Red hose
To be connected between the high pressure (Hi)
valve of the gauge manifold and the high pressure
charging valve.

Blue hose
To be connected between the low pressure (Lo)
valve of the gauge manifold and the low pressure
charging valve of the compressor.

Green hose
To be connected between the center valve of the
gauge manifold and the vacuum pump.

IMPORTANT
Connect quick joints to both the high pressure and
low pressure sides before starting air evacuation.
The check valve of the quick joint cannot hold the
vacuum status. If one side of the quick joint is not
connected, the vacuum status cannot be realized.
 115ZV EX 72-57
72 Function & Structure Operator Station Group
Air Conditioner

2. Evacuating the system 3. Checking for leaks

Valve setting Leave for 5 minutes

Valve setting Valve setting Lo Hi or more
After air evacuation Pointer of low
Lo Hi for 30 minutes Lo Hi Closed Closed pressure gauge
OpenedOpened Closed Closed moves toward "0".
Low pressure gauge
High pressure valve

Low pressure valve

Moves
toward "0".
(red) Tighten connection areas
of piping.
(blue) 97ZV72085
(green)

Leave the circuit for 5 minutes or more while each valve

(Hi)
of the gauge manifold is closed. Then, make sure that
(Lo) the pointer of each gauge does not move.

Charging valve If the pointer of the gauge moves toward "0", a leak has
on high occurred somewhere in the circuit. Tighten the connec-
pressure side
tion areas of the piping, evacuate the system again,
then make sure that there is no leaks.
Vacuum pump (operating)
Compressor (stopped) (stopped)
IMPORTANT
95ZVE72046
Make sure to tighten the connection areas of the pip-
ing at a specified tightening torque.
(a) Open both the high pressure (Hi) valve and the low For the tightening torque, refer to the volume "Mainte-
pressure (Lo) valve of the gauge manifold. nance Standard".

(b) Turn on the switch of the vacuum pump, and evac-

uate until the degree of vacuum becomes -750
mmHg or less (for approximately 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, the circuit in the vacuum
status is released to the atmosphere. First close each
valve.
115ZV EX 72-58
72 Function & Structure Operator Station Group
Air Conditioner

Refrigerant charging process

WARNING
Valve setting
When charging the refrigerant from the high pressure
Lo Hi
Closed Closed
side, the refrigerant may flow in the reverse direction
and the can and the hose may be burst if you start
the engine and operate the compressor. Never start
Press the Open the the engine.
valve pin. service
can valve.
Air purge IMPORTANT
Blue If you charge the refrigerant while making the service
Red
Service can can stand upside down, the refrigerant is sucked in
Charging hose R134a the liquid status by the compressor and the compres-
(green) 97ZV72086
sor may be damaged. Never do this.

1. Charging the refrigerant from the high pressure

Valve setting After 1~1.5 service Valve setting
cans are charged
side
Lo Hi Lo Hi
Closed Opened Closed Closed
(a) After evacuation, disconnect the charging hose
(green) of the gauge manifold from the vacuum
High pressure valve pump, and connect it to the service can.

(b) Air purge

Low pressure
valve Open the service can valve (while closing the high
and low pressure valves of the gauge manifold),
(red) and press the valve core shaft of the service port on
the low pressure side of the gauge manifold with a
screwdriver, etc. so that the air inside the charging
(blue) (green) (Hi) hose is discharged by the refrigerant pressure.

(c) Open the high pressure valve of the gauge mani-

(Lo) fold, and charge the gaseous refrigerant until the
Charging valve
on high pressure gauge pressure reaches 98 kPa (1 kgf/cm2). (One
side to one and half service cans are required.)

Compressor (d) After charging, close the high pressure valve of the
(stopped) gauge manifold and the service can valve.
Service can valve
(opened charge
R134a closed) 2. Check for gas leak
95ZVE72052

Check for gas leak in the circuit using a leak tester,

etc. If leak is detected, tighten the connection
areas.

IMPORTANT
Make sure to tighten the connection areas of the pip-
ing at a specified tightening torque.
For the tightening torque, refer to the volume "Mainte-
nance Standard".
 115ZV EX 72-59
72 Function & Structure Operator Station Group
Air Conditioner

3. Charging the refrigerant from the low pressure side (c) Start the engine, and increase the number of rota-
tions to approximately 1,500 min-1.
Charge the refrigerant
Valve setting until air bubbles seen Valve setting (d) On the control panel, press the HI blower switch to
through the sight glass
Lo Hi disappear. Lo Hi set the air quantity to the maximum value, and set
Opened Closed Closed Closed
the vent port temperature switches to the coldest
status.
High pressure valve
(e) Open the low pressure valve of the gauge manifold
and the service can valve to charge the refrigerant.
Low pressure When air bubbles seen through the sight glass of
valve the receiver dryer disappear, charge the refrigerant
further more by 150~250 g.
(red)

IMPORTANT
When replacing the service can during the refrigerant
(blue) (green) (Hi)
charging work, make sure to purge the air from the
line.
(Lo)
Charging valve
on high pressure (f) After charging, close the low pressure valve of the
side gage manifold and the service can valve. Then,
stop the engine.
Compressor
(On-load)
Service can valve
Refrigerant quantity to be charged (guideline)
(opened charge 900±50 g
R134a closed)
95ZVE72052
Refrigerant
Sight glass situation
quantity
Gas bubbles are few.
(When the number of rotations of the
Proper engine is gradually increased from the
Sight glass
idle status to 1,500 min-1, air bubbles
disappear.)

Gas bubbles are not seen in the flow at

all.
Receiver joint Too much (In this case, both the high pressure
and the low pressure are high, and the
cooling ability is deteriorated.)

Receiver dryer
Gas bubbles are seen in the flow.
Insufficient
(Gas bubbles go through continuously.)
97ZV72066

(a) Make sure that the high and low pressure valves of
the gauge manifold and the service can valve are
closed.

(b) If the inside of the cabin becomes cold during the

charging process, the compressor magnetic clutch
turns off and system charging is disabled.
When charging, open the doors and the windows of
the cabin completely.
115ZV EX 72-60
72 Function & Structure Operator Station Group
Air Conditioner

4. Guideline for judgement of the refrigerant charge 5. Disconnecting the gauge manifold
quantity

Judge the refrigerant charge quantity under the fol-

lowing condition.
Sleeve "Click" sound (OK)
Item Criteria
(A)
Doors Completely open
Temperature control switches Maximum cooling
Blower speed Hi
Inside/outside air selection Inside air (B)

Number of rotations of engine 1,500 min-1

Air conditioner switch ON
Pressure on high pressure side 1,862 kPa (19 kgf/cm2) or less
97ZV72081

IMPORTANT After inspecting the refrigerant charge, disconnect

- If the outside air temperature is high (40ºC or the charging hose from the high and low pressure
more) or if the pressure on the high pressure side charging valves using the following procedure.
is 1,862 kPa (19 kgf/cm2) or more when the judge-
ment condition above is set, perform the following (a) While pressing and holding the part (A) of the quick
so that the pressure becomes 1,862 kPa (19 kgf/ joint, slide the sleeve upward and disconnect the
cm2) or less, then check the refrigerant quantity. quick joint.
- Close the doors completely, and set the
blower fan to the low speed (by pressing (b) Attach a cap to each of the high and low pressure
the Lo switch). charging valves.
- 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 small, lubricant in the
compressor may be insufficient and a failure such
as seizure of the compressor may occur. Never do
this.
- If the refrigerant quantity is over charged, cooling
may be insufficient or the pressure inside the cir-
cuit may become abnormally high (which is dan-
gerous). Never do this.
 115ZV EX 72-61
72 Function & Structure Operator Station Group
Air Conditioner

Troubleshooting using the gauge manifold Condition

Normal status After warming up the engine, check the pressure under
the following condition.

- 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
Inside air

- Number of rotations of engine

1,500 min-1

- Temperature at suction port of air conditioner

30~35ºC (86~95ºF)

- Blower speed
High

- Temperature control switches

Maximum cooling

97ZV72091

Pressure values indicated by gauges in the normal status

A/C suction port temperature Pressure Pressure value by gauge

High pressure side 1,000~1,215 kPa (10.2~12.4 kgf/cm2)
20~25ºC
Low pressure side 127~167 kPa (1.3~1.7 kgf/cm2)
High pressure side 1,215~1,470 kPa (12.4~15.0 kgf/cm2)
25~30ºC
Low pressure side 167~215 kPa (1.7~2.2 kgf/cm2)
High pressure side 1,470~1,784 kPa (15.0~18.2 kgf/cm2)
30~35ºC
Low pressure side 215~275 kPa (2.2~2.8 kgf/cm2)
High pressure side 1,784~2,146 kPa (18.2~21.9 kgf/cm2)
35~40ºC
Low pressure side 275~353 kPa (2.8~3.6 kgf/cm2)
115ZV EX 72-62
72 Function & Structure Operator Station Group
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)

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 - Inspect receiver
both low and high quantity is leaks. completely blocked, cooling 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.
 115ZV EX 72-63
72 Function & Structure Operator Station Group
Air Conditioner

When the moisture has entered into the cooling When the compression in compressor is defec-
circuit. tive.

<Low pressure side> <High pressure side>

<Low pressure side> <High pressure side>
392~588 kPa 686~981 kPa
Abnormal status 686~981 kPa
(4~6 kgf/cm2) (7~10 kgf/cm2)
Vacuum (7~10 kgf/cm2)

Normal status
215~275 kPa 1,470~1,765 kPa
(2.2~2.8 kgf/cm2) (15~18 kgf/cm2)

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 needed. ditioner turns off,
but pressure on low moisture. 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.
115ZV EX 72-64
72 Function & Structure Operator Station Group
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)

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
rpm’s (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
 115ZV EX 72-65
72 Function & Structure Operator Station Group
Air Conditioner

When the expansion valve is opened too much

<Low pressure side> <High pressure side>

294~392 kPa 1,961~2,452 kPa
(3.0~4.0 kgf/cm2) (20~25 kgf/cm2)

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 Diaphragm

Spring

Temperature sensing rod

Needle valve Compressor return

From receiver dryer

97ZV72049
115ZV EX 72-66
72 Function & Structure Operator Station Group
Air Conditioner

Air conditioner troubleshooting  Error code table

Display Failure mode

Fault diagnosis procedure
E- No failure
E11 Wire breakage in inside air sensor
E12 Short-circuit in inside air sensor
Hearing check 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
E18 Short-circuit in insolation sensor
Phenomenon check
E21 Wire breakage in vent sensor
E22 Short-circuit in vent sensor
Basic check E43 Abnormality in vent damper
E44 Abnormality in air mixing damper
In accordance with fault phenomenon
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
 115ZV EX 72-67
72 Function & Structure Operator Station Group
Air Conditioner

Basic check
1. Check of control mechanism
Operate the switch arranged on the control panel,
to check that it is operable smoothly and securely.

2. Check of V-belt
Check that the V-belt is tensioned properly, and that
it is not damaged.

3. Check of refrigerant level through sight glass

When the air bubble is observed a lot through sight
glass, the refrigerant is probably insufficient.
In such a case, therefore, perform the checking
with using a gauge manifold.

Sight glass

Receiver joint

Receiver drier

95ZVE01003

4. Check of piping connection

At the piping connection where the oil stain is seen,
there is probably a refrigerant leakage.
In such a case, remove the stain, and then check
for gas leakage.
 <Trouble shooting charts>

Clogged inner air filter Clean the filter.

Clogged outer air filter Clean the filter.
Air Conditioner
115ZV EX 72-68

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.
72 Function & Structure Operator Station Group

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 Too low pressure at low-pressure side(Pressure is decreased to approx. 49kPa[0.5kgf/cm2] or less See C-4 .

Cooling failure
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.
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 cut
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.

Over-filled refrigerant Discharge the refrigerant 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
115ZV EX 72-69

Air Conditioner
72 Function & Structure Operator Station Group
 Air Conditioner
Unusually low outside air temperature
115ZV EX 72-70

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.
72 Function & Structure Operator Station Group

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
Over-filled refrigerant Discharge the refrigerant to proper level.

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
115ZV EX 72-71

Air Conditioner
72 Function & Structure Operator Station Group
 Insufficient Same as "Cooling failure"
wind force
Air Conditioner
115ZV EX 72-72

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
72 Function & Structure Operator Station Group

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
With diagnostic display: E45
Servo motor failure Replacement
(inside air/outside air servo motor abnormal)

Foreign matter caught Remove the foreign matter.

With diagnostic display: E11

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
115ZV EX 72-73

Air Conditioner
72 Function & Structure Operator Station Group
115ZV EX 72-74
72 Function & Structure Operator Station Group

MEMO
 115ZV EX 73-1
73 Check & Adjustment Operator Station Group

73 Check & Adjustment

Operator Station Group

Air Conditioner ......................................................................73-2

115ZV EX 73-2
73 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
excess refrigerant when removing components of the
air conditioner.

IMPORTANT
- When replacing components of the air conditioner,
if the lubricating oil quantity is too small, the com-
pressor may seize. And if the lubricating oil quan-
tity is too much, the cooling ability may deteriorate.
Be sure to correctly adjust lubricating oil quantity.
- When connecting a joint, apply compressor oil
(ND-OIL 8) on the O ring before tightening (Fig. 1).
- If the compressor oil (ND-OIL 18) sticks to the
Fig. 1
97ZV73002 paint, the paint may peel off or be damaged. If it
gets on a painted surface, wipe it off soon.
- Tighten the piping, etc. at the recommended
torque.

Tightening torque table

Connection Tightening torque

Pipe size or bolt size
area N-m (kgf-cm)

ø8 pipe 14.7 (150)

Nut type
1/2 pipe 24.5 (250)
(Fig. 2)

5/8 pipe 34.3 (350)

Fig. 2
97ZV73003
M6 bolt in receiver (4T) 6.9 (70)
Block joint
(Fig. 3) Any M6 bolt other than
11.8 (120)
above (6T)

Fig. 3 97ZV73004
 115ZV EX 73-3
73 Check & Adjustment Operator Station Group
Air Conditioner

When the compressor is replaced

Compressor mounting bolt
29 N-m (3.0 kgf-m)
New compressor Old compressor to be replaced

Hose block joint on high pressure side

12 N-m (1.2 kgf-m)

Hose block joint on low pressure side

12 N-m (1.2 kgf-m)

Example

Oil quantity Suppose that the oil quantity (A) removed from the com-
remaining (B) pressor to be replaced is 100 cm3.
inside circuit
A A Oil quantity remaining inside circuit (B)
= 180 cm3 - (100 + 20) = 60 cm3
97ZV73005
Remove 60 cm3 from the new compressor.

1. Remove the oil from the removed compressor, and

measure the oil quantity. (Approximately 20 cm3 of
oil cannot be removed, and remains inside the
compressor.).......... A cm3

2. The compressor can accommodate 180 cm3 of oil.

Obtain the remaining oil quantity using the following
equation.
Oil quantity remaining inside circuit
= 180 - (Oil quantity A discharged
from removed compressor + 20 cm3)

3. Discharge the oil by as much as the quantity

remaining inside the circuit from a new compressor,
then attach the new compressor.

Compressor lubricating oil

ND-OIL 8

IMPORTANT
3
- Oil (180 cm ) required for the cooling circuit is
sealed inside a new compressor.
When replacing the compressor, excessive oil
should be discharged from a new compressor.
- The compressor oil can easily contain moisture.
Seal the compressor immediately after adjusting
the oil quantity.
- Never use the oil for the R12.
115ZV EX 73-4
73 Check & Adjustment Operator Station Group
Air Conditioner

When the evaporator is replaced When the condenser is replaced

Lubricating oil quantity lost by replacement

Approximately 40 cm3
1
When replacing the condenser, add 40 cm3 of compres-
sor oil (ND-OIL 8) to a new condenser.

: (1): 25 N-m (2.5 kgf-m)

: (2): 15 N-m (1.5 kgf-m)

When the receiver dryer is replaced

Evaporator

Lubricating oil quantity lost by replacement

Approximately 20 cm3
Expansion valve
The oil quantity lost by replacement is within the allow-
able range, and supplement is not required at the first
time.

At the second time and later, however, add 20 cm3 of

compressor oil (ND-OIL 8) to a new receiver dryer.

: (1): 7 N-m (0.7 kgf-m)

: (2): 15 N-m (1.5 kgf-m)

97ZV73006

Lubricating oil quantity lost by replacement

Approximately 40 cm3

When replacing the evaporator, add 40 cm3 of compres-

sor oil (ND-OIL 8) to a new evaporator.

: (1): 12 N-m (1.2 kgf-m)

 115ZV EX 73-5
73 Check & Adjustment Operator Station Group
Air Conditioner

Adjustment of air gap (between 1. Remove the front cover of the magnetic clutch.
hub and rotor) in compressor 2. Measure the size A between the rotor end face and
magnetic clutch the hub end face while the magnetic clutch is OFF.

3. Apply the battery voltage directly on the connector

of the magnetic clutch, and measure the size of B in
the same way as step 2 above.
Position while magnetic
clutch is OFF Reference plane Criteria of air gap (A - B)
0.5±0.15 mm
Air gap
0.5±0.15 mm
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 utilizing the thickness of the
B (ON status) washer plate between the hub and the shaft.

Hub

Head bolt

Washer plate

Rotor

95ZVE73002

WARNING
If you adjust the air gap while the engine is rotating,
serious accidents such as injury to your hands may
occur.
Set the starter switch to OFF, stop rotation of the
engine, pull out the starter key, then start adjustment.
115ZV EX 73-6
73 Check & Adjustment Operator Station Group
Air Conditioner

Parts to be replaced periodically Receiver dryer

Air filters Replacement

Once/3 years
Air filter for outside air

Cleaning WARNING
Once/2 weeks When replacing the receiver dryer, do not release the
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.
In cleaning, blow the compressed air of 196~294 kPa (2
~3 kgf/cm2) mainly from the inside of the filter.

Replacement
Once/year

When the air quantity is so small as to hinder air condi-

tioning even after cleaning, or when the air filter has
been cleaned 20 times, replace it.

Air filters for inside air

Cleaning
Once/1 month

However, if the air filters are easily clogged, clean them

more frequently.
In cleaning, blow the compressed air of 196~294 kPa (2
~3 kgf/cm2) mainly from the inside of the filters.

Replacement
Once/3 years

When the air quantity is so small as to hinder air condi-

tioning even after cleaning, or when the air filters have
been cleaned 6 times, replace them.
INDEX
A Brake Accumulator Line ................................................... 52-9
Accelerator pedal ................................................ 62-38, 62-40 Brake Circuit ..................................................................... 92-9
Accelerator pedal installation .............................. 62-39, 62-41 Brake circuit air bleeding procedure ............................... 52-26
Accumulator ....................................................................52-10 Brake Circuit Check Valve .............................................. 52-35
Accumulator (for vibration damper) ................................42-67 Brake Circuit Oil Pressure ................................................ 53-2
Accumulator circuit pressure measurement and Brake lining wear check ................................................. 53-14
adjusting .......................................................................53-4 Brake main valve (left pedal) .......................................... 52-12
Adapter (Orifice) .............................................................42-57 Brake pilot valve (right pedal when seated in driver’s seat)
Adjusting reducing valve setting pressure ........................53-5 .................................................................................... 52-13
Adjusting set pressure ........................................ 42-48, 42-50 Brake System Outline ....................................................... 52-2
Adjusting shim ..................................................................13-6 Brake Units Layout ........................................................... 52-3
Adjusting tooth contact ...................................................23-10 Brake Valve .................................................................... 52-12
Adjusting unloader valve setting pressure ........................53-3 Brake valve oil pressure ................................................... 53-6
Adjustment ........................................................................13-3 Brake valve outline ......................................................... 52-15
Adjustment of air gap (between hub and rotor) in Brake valve performance ................................................. 53-7
compressor magnetic clutch .........................................73-5 Brake valve performance chart ...................................... 52-14
Adjustment of axle internal pressure ................................52-2 Bucket cylinder ............................................................... 42-21
Adjustment of lubricating oil quantity when components Bucket hinge pin section (#1) ........................................... 13-4
of air conditioner are replaced ......................................73-2 Bucket link pin section (#2) .............................................. 13-5
Adjustment procedure .....................................................53-14 Bucket positioner electrical circuit check ........................ 63-29
After power-off (Clutch disengaged status) ....................32-28 Bucket spool operation ................................................... 42-52
After power-on (Clutch engaged status) .........................32-29
Air compressor (with magnetic clutch) ............................72-18 C
Air Conditioner ...................................................... 72-14, 73-2 Cabin ................................................................................ 72-2
Air conditioner components ............................................72-14 Caution for diode check method ..................................... 62-86
Air conditioner functions of components .........................72-24 Cautions ......................................................................... 00-20
Air conditioner specifications (system performance) ......72-14 Cautions on Hydraulic Parts Replacement ....................... 42-3
Air conditioner structure ..................................................72-15 Cautions on installing brake discs .................................. 53-11
Air conditioner troubleshooting .......................................72-66 Cautions on Safety ........................................................... 03-2
Air conditioner unit ..........................................................72-31 Cautions Regarding Electric Circuit Check ...................... 63-2
Air distributor (hood & defroster selection box) ...............72-17 Cautions regarding parts removal .................................. 00-18
Air filters ............................................................................73-6 Cautions regarding reassembly ...................................... 00-18
Alarm monitor actuation and data storage ......................62-94 Cautions regarding welding repair service ..................... 00-20
Alternator ........................................................................62-22 Center Pin ............................................................... 12-8, 13-6
Alternator I terminal wire .................................................62-18 Changing display from one function to next ................... 62-99
Auto Brake ......................................................................52-36 Charge of refrigerant ...................................................... 72-51
Auto brake ............................................................ 52-2, 62-58 Check valve ................................................42-6, 42-62, 42-66
Auto brake circuit ............................................................52-36 Clutch combination ........................................................... 32-6
Auto brake operation set value .......................................52-36 Clutch Oil Pressure and Time Lag ................................... 33-2
Automatic shift ................................................................62-48 Clutch oil pressure control at the time of engine starting
Axle ...................................................................................23-5 .................................................................................... 32-24
Axle Assembly ...................................................... 22-11, 92-2 Clutch oil pressure measurement procedure ................... 33-3
Axle nut tightening procedure ...........................................23-5 Clutch Pack .................................................................... 32-10
Axle Support ...................................................................22-14 Clutch Solenoid Valve .................................................... 32-26
Clutch solenoid valve output electrical circuit check ...... 63-16
B Clutch specifications ......................................................... 32-7
Back-up alarm .................................................................62-55 Column shaft .................................................................. 72-13
Battery relay ....................................................................62-18 Como Utilizar o Diagrama de Ligações Eléctricas
Battery relay operation ....................................................62-18 (PORTUGUÊS) ............................................................ 62-7
Bearing installation ...........................................................23-9 Cómo utilizar un Diagrama de Alambrado Eléctrico
Bleeding air from brake pipes and hubs .........................52-27 (ESPAÑOL) .................................................................. 62-6
Bleeding air from the brake valves .................................52-27 Compressor and magnetic clutch ................................... 72-40
Bolt tightening torque ......................................................00-13 Condenser unit .................................................... 72-18, 72-43
Boom cylinder .................................................................42-21 Connection diagram ....................................................... 62-23
Boom kick-out (option) ....................................................62-83 Connector ....................................................................... 62-64
Boom spool operation .....................................................42-54 Continuity check mode ................................................... 62-86
Control panel .................................................................. 72-24 Electrical Wiring Diagram (1/3) (S/N 0154~0222) .......... 92-16
Control schematic drawing ............................................. 72-23 Electrical Wiring Diagram (1/3) (S/N 0223~) .................. 92-19
Control unit ..................................................................... 72-19 Electrical Wiring Diagram (2/2) (S/N 0101~0120) .......... 92-11
Controller ........................................................................ 62-42 Electrical Wiring Diagram (2/2) (S/N 0125~0153) .......... 92-15
Controller connection diagram ....................................... 62-44 Electrical Wiring Diagram (2/2) (S/N 11C4-0121~0124)
Controller function .......................................................... 62-45 ....................................................................................92-13
Coolant Specification ..................................................... 00-10 Electrical Wiring Diagram (2/2) (S/N 9001~9010) .......... 92-23
Coolant specification ...................................................... 00-10 Electrical Wiring Diagram (2/2) (S/N 9011~) .................. 92-25
Cooling circuit ................................................................. 72-22 Electrical Wiring Diagram (2/3) (S/N 0154~0222) .......... 92-17
Cooling mechanism ........................................................ 72-20 Electrical Wiring Diagram (2/3) (S/N 0223~) .................. 92-20
Cooling unit .................................................................... 72-15 Electrical Wiring Diagram (3/3) (S/N 0223~) .................. 92-21
Cylinder natural drift ....................................................... 43-11 Electrical Wiring Diagram (3/3) (S/N 154~0222) ............ 92-18
Cylinders .......................................................................... 42-4 Electrical Wiring Diagram (CAB) ....................................92-29
Electrical Wiring Diagram (Cabin Air Conditioner) .......... 92-40
Electrical Wiring Diagram Abbreviation Chart
D
(S/N 0101~0153, 9001~) ............................................ 92-26
Detent adjustment procedure ......................................... 42-29
Electrical Wiring Diagram Abbreviation Chart
Detent solenoid .............................................................. 62-84
(S/N 0154~0222) ........................................................92-27
Diag. Inc/Dec switch assembly (option) ......................... 62-25
Electrical Wiring Diagram Abbreviation Chart
Diagnostic (T/M controller) failure code
(S/N 0223~) ................................................................92-28
detection condition ..................................................... 62-91
Emergency Steering ..................................................... 42-114
Diagnostic failure history indication and deletion ........... 62-96
Emergency steering function (for Europe spec only) ......62-62
Diagnostic switch ........................................................... 62-98
Emergency steering hydraulic line ................................ 42-115
Diagnostic System (S/N 0101~0153, 9001~) ................. 62-89
Emergency steering oil flow .......................................... 42-116
Diagnostic system flow ........................................ 62-89, 62-93
Emergency steering operation ...................................... 42-115
Differential Gear ............................................................. 22-20
Emergency steering pump ............................................ 42-118
Differential gear adjustment procedure ............................ 23-7
Emergency steering valve assembly ............................ 42-119
Diode .............................................................................. 62-85
Engine ..............................................................................23-2
Diode check method ...................................................... 62-86
Engine / Transmission ...................................................... 22-3
Diode check mode ......................................................... 62-86
Engine / transmission mount ............................................22-3
Diode unit ....................................................................... 62-19
Engine diagnostic switch (option) ................................... 62-27
Directional control valve ................................................... 42-6
Engine Start Circuit ......................................................... 62-14
Disconnecting or reinstalling connector ........................... 63-2
Engine start circuit diagram (S/N 0101~0153, 9001~)
Dust seal .......................................................................... 12-9
....................................................................................62-14
Engine start circuit diagram (S/N 0154~) ........................ 62-15
E Equipment Operation Table (Cabin Air Conditioner) ......92-41
ECM (Engine Controller) ................................................ 62-23
Electrical Cable Color Codes ........................................... 62-8 F
Electrical circuit .............................................................. 72-23
Failure code (T/M controller) ..........................................62-90
Electrical Circuit Check (S/N 0101~0153, 9001~) .......... 63-10
Failure diagnosis ............................................................ 62-25
Electrical Circuit Diagram (Cabin Air Conditioner) ......... 92-50
Failure diagnostic chart ..................................................62-28
Electrical Circuit Symbols ................................................. 62-9
Failure history deletion ...................................................62-97
Electrical Connection Diagram (1/2) (S/N 0223~) .......... 92-35
Failure history indication ................................................. 62-96
Electrical Connection Diagram (2/2) (S/N 0223~) .......... 92-36
Fan maximum revolution measurement
Electrical Connection Diagram (S/N 0101~0120) .......... 92-31
(S/N 0101~0120, 9001~9010) ....................................43-14
Electrical Connection Diagram (S/N 0121~0124) .......... 92-32
Fan maximum revolution measurement
Electrical Connection Diagram (S/N 0125~0153) .......... 92-33
(S/N 0121~, 9011~) .................................................... 43-16
Electrical Connection Diagram (S/N 0154~0222) .......... 92-34
Fan motor (FM30) (S/N 00168~) .................................. 42-108
Electrical Connection Diagram (S/N 9001~9010) .......... 92-37
Fan Motor (GM30C) ..........................................42-98, 42-106
Electrical Connection Diagram (S/N 9011~) .................. 92-38
Fan motor check valve (Make-up valve) ....................... 42-113
Electrical Detent Circuit .................................................. 62-82
Fan Motor Line (S/N 0101~0120, 9001~9010) ............... 42-96
Electrical Equipment Layout ........................................... 92-42
Fan Motor Line (S/N 0121~, 9011~) ............................. 42-104
Electrical Transmission Control System Troubleshooting
Fan Motor Line (S/N 5001~5030) ................................... 42-95
Flowchart (S/N 0101~0153, 9001~) ............................. 63-5
Fan motor relief valve ................................................... 42-113
Electrical Wiring (for Reversing Fan) ............................. 92-29
Fan Motor Relief Valve Assembly ................................ 42-112
Electrical Wiring Diagram (1/2) (S/N 0101~0120) .......... 92-10
Fan Motor Revolution .....................................................43-14
Electrical Wiring Diagram (1/2) (S/N 0121~0124) .......... 92-12
Fan motor specifications ................................................. 42-98
Electrical Wiring Diagram (1/2) (S/N 0125~0153) .......... 92-14
Fan motor system .............................................................42-9
Electrical Wiring Diagram (1/2) (S/N 9001~9010) .......... 92-22
Fan revolution adjustment procedure ..................43-15, 43-17
Electrical Wiring Diagram (1/2) (S/N 9011~) .................. 92-24
Fault diagnosis procedure .............................................. 72-66
Fault diagnostic result storage condition ........................62-92 Hydraulic System Operation ............................................. 42-8
First propeller shaft assembly ...........................................22-7 Hydraulic system operation outline .................................. 42-8
Flanged hexagon bolt .....................................................00-16 Hydraulic Tank ............................................................... 42-11
Float ................................................................................62-83 Hydraulic tank (S/N 0101~0200, 9001~) ........................ 42-12
Floor board .......................................................................12-7 Hydraulic tank (S/N 0201~) ............................................ 42-14
Floor board mount ............................................................12-7 Hydraulic tank breather valve (tank cap)
Flow amplifier notch and pilot orifice ...............................42-88 (S/N 0101~0200, 9001~) ........................................... 42-13
Flow control valve .............................................................42-5 Hydraulic tank breather valve (tank cap) (S/N 0201~) ... 42-15
Flushing Hydraulic Circuit .................................................42-2 Hydraulic tank specifications .......................................... 42-11
For high/reverse and speed clutches ..............................32-28
Forward ...........................................................................32-11
I
Forward 1st speed ..........................................................32-11
If the input units or circuit are not defective ...................... 63-7
Forward 2nd speed .........................................................32-12
Inching (Declutch) input electrical circuit check .............. 63-12
Forward 3rd speed ..........................................................32-12
Increment decrement switch (option) ............................. 62-29
Forward 4th speed ..........................................................32-13
In-Line Filter ................................................................... 52-11
Forward/reverse (F/R) shifting and speed change .........62-45
Inspection and maintenance table .................................... 00-5
Friction plate .....................................................................32-8
Installing bearing cover .................................................... 13-6
Front Chassis ....................................................................12-2
Installing bearing outer ring .............................................. 13-6
Front wiper ........................................................................72-7
Instrument panel ............................................................. 62-74
Fuel gauge circuit ...........................................................62-80
Instrument Panel and Switch .......................................... 62-74
Fuel level gauge electrical circuit check .........................63-27
Instrument panel rear surface ........................................ 62-76
Fuel tank ...........................................................................12-5
Items to be monitored and operation condition .............. 62-68
Function of differential gear ............................................22-24
Function of ECM .............................................................62-23
Fuse ................................................................................62-11 L
Fuse box .........................................................................62-12 Layout of Hydraulic Units ............................................... 42-10
Fuse box location ............................................................62-11 Layout of main components ............................................. 00-4
Fusible link ......................................................................62-13 LED inspection windows ................................................ 62-43
Left turn position ............................................................. 42-80
G Liner ................................................................................. 13-2
Linkage Pin ....................................................................... 13-2
Gauge circuit ...................................................................62-78
Liquid gasket and screw lock agent ............................... 00-18
Gauge circuit electrical circuit check ...............................63-25
Loading and pilot and brake pump ................................. 42-17
Gauge port ........................................................................33-2
Loading circuit relief valve setting pressures .................... 43-2
Gear pump specifications .................................................32-4
Loading linkage ................................................................ 12-2
Gear train and number of teeth .........................................32-7
Loading linkage pin .......................................................... 12-4
Glass .................................................................................72-4
Loading System .............................................................. 42-23
Greasing ...........................................................................23-9
Loading system ................................................................ 42-8
Loading/Steering Circuit Relief Valve ............................... 43-2
H Loading/Steering Hydraulic Circuit (S/N 0121~) .............. 92-6
Heater and accessories ..................................................72-17 Loading/Steering Hydraulic Circuit (S/N 5035~) .............. 92-9
Hexagon bolt ...................................................................00-13 Loading/Steering Hydraulic Circuit (S/N 9001~9010) ...... 92-7
Hose band tightening torque ...........................................00-17 Loading/Steering Hydraulic Circuit (S/N 9011~) .............. 92-8
How to assemble .................................................... 13-4, 13-5 Loading/Steering Hydraulic Line (S/N 0101~0120) .......... 92-5
How to attach the probes of the circuit tester ...................63-4 Lower center pin ............................................................... 12-8
How to Use Electrical Wiring Diagram ..............................62-2 Lubrication chart ............................................................. 00-11
How to Use Manual ..........................................................00-2
How to wind a seal tape ..................................................00-19
M
Hydraulic Circuit Diagram ...............................................32-17
Machine control unit (MCU) ............................................ 62-63
Hydraulic Circuit Symbols .................................................42-4
Machine control unit (MCU) connection diagram
Hydraulic Cylinder ............................................... 42-21, 43-11
(S/N 0154~0222) ....................................................... 62-65
Hydraulic cylinder specifications .....................................42-22
Machine control unit (MCU) connection diagram
Hydraulic lines ..................................................................42-4
(S/N 0223~) ............................................................... 62-66
Hydraulic oil level check .................................................42-11
Machine control unit (MCU) failure warning ................... 62-67
Hydraulic Pump .................................................. 42-16, 42-17
Machine speed sensor input electrical circuit check ...... 63-15
Hydraulic pump bushing lubrication ................................42-20
Machine speed sensor/Engine speed sensor ................ 62-49
Hydraulic pump oil amount and steering force ...............42-75
Magnet switch ................................................................ 62-20
Hydraulic pump principle ................................................42-19
Main relief valve operation ............................................. 42-47
Hydraulic pump wear plate .............................................42-20
Main valve (tandem type) operation ............................... 52-16
Hydraulic System Diagram .............................................32-16
Make-up valve operation ........................42-51, 42-86, 42-102
Measurement instrument ................................................. 33-2 Orbitrol® .......................................................................... 42-70
Measurement procedure .....................53-3, 53-4, 53-7, 53-10 Orbitrol® feed-back mechanism operation ......................42-74
Measuring clutch oil pressure .......................................... 33-2 Orbitrol® operation .......................................................... 42-72
Measuring clutch time lag ................................................ 33-4 Orbitrol® specifications ...................................................42-71
Measuring engine oil pressure ......................................... 23-2 Orbitrol® structure ...........................................................42-70
Measuring engine speed .................................................. 23-2 Outline ..............................................................................00-4
Measuring loading circuit main relief pressure ................. 43-4 Overload relief valve operation ............................42-49, 42-86
Measuring loading circuit overload relief pressure ........... 43-5
Measuring pilot circuit relief pressure ............................... 43-6
P
Measuring pilot circuit relief pressure (reducing pressure)
Parking Brake ......................................................52-28, 53-12
(S/N 0101~, 9004~) ................................................... 43-10
Parking brake ........................................................52-2, 62-56
Measuring reducing valve setting pressure ...................... 53-4
Parking brake clearance adjustment .............................. 53-14
Measuring steering circuit main relief pressure ................ 43-8
Parking brake electrical circuit check ............................. 63-21
Measuring steering circuit overload relief pressure .......... 43-9
Parking Brake Manual Release ...................................... 52-32
Miscellaneous hydraulic symbols ..................................... 42-7
Parking brake operation ................................................. 52-30
Modalità di utilizzo dello schema dei collegamenti
Parking brake performance check ..................................53-12
elettrici (ITALIANO) ...................................................... 62-5
Parking brake solenoid valve ...............................52-31, 62-57
MODM (S/N 0154~) ....................................................... 62-99
Parking Brake Spring Chamber ...................................... 52-34
MODM function .............................................................. 62-99
Part number 32011-21500 ................................................ 72-6
MODM: Input/Output Monitor - Input/Output Signal
Part number 32011-21690 ................................................ 72-5
Correspondence Table ............................................ 62-106
Part number 32011-21700 ................................................ 72-5
Modulation at clutch switching ....................................... 62-51
Parts to be replaced periodically ......................................73-6
Modulation Mechanism .................................................. 32-23
Pilot Valve (for Steering) ................................................. 42-70
Modulator valve 1 ........................................................... 32-23
Pilot Valve (S/N 0101~0140, 9001~9020) ......................42-25
Modulator valve 2 ........................................................... 32-24
Pilot valve (S/N 0141~0172, 9021~) ...............................42-30
Modulator valve function ................................................ 32-23
Pilot valve (S/N 0173~0176) ........................................... 42-35
Modulator valve operation .............................................. 32-25
Pilot valve (S/N 0177~) ...................................................42-40
Modulator valve output electrical circuit check ............... 63-18
Pilot valve detent magnet solenoid ................................. 42-29
Modulator Valve Unit ...................................................... 32-20
Pilot valve function ...............................................42-37, 42-42
Monitor Changeover ....................................................... 62-99
Pilot valve operation ............................................42-27, 52-17
Monitor Circuit ................................................................ 62-68
Pilot valve operation (modulated position)
Monitor controller ................................................ 62-62, 62-93
............................................................. 42-32, 42-37, 42-42
Monitor controller (S/N 0101~0153, 9001~) ................... 62-71
Planetary gear ..................................................................32-6
Monitor lamp test ............................................................ 62-24
Planetary gear oil drain and refill ......................................23-6
Monitoring sensor and switch ......................................... 62-73
Possible causes for clutch time lag .................................. 33-4
Multiple Control Valve (KML35A/2T103) ........................ 42-45
Possible causes for low clutch oil pressure ......................33-3
Multiple control valve boom spool .................................. 42-54
Power flow path ................................................................32-3
Multiple control valve bucket spool ................................ 42-52
Power Flow Path in the Transmission ............................32-11
Multiple control valve main relief valve ........................... 42-47
Power Generating/Charging Circuit ................................ 62-22
Multiple control valve make-up valve ............................. 42-51
Power Line ........................................................................22-2
Multiple control valve overload relief valve ..................... 42-49
Power mode change ....................................................... 62-37
Multiple control valve specifications ............................... 42-46
Power transmission ........................................................22-24
Power up switch operation ...............................................32-6
N Pre-detent and detent magnet solenoid
Neutral ............................................................................ 42-72 ............................................................. 42-34, 42-39, 42-44
Neutral position (steering spool in "Neutral") ................. 42-79 Preload adjustment ........................................................... 23-8
Neutral relay ................................................................... 62-19 Pressure control valve ...................................................... 42-5
Neutral relay electrical circuit check ............................... 63-20 Pressure difference sensor (S/N ~0250) ........................ 32-24
Neutral starter ................................................................ 62-16 Pressure relief valve ....................................................... 72-48
Pressure switch (for Declutch) ........................................ 52-19
Pressure switch (for stop lamp) ...................................... 52-18
O
Pressure switch for inching (Declutch) ........................... 62-54
Oil flow in the torque converter line ................................ 32-19
Pressure switch specifications ........................................ 52-19
Oil flow to the clutch ....................................................... 32-19
Pressure switch structure ............................................... 52-18
Oil seal installation ........................................................... 23-9
Pressure switches .......................................................... 72-47
Operation methods ........................................................... 42-5
Principle of cooling ......................................................... 72-20
Operation monitor lamps ................................................ 62-70
Propeller Shaft .........................................................22-6, 23-3
Operation of differential gear .......................................... 22-24
Propeller shaft phase ........................................................ 23-3
Operator Seat ................................................................. 72-10
Proximity switch ..............................................................62-84
Orbit rotor operation principle ......................................... 42-76
Pump specifications ........................................................42-17
Pumps & motors ...............................................................42-4 Solenoid valve ..................................................... 42-63, 42-65
Purpose of flushing ...........................................................42-2 Solenoid valve (for auto brake circuit) ............................ 52-37
Solenoid Valve (for Fan Speed Control) ....................... 42-103
Solenoid valve (for fan speed control) operation .......... 42-103
Q
Solenoid valve operation ................................................ 52-31
QUAD (shift) switch operation ........................................62-50
Solenoid valve specifications ............................ 42-103, 52-31
QUAD switch input electrical circuit check ......................63-14
Standard measurement value .......................................... 33-3
Quantum fault code information ......................................62-30
Standard troubleshooting flowchart .................................. 63-5
Starter switch .................................................................. 62-17
R Steel plate ........................................................................ 32-9
Radiator ............................................................................22-4 Steering and Transmission Shift Lever .......................... 72-11
Radiator mount .................................................................22-5 Steering circuit relief valve setting pressures ................... 43-7
Rear Chassis ....................................................................12-5 Steering cylinder ............................................................. 42-22
Rear wiper ........................................................................72-7 Steering Line Filter ......................................................... 42-94
Receiver dryer ...................................................... 72-45, 73-6 Steering Lock Line .......................................................... 42-95
Recommended lubricants .................................................00-8 Steering pilot circuit and its operation ............................ 42-87
Recommended mixture of antifreeze ..............................00-10 Steering pump ................................................................ 42-18
Reducing valve ..................................................... 42-62, 52-7 Steering pump specifications ......................................... 42-18
Reducing Valve (Direct Acting Type) ..............................42-93 Steering speed and flow rate control .............................. 42-75
Reducing Valve (for Orbitrol®) ........................................42-93 Steering spool variable throttle ....................................... 42-81
Reducing Valve (for Pilot Pressure) ................................42-24 Steering System ............................................................. 42-69
Refrigerant ......................................................................72-20 Steering system ................................................................ 42-9
Refrigerant characteristics ..............................................72-21 Steering Valve (KVS32-A4.0/21) .................................... 42-77
Refrigerant charging procedure ......................................72-56 Steering valve flow control spool .................................... 42-82
Refrigerant charging tools ...............................................72-53 Steering valve main relief valve ...................................... 42-83
Refrigerant hose .............................................................72-50 Steering valve operation ................................................. 42-79
Relay A ...........................................................................72-49 Steering valve overload relief valve ................................ 42-85
Relay B ...........................................................................72-49 Stop Lamp Pressure Switch ........................................... 52-18
Relief Valve (Two-step Relief) ......................................42-100 Stop Valve ........................................................... 42-89, 43-13
Resistance check mode ..................................................62-87 Stop valve adjustment procedure ................................... 43-13
Reverse ..........................................................................32-14 Stop valve function ......................................................... 42-91
Reverse 1st speed ..........................................................32-14 Stop valve operation ....................................................... 42-92
Reverse 2nd speeds .......................................................32-14 Straight ........................................................................... 22-24
Reverse 3rd speed .........................................................32-15 Surge voltage and surge suppression diodes ................ 62-88
Rotor part ........................................................................42-71 Switching from automatic to manual .............................. 62-50
Symbols ............................................................................ 00-3
S
Safety precautions ............................................................00-2 T
Screw lock agent application procedure .........................00-19 T/C and T/M Oil Circulation ............................................ 32-18
Second propeller shaft alignment .....................................23-3 Tachometer circuit .......................................................... 62-81
Second propeller shaft assembly ......................................22-8 Temperature sensor ....................................................... 62-79
Sensor Mount .................................................................62-10 Thermo Sensing Valve ................................................. 42-110
Service Brake ....................................................... 52-20, 53-8 Thermo sensing valve operation .................................. 42-111
Service brake ....................................................................52-2 Third propeller shaft assembly ....................................... 22-10
Service brake friction plate .............................................52-21 Tightening torque ............................................................. 23-4
Service brake friction plate wear measurement ................53-9 Tilt case .......................................................................... 72-12
Service brake operation ..................................................52-20 Tolerance ring ................................................................ 52-25
Service brake pedal stroke adjusting mechanism ..........52-24 Torque Converter ............................................................. 32-2
Service brake performance check ....................................53-8 Torque Converter and Transmission ................................ 92-4
Service brake piston .......................................................52-23 Torque Converter Gear Pump .......................................... 32-4
Service brake steel plate ................................................52-22 Torque Converter structure .............................................. 32-3
Shift lever ........................................................................72-13 Torque multiplication ........................................................ 32-3
Shift lever forward/reverse (F/R) position .......................62-16 Transmission .................................................................... 32-5
Shift lever input electrical circuit check ...........................63-10 Transmission Control Circuit (S/N 0101~0153, 9001~)
Shift lever neutral (N) position ........................................62-16 .................................................................................... 62-42
Shift lever position ............................................................32-6 Transmission Control Circuit (S/N 0154~) ...................... 62-63
Shuttle Valve ...................................................................52-38 Transmission controller .................................................. 62-89
Shuttle valve ...................................................................42-65 Transmission Controller Abnormal Operation
Sight glass ......................................................................72-47 Judgment (S/N 0101~0153, 9001~) ............................. 63-6
Solenoid specifications ...................................................52-37 Transmission controller check .......................................... 63-6
Transmission controller failure warning .......................... 62-61
Transmission controller LED indicator ............................. 63-8
Transmission cut off (Declutch) ...................................... 62-53
Troubleshooting using the gauge manifold .................... 72-61
Turn ..................................................................... 22-25, 42-73

U
Unloader Valve ................................................................. 52-4
Unloader valve operation ................................................. 52-6
Unloader valve setting pressure ....................................... 53-2
Upper center pin ............................................................... 12-8
Utilisation des schémas des câblages électriques
(FRANÇAIS) ................................................................ 62-3

V
Valve Assembly (for Fan Motor) ..................................... 42-99
Valve part ....................................................................... 42-70
Valve Unit (Main Brake Manifold Block) ........................... 52-8
Verwendung des elektrischen Schaltplans (DEUTSCH)
...................................................................................... 62-4
Vibration Damper (OPT) ................................................ 42-58
Vibration damper function .............................................. 42-58
Vibration damper hydraulic circuit .................................. 42-58
Vibration damper hydraulic line ...................................... 42-68
Vibration damper operation ............................................ 42-59
Vibration damper system (OPT) ....................................... 42-9
Vibration damper valve assembly (Accumulator circuit)
.................................................................................... 42-64
Vibration damper valve assembly (Reducing valve circuit)
.................................................................................... 42-61
Viscous mount .................................................................. 12-7
Voltage relay .................................................................. 62-20

W
Weight of main components ........................................... 00-12
When the "controller failure" monitor lamp lights: ............ 63-6
When the compressor is replaced .................................... 73-3
When the condenser is replaced ...................................... 73-4
When the evaporator is replaced ..................................... 73-4
When the output units (solenoid valve, etc.) do not
operate properly: .......................................................... 63-6
When the pressure exceeds the preset value ................ 42-84
When the pressure is at the preset value or less ........... 42-83
Wiper motor ...................................................................... 72-8
Wiper mount ..................................................................... 72-7
Work procedure .............................................................. 72-52
MEMO
Maintenance Log

Date Machine hours Service performed

Date Machine hours Service performed
Date Machine hours Service performed
Date Machine hours Service performed
Notes
 93216-00230

115ZV
June 2009

SHOP MANUAL
SHOP MANUAL

WHEEL LOADER

Troubleshooting
115ZV
Troubleshooting
Measurement for Performance
93216-00230
Check

Powered by CUMMINS QSK19-C Engine

Serial No. 11C4-0101~

11C4-9001~
©2004 KCM Corporation. All rights reserved. Printed in Japan (k)
( ヨーロッパ・輸出一般用 )
 93216-00230
June 2004
Foreword
To ensure good machine performance, reduce failures or problems, and prolong the service life of each
component, it is necessary to operate the machine as is directed in the Operator and Maintenance Manual.

To effectively diagnose and repair the machine, it is important to follow the guidelines laid out in this Shop Manual.

Troubleshooting
Measurement for Performance Check

For the engine, refer to the engine Shop Manual provided by the engine manufacturer.

The purpose of this manual is to provide information on the product and the correct maintenance and repair
methods. Please read this manual to ensure correct troubleshooting and good repair service.

This manual will be periodically reviewed and revised for more satisfactory content. If you have any opinion or
requests, please inform us.

(1)
Safety Precautions
The most important point in providing repair service is safety. To ensure safety, observe the general cautions
described below.

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

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

●Carefully read this manual to thoroughly understand the operation method before you operate or repair the machine.

●Be sure to wear appropriate clothes and protectors, such as safety boots, hard hat and goggles.

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

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

●Be sure to release the internal pressure before you remove a pipe, such as the hydraulic oil, air, or engine coolant pipe.

●Be sure to apply the articulation stopper before starting work.

●While supporting the bottom of the chassis using a jack, be sure to support the chassis using the blocks.

●When the boom or bucket is raised or when a unit is lifted by a crane, be sure to place a stand or adequate
cribbing under the unit to prevent unexpected dropping.

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

●To remove a heavy unit (20kgf (40 lbs) or more), be sure to use a crane or other lifting tool.

●Just after stopping operation, be careful not to directly touch a hot component. You may get burned.

●Contact tire manufacturer's local dealer for tire servicing and changing.

●Always store the tools in good condition, and use them properly.

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

●Avoid the use of flammable solvents and cleaners.

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

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

(2)
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.

(3)
Symbols
For safe and effective service work, the following symbols are used for notes
and useful information in this manual.

Symbol Item Description

Shows the condition or procedure that will be

Reference
useful or efficient in doing service work.

Shows the weight of a part or unit. The weight

should be considered in selecting wire rope or
Weight
cable for slinging work or determining the working
posture.
Shows the tightening torque of a section that
Tightening
torque should be carefully tightened during assembly
work.

Shows the type of coating or adhesive and the

Coating
coating section.

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

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 performance of the product will be reduced.
The message shows the preventive measures.

Abbreviation
To save space, abbreviations are used in sentences. To understand the contents of this manual, refer to the
following abbreviation list.

E/G ………Engine B …………Battery 1st ………1st speed

T/C ………Torque converter R …………Rear or Reverse 2nd ………2nd speed
T/M ………Transmission RH …………Right hand side 3rd ………3rd speed
SOL ………Solenoid valve LH …………Left hand side 4th ………4th speed
SW ………Switch H …………High DD ………Dynamic Damper
F …………Front or Forward L …………Low M/C ………Machine
QUAD ……Quick Up and Down GND ………Ground min-1 ………RPM
Shift OPT ………Option
A/M ………Auto/Manual Assy ………Assembly

(4)
TROUBLESHOOTING ....................................................01-1
MEASUREMENT FOR PERFORMANCE CHECK .........03-1
MEMO
 Troubleshooting

01

Cautions Regarding Troubleshooting .........................................................01-3

How to Use Quick Troubleshooting Table ..................................................01-4
Safety Precautions ......................................................................................01-5
Quick Troubleshooting Table
Torque Converter and Transmission Group
1. Machine does not move in any shift lever position ...........................01-6
2. Machine does not move at a certain shift lever position ...................01-7
(or: Machine moves only in a certain shift lever position)
3. Machine moves at the neutral position .............................................01-8
(Example: Machine moves forward at the neutral position)
4. Large shock at starting or changing speeds / direction ....................01-9
5. Large time lag at starting or changing speed / direction .................01-10
6. Low power .......................................................................................01-11
(Defective torque converter or transmission)
7. Torque converter oil is overheating ................................................01-12
8. Machine moves reverse when starting to
climb up on a slope using inching brake ..........................................01-13
9. Automatic speed change is not possible ....................................... 01-14
10. QUAD switch does not work .......................................................... 01-15

01-1
Hydraulic Group
1. Boom and/or bucket do not move ...................................................01-16
2. Boom and/or bucket have low power, or move too slowly ............. 01-17
3. Excessive cylinder drift .................................................................. 01-18
4. Boom and/or bucket are spongy ......................................................01-19
(Holding bucket against the ground is not possible)
5. Bucket positioner (kick out) does not work .................................... 01-20
6. Steering is not possible or hard to steer ........................................ 01-21
7. Machine sways, or has a shock during steering ............................ 01-22
8. Abnormal noise in hydraulic system .............................................. 01-23
9. Others ..............................................................................................01-24
Brake Group
1. Brake does not work well
(In the worst case, the brake does not work at all) ........................ 01-25
2. Brake is dragging when released .................................................. 01-26
3. Stepping on the brake pedal sounds the buzzer ........................... 01-27
4. Accumulator pressure does not rise, or too slow in rising ............. 01-28
5. Parking brake does not work ......................................................... 01-29
(or: Releasing the brake is not possible)
6. Auto brake does not work .............................................................. 01-30
Electrical Group
1. Instrument panel does not indicate properly .................................. 01-31
2. Breaker of the transmission controller is turned off ....................... 01-32
Operator Station Group
1. Air conditioner..................................................................................01-33

01-2
 Cautions Regarding Troubleshooting
● Important points
The important points for troubleshooting is to The following questions will be helpful in determining
carefully read the operation manual and shop of the cause. Answer the questions to prevent an
manual to get enough information on the operation, incorrect diagnosis.
circuits, structure, and function of each component. 1. Did the problem occur suddenly?
If you have enough knowledge of each component 2. When did the operator notice the problem?
and system, you can easily determine the cause of 3. Is there any past problem that may be the cause
the problem. of this problem?
There may be various causes for each problem, 4. When the problem occurred, what kind of work
therefore experience will be needed to determine was the operator doing?
which is the actual cause of the problem. 5. Has the machine had the same kind of problem
it is necessary to know the normal operation of each before?
component. In addition, it is also important to know 6. Has the machine been repaired or inspected
the abnormal condition when a problem occurs. This recently?
chapter shows various examples of past problems, 7. Does the machine have any other problem?
and describes possible causes and remedies for
each problem. ● Troubleshooting
- Check before determination of cause
● Before starting troubleshooting A problem may be caused by poor daily
To prevent incorrect diagnosis, talk with the persons maintenance, such as lack of grease, low or
concerned, particularly with the operator, to get improper oil or a clogged filter. Be sure to check the
enough information on the problem. If possible, machine for oil level, appearance, unpleasant odor,
check the machine by repeating the symptom. etc. to prevent time loss due to other unnecessary
If the problem cannot be repeated, do not provide tests.
any repair service. - Inspection procedure
For instance, assume that the operator complains As a rule, check the easy-to-be-repaired system first
that the boom power is low, and the rim-pull is also (excluding the cases where the cause can be easily
low. In this case, there are two possible causes ; low determined based on the past experiences).
hydraulic power and low rim-pull. The remedies This machine is controlled by electrical, hydraulic,
against both causes are much different from each and mechanical systems. The most easy-to-be-
other. repaired system is the electrical system. Check the
If you hastily determine the wrong cause without electrical system first. If no problem is detected in
checking the actual condition of the problem, it will the electrical system, check the hydraulic system,
take too much time and expense to solve the and then the mechanical system.
problem. As a result, you will not be trusted by the
user.

01-3
 How to Use Quick Troubleshooting Table
To immediately determine the cause of the problem
without disassembling parts, use the quick
troubleshooting table. From the problem explained by
the user and the check points written in the table, you
can immediately determine the cause of the problem.

● How to use quick troubleshooting table

(1) According to the problem explained by the user,
open the quick troubleshooting table to the page
where the corresponding problem is described.
(2) Check the machine according to the
"Symptoms/check point" field in the table. Start
from the most easily checked point.
(3) Operate the machine, and write the check marks
" " in the corresponding circles " " if the
problem occurs.
(4) Generally, the possible cause that has many check
marks will be actual cause. If two or more possible
causes have several check marks, check each
possible cause to prevent an incorrect diagnosis.
In this case, start from the most easily checked
item.

01-4
Safety Precautions 115ZV TROUBLESHOOTING 01

Safety Precautions

DANGER WARNING
Entering the articulation area of the machine Service work under the machine may cause an
body while the engine is running may cause accident resulting in injury or death. To prevent
severe accidents. such an accident, be sure to observe the
Make sure to stop the engine, pull out the starter following items.
key, and attach a "DO NOT OPERATE!" tag to the - Park the machine on level ground.
cab before entering the articulation area. - Apply the parking brake.
- Block the tires with chocks to prevent the tires
WARNING from moving.
Unexpected movement of the machine may - Stop the engine.
cause an accident resulting in injury or death. - Give signals to the person in the cab during the
Therefore, to provide repair service with the work.
engine running, be sure to observe the following
items. CAUTION
- Park the machine on level ground. Do not touch the fan or V-belt of the engine or a
- Apply the parking brake. high-temperature section if the engine is running.
- Block the tires with chocks to prevent the tires An accident resulting in injury may occur.
from moving. Be sure to stop the engine before you open the
- Determine the signals between the service man. side cover of the engine room.
- Prohibit any person from walking into Avoid high temperature components even when
dangerous areas. the engine is stopped.
- Near articulation areas of the machine
- Under the machine CAUTION
- Around the engine Be careful not to be burnt by bursting high
- In front of or behind the machine pressure oil.
Release the pressure remaining inside the circuit
WARNING and open the cap of the hydraulic oil tank before
Standing under the boom or bucket during removing the plug from the pressure
service work is dangerous. An accident resulting measurement port so that the internal pressure
in injury or death may be caused. of the hydraulic oil tank is released and burst of
To prevent such an accident, be sure to observe the high pressure oil can be prevented.
the following items.
- Park the machine on level ground.
- Apply the parking brake.
- Block the tires with chocks to prevent the tires
from moving.
- Place a stand under the boom to support it.
- Apply the safety look of the boom and bucket
control lever provided in the cab.
- Remove the starter key, and attach a "DO NOT
OPERATE!" tag to the cab.

01-5
Torque Converter and Transmission Group 115ZV TROUBLESHOOTING 01

Torque Converter and Transmission Group

1. Machine dose not move in any shift lever

Setting the T/M(transmission)cut-off switch to OFF allows normal operation

position

Even if the breaker of the controller is turned ON, the breaker will be
Check before starting work
(1) Check that the parking brake is released.
(2) Check that the solenoid valve for auto brake is
released.

Torque converter oil becomes milky and cloudy in color

(3) Check the torque converter oil level.

Symptoms/check point
Low clutch oil pressure at all the shift lever positions

Temperature of the torque converter oil is too high

(4) Check the fuse of the controller system.
(5) Check that the circuit protector of the controller is

Pump produces an abnormal(shrieking)noise

ON.
(6) Check the 70A fusible link.

Filter of the torque converter is clogged

The controller LED "X" indicator is OFF

(If the 70A fusible link is off, no electrical circuits
will operate except horn circuit and hazard

Controller LED "I" indicator is ON

flasher [opt.].)

Pump is extremely heated

immediately turned OFF

Possible cause Solution

Air drawn into suction line of the torque converter pump Tightening hose band
Defective torque converter pump Pump replacement
Damaged torque converter Disassembly & repair
Sticking clutch pressure modulator valve (1) Disassembly & repair
Malfunctioning inching pressure switch Switch replacement
Defective controller Controller replacement
Neutral relay, controller fault relay, parking switch wirings
short circuited Repairing wiring

Restricted suction line - pinched, plugged, or internally

defective. Replace hose

01-6
 Seized clutch
Clutch slipping
lever position

lever position)

Defective controller
Clutch oil leaks internally
Possible cause

Damaged clutch solenoid valve diode

Short circuited clutch solenoid or wiring

Coil of clutch solenoid valve is defective
Torque Converter and Transmission Group

Clutch solenoid valve sticking in ON position

Clutch solenoid valve sticking in OFF position
Harness of clutch solenoid valve disconnected
(OR:Machine moves only in a certain shift
2. Machine dose not move at a certain shift

Shift lever switch sticking in ON (regardless of position)

Symptoms/check point

Shift lever switch sticking in OFF (regardless of position)

Machine does not move at a certain shift lever position, but moves at all the other positions

01-7
Machine moves at a certain shift lever position, but hesitates to move at any other positions
115ZV

Torque converter oil looks and smells as if it was scorched (black)

Clutch oil pressure is low at a certain position only. At all the other positions, the pressure is normal
Resistance of the solenoid valve coil is infinite Ω
24V power is not supplied to the solenoid valve (output LED OK)
Even when pressing solenoid valve, machine does not move
Clutch oil pressure is always high despite shift lever position and output LED
At a certain shift lever position, the controller input LED is turned on and will not go out
Clutch can be engaged at a certain shift lever position, though the clutch will not be engaged at any other position
Controller input LED will not light at a certain shift lever position
Breaker of the controller will be turned off at a certain shift lever position
Controller IN and OUT LED do not correspond with each other, controller failure light on dash is ON
Machine may move even when shift lever is in "NEUTRAL"

& repair
& repair
& repair

Controller
Shift lever
Shift lever

replacement
replacement
replacement
replacement
replacement
replacement
replacement
Disassembly
Disassembly
Disassembly

Repair cable
Repair cable
Solution

Solenoid valve
Solenoid valve
Solenoid valve
Solenoid valve
TROUBLESHOOTING 01
Torque Converter and Transmission Group 115ZV TROUBLESHOOTING 01

3. Machine moves at the neutral position

When the lever is shifted to the reverse position, the machine does not move
When the lever is shifted to the forward position, the machine moves forward

Controller output LED "F" will go out when shifted to reverse (output LED "R"
(Example: Machine moves forward at the
neutral position)

Check before starting work

Controller output LED "F" indicator is on and will not go out

(1) Check that the ground is level

Controller input LED "F" indicator is on and will not go out

Symptoms/check point

reverse (as if the brake is applied)

Oil is black and smells scorched

will not turn on).

Possible cause Solution

T/M disassembly and
Seized clutch on forward side * repair
Malfunctioning forward solenoid valve Solenoid valve
(sticking at ON position) * replacement
Defective controller(malfunctioned after outputting "F") * Controller replacement
Defective shift lever (switch stuck in "F" position) * Shift lever replacement
* The same possible cause but involving the reverse clutch or circuit could occur with the opposite symptoms.
* Remarks

01-8
Torque Converter and Transmission Group 115ZV TROUBLESHOOTING 01

4. Large shock at starting or changing

speeds / direction

Main oil pressure rises too quickly at all the shift lever positions
Controller output LED "DC" indicator does not light properly

Resistance of the modulator valve (2) coil is infinite Ω

Symptoms/check point

Temperature of the torque converter oil is too high

Large shock at a certain shift lever position only
Large shock at all the shift lever positions

Line filter is clogged

Possible cause Solution

Modulator valve (1) sticking in ON position Disassembly&repair
Harness of modulator valve (2) disconnected Repair
Modulator valve (2) sticking in OFF position Disassembly & repair
Defective controller Controller replacement
T/M disassembly and
Damaged or worn clutch disk repair

01-9
 speed / direction

Defective controller
Internally leaked clutch oil
(or sticking in OFF position)
Defective torque converter pump
Possible cause

Malfunctioning inching pressure switch

Malfunctioning pressure difference sensor
Torque Converter and Transmission Group

5. Large time lag at starting or changing

Harness of modulator valve (1) disconnected

Restricted suction line-pinched, internally defective
Symptoms/check point
Large time lag at all the shift lever positions

01-10
Main oil pressure rises too slowly at all the shift lever positions
115ZV

Controller output LED "DC" indicator does not light properly

Main oil pressure is too low at all the shift lever positions
Large time lag at a certain shift lever position only
Clutch oil pressure is too low or rises too slowly at a certain shift lever
position only
Time lag just after using the inching brake
No change even if all the wirings are disconnected
Torque converter oil overheats
Abnormal noise from charge pump (shrieking)
Charge pump extremely heated

repair
Replace hose

Replace sensor
Solution
Pump replacement

Switch replacement
T/M disassembly and
Disassembly & repair

Controller replacement
TROUBLESHOOTING 01
Torque Converter and Transmission Group 115ZV TROUBLESHOOTING 01

6. Low power
(Defective torque converter or
transmission)

Machine moves even if the shift lever is set to the neutral position*
Check before starting work

Clutch oil pressure is too low at a certain shift lever position

(1) Check the parking brake and service brake for

Silver powder (Aluminum) is on the line filter and strainer

Output power is low at a certain shift lever position only
dragging.

Torque converter oil is discolored or emits nasty smell

Symptoms/check point
(2) Check the torque converter oil level.

Temperature of the torque converter oil is too high

Large time lag at a certain shift lever position only
(3) Check that no unusual load is applied to the

Output power is low at all the shift lever positions

Torque converter oil is milky and cloudy in color

hydraulic line(like excessive pilot pressure).

Pump produces an abnormal(shrieking)noise

(4) Check that the engine speed is standard value.

Pump is extremely heated

Possible cause Solution

Tightening suction hose
Air drawn into suction line of torque converter band
Restricted suction line-pinched, internally defective Replace hose
T/C disassembly and
Broken torque converter turbine and pump repair
Torque converter internal pressure too low Regulator valve check
T/M disassembly and
Seized clutch repair
T/M disassembly and
Clutch slipping repair
T/M disassembly and
Internally leaking clutch oil repair
Harness of modulator valve (1) disconnected Disassembly & repair
(or sticking in OFF position)
Defective controller Controller replacement
* if the seized clutch is Forward or Reverse clutch.
* Remarks

01-11
Torque Converter and Transmission Group 115ZV TROUBLESHOOTING 01

Thermometer in T/C out line indicates less than 250°F/120°C when gauge or light indicates overheat
7. Torque converter oil is overheating

Machine does not move at a certain shift lever position (or dragging is felt)

Less difference in torque converter oil temperature between cooler inlet and outlet
Foreign material is on the filter-especially silver powder (Aluminum)
Check before starting work
(1) Check the torque converter oil level.
Oil lever too high.
(2) Check the engine coolant for overheat.

Output power is too small at a certain shift lever position

Torque converter oil is discolored or emits nasty smell
(3) Check the pressures - adjust to specification.

Engine speed at no load or during stall test is too low

Symptoms/check point
Torque converter oil is milky and cloudy in color

Pump produces an abnormal(shrieking)noise

Parking brake is excessively hot/discolored

Torque converter inlet pressure is too low
Clutch oil pressure is too low

Pump is extremely heated

Possible cause Solution

Tightening hose
Air drawn into suction line of torque converter band

Internally torque converter leakage T/C disassembly

and repair
T/C disassembly
Damaged torque converter and repair

Torque converter pump discharge amount too small T/C pump disassembly
and repair
Seized clutch T/M disassembly
and repair
T/M disassembly
Clutch slipping
and repair

Scale deposited in water line of torque converter cooler Cooler cleaning

Restricted suction line-pinched, internally defective Replace hose

Replace
Wrong oil viscosity is used
w/proper oil
Test/repair
Service or parking brake dragging brake circuit
Operator is using too high gear for loading Train operator
Test/replace
Incorrect indication of gauge (no alarm)
gauge or sender
Alarm switch defective (gauge in green zone) Replace switch
Contamination in oil cooler (oil side) Replace cooler
Engine speed too low / Engine power too low

01-12
Torque Converter and Transmission Group 115ZV TROUBLESHOOTING 01

8. Machine moves reverse when starting to

After pedal release, too much time is required to turn off the controller LED"I"
climb up on a slope using inching brake

Symptoms/check point

indicator

Possible cause Solution

Refer to description
Large time lag in clutch engagement of time lag
Delay in resetting inching pressure switch Switch replacement

01-13
Torque Converter and Transmission Group 115ZV TROUBLESHOOTING 01

9. Automatic speed change is not possible

Controller LED for machine speed does not change even if machine speed is
Actual speed increase or reduction does not correspond with the set speed
Speed is fixed to 2nd speed, and automatic speed change is not possible

One or more planetaries are excessively hot/parking brake is hot or

Check before starting work

Speed is fixed to 3nd speed, and is not increased to 4th speed

(1) Manually change the speed from 1st speed to
3rd speed. If manual speed change is
impossible, refer to "Machine does not move at a
certain shift lever position."

Symptoms/check point

Speed is properly increased on a downward slope

Controller input LED "A" indicator does not light

discolored
changed

Possible cause Solution

Defective shift lever "A" position or defective wiring to Shift lever replacement
controller or repairing wire
Sensor replacement or
Damaged speed sensor or disconnected sensor repairing wire
Speed sensor signal output error or improperly Sensor replacement or
adjusted speed sensor readjustment
Defective controller Controller replacement
Low machine speed (engine output power too low) Inspection & repair
Parking or service brakes dragging Test/repair brake circuit

01-14
Torque Converter and Transmission Group 115ZV TROUBLESHOOTING 01

10. QUAD switch does not work

Controller input LED "S" indicator lights when the QUAD switch is turned on
Controller input LED "S" indicator does not light when the QUAD switch is
Check before starting work
(1) Check that the QUAD switch is being used only at
the 2nd forward/reverse speed position.
At other positions, shifting down is not possible.
(2) Check the fuses.

Symptoms/check point

turned on

Possible cause Solution

Defective switch Switch replacement
Disconnected switch or wiring Repair wire
Defective controller Controller replacement

01-15
Hydraulic Group 115ZV TROUBLESHOOTING 01

Hydraulic Group
1. Boom and/or bucket do not move

Boom and bucket move with no load, though they do not move when loaded

Bucket moves if the overload relief valves are exchanged with each other *
Cylinder does not operate, though oil is discharged from the return port
Boom and bucket do not move normally while the engine runs idle but

Main relief pressure is too low when the boom or bucket is operating
Check before starting work
(1) Check the oil level.

After warm-up, it is possible to operate the bucket and boom

(2) Check that the loading control lock lever is fully
released.
(3) Check that the pilot valve inline filter is not

Symptoms/check point

appears to move normally while it runs at full speed

clogged.

Either the boom or bucket does not move

Main relief valve produces a noise

Steering is not possible either

Pilot relief pressure is too low

No main relief pressure built

No pilot relief pressure built

Pump is extremely heated

Possible cause Solution
Pump
Broken pump drive shaft replacement
Disassembly
Internally damaged steering pump
Pump

& repair
Disassembly
Internally damaged main pump & repair
Disassembly
Internally damaged pilot pump & repair
Disassembly
Multiple control valve

Main relief valve internal oil leakage or low setting pressure & readjustment
Disassembly
Overload relief valve internal oil leakage or low setting pressure & readjustment
Plunger
Multiple control valve spool sticking replacement
Disassembly
Defective valve assembly reducing valve & readjustment
Disassembly
Internally damaged cylinder & repair

* Exchange of the overlord relief valve means that the valves should be changed between the rod and bottom sides.
* Remarks

01-16
Hydraulic Group 115ZV TROUBLESHOOTING 01

2. Boom and/or bucket have low power, or

move too slowly

Check before starting work

(1) Check the oil level.
(2) Check that the loading control lock lever is fully

Either the boom and bucket does not operate properly

released.

Symptoms/check point

Both the boom and bucket do not operate properly

(3) Check that the engine speed is standard value.
(4) Check that the machine does not move if the shift

Only bucket "roll back" operation is abnormal

Oil is foamy or milky looking after operation.

lever of the transmission is at the natural position.
Steering system does not operate properly
Dragging/seized clutches reduce power available
to hydraulics.
(5) Check that the machine rolls freely in neutral. Steering system operates properly

Main relief valve produces a noise

If the brakes, service or parking, drag it reduces

Pump makes noise (shrieking)

the power available to hydraulics when the

Bucket drifts down when full

Pump is extremely heated
machine is moving.(Static testing will show
normal hydraulic power and speed.)
(6) Check that the pilot valve filter is not clogged.

Possible cause Solution

Internally damaged steering pump Disassembly & repair
Internally damaged main pump Disassembly & repair
Main relief valve internal oil leakage or low setting Disassembly
pressure & readjustment
Internal oil leakage from overload relief valve for bucket Disassembly
bottom side & readjustment
Internally damaged cylinder Disassembly & repair
Warm up hydraulics
Oil is cold, wrong oil viscosity (too thick) Replace oil w/proper oil
Check & repair
Suction side air leak-clamp, hose, o-rings
suction line
Check & repair
Suction line pinched or internally defective suction line
Defective valve assembly reducing valve Disassembly & readjustment
Bucket or boom spool does not move smoothly Disassembly & repair

01-17
Hydraulic Group 115ZV TROUBLESHOOTING 01

3. Excessive cylinder drift

When the piping for cylinder rod side is removed, pressurised oil spouts out *
In the case that the overlord relief valve is switched or replaced, excessive

Front wheels drift down when the front wheels are lifted off the ground by
The maximum drift rate is measured according to
instructions on "Measuring Cylinder Drift".

Symptoms/check point

means of the boom cylinder

Excessive drift of bucket
Excessive drift of boom

drift stops

Possible cause Solution

Internal boom cylinder piston seal oil leakage Seal replacement
Internal bucket cylinder piston seal oil leakage Seal replacement
Internal oil leakage from multiple control valve main spool Disassembly & repair
Internal oil leakage from multiple control valve overload Disassembly & repair
relief valve
* This test may cause a serious accident. The test must be done carefully.
* Remarks

01-18
Hydraulic Group 115ZV TROUBLESHOOTING 01

4. Boom and /or bucket are spongy

Boom and bucket are strong enough if the engine runs at the full speed while
During digging operation, the bucket tilts back even though the lever is at the

Bucket cannot support the lifted front wheels, or the lifted front wheels soon

Boom cannot support the lifted front wheels, or the lifted front wheels soon
In case that the overload relief valves are switched*, the boom and bucket
(Holding bucket against the ground is not
possible-front wheels off the ground)

Symptoms/check point

are strong enough to support the front wheels.

Boom is spongy just after quick lowering

Bucket is spongy just after dumping
Overload relief pressure is too low

dumping or lowering
neutral position

drop

drop
Possible cause Solution
Internal oil leakage from overload relief valve for bucket Disassembly & repair
rod side
Internal oil leakage from make-up valve for bucket rod side Disassembly & repair
Make-up valve does not open on bucket rod side Disassembly & repair
Internal oil leakage from make-up valve for boom rod side Disassembly & repair
Make-up valve opening impossible on boom rod side Disassembly & repair
* Regarding check point above, switching the overload relief valves means that the valves should be changed between
the rod and bottom sides of the bucket circuit.
* Remarks

01-19
Hydraulic Group 115ZV TROUBLESHOOTING 01

5. Bucket positioner (kick-out) does not work

Remove the connector of the proximity switch, and connect the wire harness (brown/white), from the
pilot valve, of the connector on the chassis side to the ground. Check that the lever is held properly.
LED lamp of the proximity switch does not light (starter switch ON &
Check before starting work
(1) Check the fuses.
(2) Check that the distance between the proximity

Magnet coil resistance value is indicated as infinity or 0 Ω

switch and detection bar is properly adjusted.
5 ± 2mm (0.2 ± 0.08in)

Symptoms/check point
(3) Check all the connectors of the electrical power
line to be sure they are properly connected.

metal plate in front of proximity switch face)

Possible cause Solution

Proximity switch
Defective proximity switch replacement
Broken detent solenoid coil inside pilot valve Magnet replacement
Disconnected electrical power line Repair

01-20
Hydraulic Group 115ZV TROUBLESHOOTING 01

6. Steering is not possible or hard to steer

If the overload relief valves are exchanged*, steering problem switches sides
Steering is not possible (or hard) in both the right and left directions
Check before starting work
(1) Check the oil level in the hydraulic tank.
(2) Check that the stop bolts for the stop valves are

Steering is not possible at both the idling and full speeds

properly adjusted.

Increasing the engine speed enables smooth operation

(3) Check operating conditions. Full brake

Steering is possible in either the right or left direction

Symptoms/check point
Steering wheel does not rotate or is heavy to rotate
application & heavy loading may create hard
steering even when steering system is normal.
(4) Measure steering wheel force to see if it is
greater than normal.
(5) Check that the pilot valve inline filter is not

Steering relief valve produces a noise

clogged. Steering wheel is too loose (too light)

Overload relief pressure is too low

Steering relief pressure is too low

Pump is extremely heated

Boom is too slow in rising

Possible cause Solution

Internally damaged Orbitrol ® Disassembly & repair
Sticking stop valve spool Disassembly & repair
Internally damaged steering pump
Disassembly & repair
(deteriorated performance)
Malfunctioning steering valve or flow control spool Disassembly & repair

Defective main relief valve Disassembly & repair

Defective overload relief valve Disassembly & repair

Defective steering cylinder Disassembly & repair

Suction line is pinched or internally defective Check & repair

Warm up hydraulics
Cold oil / viscosity too thick for weather
Replace oil w/proper oil
Defective steering pilot line reducing valve Disassembly & repair
* Regarding check point above, exchange of the overload relief valve means that the valves should be changed
between the left and right sides. The problem will switch sides also (weak steering to the left will, after exchange, become
weak steering to the right).
* Remarks

01-21
Hydraulic Group 115ZV TROUBLESHOOTING 01

7. Machine sways, or has a shock during

steering

While the machine is travelling straight, the machine sways even if the

Shock is noticed only when steering fully to right or left

Symptoms/check point

Shock is applied to the machine after quick steering

Steering cylinders or circuit recently repaired

Machine sways after quick steering
steering wheel is held steady

Possible cause Solution

Pin replacement or shim
Loose steering cylinder pin * add
Use of equal diameter
Tire having different diameter tires
Large difference in air pressure of tires Air pressure adjustment

Steering stopper bolt or bolts misadjusted or missing Adjust stopper bolts

Steer full L & R several

Air trapped in steering cylinders times to purge air
* Have an operator quickly move the steering wheel right and left a few degrees. If the cylinder pin moves back & forth
replace the pin & bushing. If the cylinders jump up & down add shims.
* Remarks

01-22
Hydraulic Group 115ZV TROUBLESHOOTING 01

8. Abnormal noise in hydraulic system

Increasing the engine speed emits a whining sound-Hydraulics slow

Noise may vary with engine speed or circuit being used
Symptoms/check point
Pump emits a shrieking sound

Possible cause Solution

Hose band tightening
Air drawn into pump suction line and inspection
Internally broken pump Disassembly & repair
High-pressure hose contact with chassis - loose sheet Hose clamp check
metal and repair
Suction hose pinched or internally defective Inspect or replace hose
Suction line or strainer restricted Drain & inspect tank

01-23
Hydraulic Group 115ZV TROUBLESHOOTING 01

When the boom lever is switched from"DOWN" to "NEUTRAL" , the boom will
9. Others

When the boom lever is set to "UP" position, the boom will drop slightly first

When the bucket lever is set to "Roll-back" position, the bucket will be

Engine cooling water (torque converter oil) overheats.

Symptoms/check point

Boom or bucket control lever is too tight or too loose

Hydraulic oil is mixed with the torque converter oil

dumped slightly down first and then tilt back

Hydraulic cylinder packings leak repeatedly

(Fan motor does not switch to high speed.)

Hydraulic oil is foaming
continue to lower*

Oil milky white

and then rise

Possible cause Solution

Defective (incompletely closed) load check valve in Disassembly & repair
multiple control valve boom line
Defective (incompletely closed) load check valve in Disassembly & repair
multiple control valve bucket line
Clogged orifice of adapter in boom line* Disassembly & repair
Malfunctioning multiple control valve or pilot valve is Disassembly & repair
sticking
Tightening hose
Air drawn into pump suction line
band
Pump disassembly
Damaged hydraulic oil pump
and repair
Excessive hydraulic oil temp, due to cooler problems or Test cooling
improper operation Change operation
Water in hydraulic oil Drain & replace oil
Defective solenoid valve in fan motor circuit (~ S/N 9010) Disassembly & repair
Defective two-step relief valve (~ S/N 9010) Disassembly & repair
Defective fan motor relay (~ S/N 9010) Relay replacement
Defective wiring between ECM and fan motor relay (~ S/N 9010) Repair
Defective thermo sensing valve (S/N 9011 ~) Disassembly & repair
Defective relief valve (S/N 9011 ~) Check & repair
* Very cold or thick oil will also cause this symptom. If the problem stops when the oil warms up or the proper viscosity
oil is used the orifice is normal. Clogged adapter orifice will cause slow boom response in both up and down
* Remarks

directions.

01-24
Brake Group 115ZV TROUBLESHOOTING 01

Brake Group

When the pedal is pressed, the brake oil pressure greatly deffers between the
1. Brake does not work well

Measure the wear of the brake disk using calipers. The obtained wear value

Machine turns when the brake is applied suddenly (the steering wheel slips
(In the worst case, the brake does not work

Both the right and left pedals have low breaking resistance when pressed
at all)

Check before starting work

Brake is hard to work when the right pedal is depressed

(1) Check the Nitrogen gas pressure in the

Symptoms/check point
accumulator.
(2) Check the brake piping for leakage

front axle brake and rear axle brake.

is less than the specified limit value.

Brake pedal stroke is large

from our hands)

Possible cause Solution

Worn brake disk Disassembly & repair
Defective accumulator Disassembly & repair
Sticking brake valve spool Disassembly & repair
Damaged brake oil pipe Pipe replacement
Improperly aligned oil passages inside wheel hub Remove & realign
Damaged brake piston seals one wheel Seal replacement
Defective pedal stroke adjustment Disassembly & repair

01-25
Brake Group 115ZV TROUBLESHOOTING 01

2. Brake is dragging when released

Check before starting work

(1) Check that the solenoid valve for auto brake is
released.

How to check dragging:

Symptoms/check point
(1) Check that the cover of the planetary gear is too
hot(more than 100°C [212°F]).

Either the left or right wheel causes dragging

Either the front or rear axle causes dragging
(2) Jack up the tires, and check that manual rotation

Manual rotation of the tire is not possible

Manual rotation of the tire is possible

Possible cause Solution

Stepping on brake pedal during traveling (Riding the brakes) Instruction for operator
Insufficient return of brake pedal Disassembly & repair
Disassembly, repair,
Incomplete air bleeding from the brake oil circuit
and air bleeding
Distorted brake disk due to seizure Disassembly & repair
Insufficient return of brake piston Disassembly & repair
Non-returned brake piston after replacement of brake disk Disassembly & repair
Defective pedal stroke adjustment Disassembly & repair
Defective brake valve Disassembly & repair

01-26
Brake Group 115ZV TROUBLESHOOTING 01

3. Stepping on the brake pedal sounds the

buzzer

Conditions for buzzer sounding:

(1) Low accumulator pressure

Too much time is required for accumulator gas charging

Buzzer sounds each time the brake pedal is stepped on

Buzzer sounds when the pedal is repeatedly depressed

[3.9MPa (40kgf/cm2) (569 psi) or less].

Symptoms/check point
Check before starting work:
(1) Check the accumulator Nitrogen gas pressure

Pedal resistance is too low when depressed

(2) Step on the pedal, and check that oil is not

Unloader valve on-load pressure is too low

leaking.

Auto brake does not work well

Parking brake is not released
External pipe is oily, leaking

Possible cause Solution

Insufficient Nitrogen gas pressure in main accumulator Adjust gas pressure
Inspection &
Low unloader valve switching pressure readjustment
Inspection &
Delay in working unloader valve readjustment
Large amount of oil leakage from brake piping Disassembly & repair
Defective low oil pressure warning switch Replace switch
Defective pilot pump Replace pump
Brake oil piping damaged or loose Repair / tightening

01-27
Brake Group 115ZV TROUBLESHOOTING 01

4. Accumulator pressure does not rise, or too

slow in rising.

Low accumulator pressure in a certain accumulator only

Symptoms/check point
Low accumulator pressure in all two accumulator

Possible cause Solution

Low unloader valve switching pressure Inspection & readjustment
Defective unloader valve Disassembly & repair
Internally damaged accumulator Disassembly & repair
Defective pilot pump Replace pump

01-28
Brake Group 115ZV TROUBLESHOOTING 01

Even if the manual release button of solenoid valve for auto brake is pushed in,
Turning on /off the parking brake switch causes a solenoid valve emitting noise
5. Parking brake does not work

Turning on /off the parking brake switch activates the link under the cylinder
(or: Releasing the brake is not possible)

Setting the manual release knob of the solenoid valve to ON releases the
Brake does not work even if the parking switch is turned to "ON" position

Coil of the solenoid valve has extremely high or zero resistance

Check before starting work:
(1) Check the fuses of the electrical system.

Heavy movement of solenoid valve manual release knob

(2) Check the main accumulator pressure.

Symptoms/check point

Parking brake remains unreleased

the auto brake does not work

parking brake

Possible cause Solution

Solenoid valve
Defective coil of parking solenoid valve replacement
Solenoid valve
Sticking spool of parking solenoid valve replacement
Oil leaking from line between solenoid valve and Inspection & repair
parking brake spring chamber
Defective parking brake switch Switch replacement
Disconnected or defective electrical line Repair cable
Sticking parking brake spring chamber Inspection & repair
Defective link between parking brake spring chamber Inspection & repair
and brake drum
Worn brake lining Readjustment
Accumulator pressure in main accumulator is low Inspection & repair

01-29
Brake Group 115ZV TROUBLESHOOTING 01

6. Auto brake does not work

Auto brake works when the manual release button of solenoid valve for auto

Heavy movement of the manual release button of solenoid valve for auto
Check before starting work

Brake does not work well even when the brake pedal is pressed

Controller output LED "BRK" will not light even when shifted to
(1) Check the fuses of the electrical system.
(2) Check the main accumulator pressure.

Symptoms/check point

Coil of the solenoid valve has infinite resistance

It is not possible to release the parking brake

reverse/forward with machine high speed

Automatic speed change is unstable
brake is pushed in

brake

Possible cause Solution

Defective controller Replacement
Defective machine speed sensor Replacement
Disconnected or defective electrical line Inspection & repair
Defective coil of auto brake solenoid valve Replacement
Sticking spool of auto brake solenoid valve Inspection & repair
Accumulator pressure in main accumulator is low Inspection & repair
Defective service brake system Inspection & repair

01-30
Electrical Group 115ZV TROUBLESHOOTING 01

Electrical Group

T/M(transmission) solenoid valve does not operate based on the speed set by the shift lever
1. Instrument panel does not indicate

Speed indicated on the instrument panel does not correspond with the speed set by the shift lever
Two or more monitor lamps will not light after setting the starter key to ON
properly

One of the monitor lamps will not light after setting the starter key to ON
Check before starting work

During operation, two or more monitor lamps light improperly *

(1) Check the fuses.

During operation, one of the monitor lamps lights improperly *

(2) Lamp test
Turn the starter switch key to "ON" position and
leave it there for 3 seconds. Check the indicator

Pointers of all the gauges are deflected to their limits

Symptoms/check point
lamps.

One of the gauges does not indicate properly *

One of the gauge pointers does not move
Pointer of the tachometer does not move

All the gauge pointers do not move

Hour meter does not operate

Possible cause Solution

Bulb of monitor lamp burnt out Bulb replacement
Defective sensor or improper wiring Sensor replacement
Disconnected or defective electrical circuit Repairing cable
Connector check and
Loose connector
re-connection
T/M controller breaker turned off Inspection & repair
T/M controller failure alarm turned on Inspection & repair
Defective T/M controller Controller replacement
Defective inside mechanism of gauge or meter Replacement
Defective board of instrument panel Replacement
T/M solenoid valves improperly connected Properly connect
Gauge circuit grounded improperly Inspection & repair
* If the gauge and warning lamps do not agree there probably is a defect in the wiring. Stop immediately and diagnose
the defect.
* Remarks

01-31
Electrical Group 115ZV TROUBLESHOOTING 01

2. Breaker of the transmission controller is

In the solenoid valve continuity test, change the positive and negative sides

Both the forward and reverse shift lever position enable the engine to start
turned off

Parking brake remains unreleased regardless of the parking brake switch

to each other. After that, power is still supplied to the solenoid valve

Breaker is turned off when a certain speed or direction is selected

Breaker is turned off if the machine sways during travelling
Coil of the solenoid valve has extremely low resistance
Symptoms/check point
Breaker is turned off immedeately after turning on

position

Possible cause Solution

Transmission controller power line contact with chassis
Inspection & repair
(Wire chaffed or pinched by other components, etc.)
Transmission controller power line occasional contact Inspection & repair
with chassis
Solenoid valve
Clutch solenoid valve coil shortcircuited replacement
Solenoid valve
Clutch solenoid valve diode failed replacement
Neutral or controller failure relay power line contact with Inspection & repair
chassis
Neutral or controller failure relay power line occasional
Inspection & repair
contact with chassis
Parking brake solenoid valve power line contact with Inspection & repair
chassis
Parking brake solenoid valve power line occasional Inspection & repair
contact with chassis
Monitor controller power line contact with chassis Inspection & repair
Monitor controller power line occasional contact with Inspection & repair
chassis

01-32
Operator Station Group 115ZV TROUBLESHOOTING 01

Operator Station Group

1. Air conditioner <Basic check>
<Fault diagnosis procedure> 1) Check of control mechanism
Operate the switch arranged on the control panel, to
check that it is operable smoothly and securely.
Hearing check

2) Check of V-belt
Phenomenon check
Check that the V-belt is tensioned properly, and that
it is not damaged.
Basic check
- Control
mechanism
In accordance with fault phenomenon 3) Check of coolant level through sight glass
- V-belt
- Sight glass When the air bubble is observed a lot through sight
- Piping glass, the coolant is probably insufficient.
Coolant cycle check Electrical connection
In such a case, therefore, perform the checking,
- Hydraulic pressure system
check check using a gauge manifold.
- Gas leak check

Sight glass
Repair/check

Receiver joint
End 95ZVE01002

Receiver
drier 95ZVE01003

4) Check of piping connection

At the piping connection where the oil stain is seen,
there is probably a coolant leakage.
In such a case, remove the stain, and then check for
gas leakage.

01-33
 Clogged inner air filter Clean the filter.
Clogged outer air filter Clean the filter.
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 the A-1.
Blower motor Adhesion of dust to surface of evaporator Clean the surface of evaporator.
rotation
Operator Station Group

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
Blower motor position. Blown fuse the fuse with that of the same capacity. See the B-1.
rotation Blower main relay failure Replace the blower main relay with a new one.
failure Blower motor failure Replace the blower main relay 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 looked motor
Normal pressure Mixing of outside air Close the window and door.

01-34
115ZV

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 the C-2.
Too low pressure at high-pressure side(Pressure is not increased to approx. 981kPa[10kgf/cm2] or over) See the C-3.
Pressure error Too low pressure at low-pressure side(Pressure is decreased to approx. 49kPa[0.5kgf/cm2] or less See the C-4.

Cooling failure
Normal air High pressure both at high-pressure side and low-pressure side See the C-5.
flow rate Low pressure both at high-pressure side and low-pressure side Insufficient coolant

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 the D-1.
Clutch engagement failure due to Check the wiring. See the 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 the C-1.
With diagnostic display:
E51 (Coolant high/lower Operation of low-pressure
pressure error) See the C-3.
function

95ZVE01001
TROUBLESHOOTING 01
 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
Operator Station Group

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 ± 5mm).
A-1
12 ± 5 mm

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 system.

01-35
115ZV

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 coolant Discharge the coolant to proper level.
Mixing of air during refrigerating cycle Fully discharge the coolant, and execute the
evacuation, and fill the coolant again to proper level.

Over-filled coolant Discharge the coolant 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 bulb

95ZVE01004
TROUBLESHOOTING 01
 Unusually low outside air temperature
Limited coolant Limited amount of coolant filled Fill the coolant to proper level.
Gas leakage Perform the leak test and repair the location of
Operator Station Group

failure before filling the coolant.

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 bulb 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 coolant Limited amount of coolant filled Fill the coolant to proper level.

01-36
115ZV

Gas leakage Perform the leak test and repair the location of
failure before filling the coolant.

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 bulb 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
Over-filled coolant Discharge the coolant to proper level.

95ZVE01005
TROUBLESHOOTING 01
 Operator Station Group

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

01-37
115ZV

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
Coolant high/low-pressure switch failure Replacement
High-pressure error Excessively high pressure [2452 kPa(25kgf/cm2)or over] C-1
Excessively low pressure [981 kPa(10kgf/cm2)or over] C-4

95ZVE01006
TROUBLESHOOTING 01
 Insufficient Same as "Cooling failure"
wind force
Operator Station Group

Heating failure
Low water temperature

Normal wind
force

The air is mixed in hot-water circuit. Discharge the air.

Clogged or bent pipng 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.

01-38
115ZV

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 system.
controller LED is not
operated properly. Servo motor failure Replacement

Leakage of water in
Clogged drain hole Cleaning
operator's cabin

95ZVE01007
TROUBLESHOOTING 01
 Without diagnostic display
Disengaged link Re-set the link.
(blow-off servo motor normal)
Operator Station Group

Blow-off changeover Wiring failure, disconnection, disconnected connector Check the wiring system.
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
With diagnostic display: E45
Servo motor failure Replacement
(inside air/outside air servo motor abnormal)

01-39
115ZV

Foreign matter caught Remove the foreign matter.

With diagnostic display: E11

Disconnected harness, disengaged connector Re-check the wiring system.
(disconnected inside air sensor)

Disconnected inside air sensor Replacement

Room temperature With diagnostic display: E12

Short-circuit harness Check the wiring system.
higher or lower than (short-circuit inside air sensor)
setting temperature
Short-circuit inside air sensor Replacement

Without diagnostic display: E11, E12 Perform the checking in

Cooling failure, heating failure accordance with the paragraph
(without inside air sensor error)
"Cooling failure/heating failure".

95ZVE01008
TROUBLESHOOTING 01
MEMO
MEASUREMENT FOR PERFORMANCE CHECK

03

Standard Measurement Values for Performance Check ............................03-2

Preparation for Performance Check .........................................................03-10
Measuring Engine Speed .........................................................................03-12
Measuring Clutch Oil Pressure and Time Lag ..........................................03-15
Measuring Cylinder Drift ...........................................................................03-17
Measuring Boom Cycle Time ....................................................................03-19
Measuring Full Steering Cycle Time .........................................................03-20
Measuring Relief Valve Setting Pressures ...............................................03-21
Measuring Fan Revolution ........................................................................03-27
Checking Brake Performance ...................................................................03-30
Measuring Brake Line Oil Pressure ..........................................................03-32
Measuring Accumulator Circuit Charging Time ........................................03-35
Measuring Number of Brake Pedal Applications ......................................03-36
Measuring Declutch Engagement .............................................................03-37

03-1
Standard Measurement Values for Performance Check 115ZV MEASUREMENT FOR PERFORMANCE CHECK 03

Standard Measurement Values for Performance Check

For standard specification (S/N 11C4-0101~0120)
Measurement conditions:
Temperature of torque converter oil : 50 to 80°C (120~180°F)
Temperature of hydraulic oil : 50 to 80°C (120~180°F)
Temperature of engine coolant : 50 to 80°C (120~180°F)
Item Standard measurement values
for performance check Remarks
System Measurement item Normal Power
Minimum no-load speed, Low Idle (LI) 775 ± 50
Maximum no-load speed, High Idle (HI) 2,350 ± 50
Engine

Engine speed Maximum speed in torque converter stall mode 2,130 ± 100
(min-1) (rpm) Maximum speed in multiple control valve relief mode 2,140 ± 100

Maximum speed in torque converter stall plus multiple

1,520 +150
- 100 1,650 +150
- 100
control valve relief mode

1st speed 2.2 ~ 2.3 (22 ~ 23) (313 ~ 327)

Low idle
Clutch pressure Except 1st speed 2.5 ~ 2.6 (25 ~ 26) (356 ~ 370)
Transmission

Engine speed
MPa (kgf/cm2) (psi) 1st speed 2.5 ~ 2.6 (25 ~ 26) (356 ~ 370)
High idle
Except 1st speed 2.6 ~ 2.9 (27 ~ 30) (384 ~ 427)

Clutch time lag Neutral → Forward 1st speed

0.3 ± 0.1 Before wheels move
(sec) (engine speed: 1,500 min-1 (rpm))

Cylinder drift (when

Boom cylinder 3 (1/8) or less
boom and bucket
are horizontal and
with no load) Bucket cylinder 4 (5/32) or less
(mm/min) (in/min)

Idling (LI) 23 ± 3.0

Boom rising time
(no load) Engine speed 1,500 min-1 (rpm) 10.5 ± 1.0
(sec) Maximum (HI) 8.4 ± 0.5
Idling (LI) 5.0 ± 0.5
Full steering time
Engine speed 1,500 min (rpm)
-1
3.9 ± 0.3
(sec)
Maximum (HI) 3.9 ± 0.3

20.6 ± 0.5 (210 ± 5)

Hydraulic line

Loading line main relief pressure (HI)

(2,986 ± 71)

23.5 ± 0.5 (240 ± 5) Run engine at lowest

Loading line overload relief pressure (LI)
(3,413 ± 71) possible speed while setting

Relief valve 20.6 ± 0.5 (210 ± 5)

Steering line main relief pressure (HI)
setting pressure (2,986 ± 71)
MPa (kgf/cm2) (psi)
24.5 +1.0 +10
0 (250 0 ) Run engine at lowest
Steering line overload relief pressure (LI) +142
(3,555 0 ) possible speed while setting

✽ Low press.: 9.5 (97) (1,380)

Fan motor line relief pressure (HI) (Reference values)
❈ High press.: 19.0 (194) (2,755)

3.5 (36)
Pilot line reducing pressure (LI)
(512)

Fan Max. revolution Engine water temp. < 94 °C (200 °F) 1,120 ✽ Low press. 9.5 MPa
min-1 (rpm) Engine water temp. > 94 °C (200 °F) 1,600 ❈ High press. 19.0 MPa

03-2
Standard Measurement Values for Performance Check 115ZV MEASUREMENT FOR PERFORMANCE CHECK 03

Item Standard measurement values

for performance check Remarks
System Measurement item Normal Power
Shift lever Slowly increase the
2nd speed reverse
position 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 Before brake check,

3rd speed reverse
position be sure to disconnect
Performance of
↑ the cable connector of
parking brake
parking brake solenoid
Engine speed Maximum (HI)
valve.

11.8 ± 0.5 (120 ± 5)

Off (Cut-out)
(1,706 ± 71)
Unloader valve
setting pressure 6.9 ± 1.0 (70 ± 10)
On (Cut-in)
(995 ± 142)
Brake line setting
pressure Low-pressure alarm switch setting pressure 3.9 ± 0.3 (40 ± 3)
MPa (kgf/cm2) (psi) (For brake accumulator circuit) (569 ± 43)
Brake

12.3
Brake line reducing pressure (125)
(1,778)

3.5 (36)
Auto brake reducing pressure (512)

Accumulator charge The time from the low-pressure alarm

Engine speed
time is turned off till the unloading valve 16
(LI)
(sec) cuts off 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.) at least brake pedal as follows:
pedal applications Step on the brake pedal and release, and check the 11 times On: 5 sec.
number of times until the low-pressure alarm is turned on. Off: 5 sec.

Declutch 1/5 slope

Engine: Maximum speed / Inching pedal: Quick release
engagement 15 (6) or less (approx. 11°), unladen,
(Distance the loader rolls back before moving forward)
(cm) (in) 1st speed

03-3
Standard Measurement Values for Performance Check 115ZV MEASUREMENT FOR PERFORMANCE CHECK 03

For standard specification (S/N 11C4-0121~)

Measurement conditions:
Temperature of torque converter oil : 50 to 80°C (120~180°F)
Temperature of hydraulic oil : 50 to 80°C (120~180°F)
Temperature of engine coolant : 50 to 80°C (120~180°F)
Item Standard measurement values
for performance check Remarks
System Measurement item Normal Power
Minimum no-load speed, Low Idle (LI) 775 ± 50
Maximum no-load speed, High Idle (HI) 2,350 ± 50
Engine

Engine speed Maximum speed in torque converter stall mode 2,130 ± 100
(min-1) (rpm) Maximum speed in multiple control valve relief mode 2,140 ± 100

Maximum speed in torque converter stall plus multiple

1,520 +150
- 100 1,650 +150
- 100
control valve relief mode

1st speed 2.2 ~ 2.3 (22 ~ 23) (313 ~ 327)

Low idle
Clutch pressure Except 1st speed 2.5 ~ 2.6 (25 ~ 26) (356 ~ 370)
Transmission

Engine speed
MPa (kgf/cm2) (psi) 1st speed 2.5 ~ 2.6 (25 ~ 26) (356 ~ 370)
High idle
Except 1st speed 2.6 ~ 2.9 (27 ~ 30) (384 ~ 427)

Clutch time lag Neutral → Forward 1st speed

0.3 ± 0.1 Before wheels move
(sec) (engine speed: 1,500 min-1 (rpm))

Cylinder drift (when

Boom cylinder 3 (1/8) or less
boom and bucket
are horizontal and
with no load) Bucket cylinder 4 (5/32) or less
(mm/min) (in/min)

Idling (LI) 23 ± 3.0

Boom rising time
(no load) Engine speed 1,500 min-1 (rpm) 10.5 ± 1.0
(sec) Maximum (HI) 8.4 ± 0.5
Idling (LI) 5.0 ± 0.5
Full steering time
Engine speed 1,500 min (rpm)
-1
3.9 ± 0.3
(sec)
Maximum (HI) 3.9 ± 0.3

20.6 ± 0.5 (210 ± 5)

Hydraulic line

Loading line main relief pressure (HI)

(2,986 ± 71)

23.5 ± 0.5 (240 ± 5) Run engine at lowest

Loading line overload relief pressure (LI)
(3,413 ± 71) possible speed while setting

Relief valve 20.6 ± 0.5 (210 ± 5)

Steering line main relief pressure (HI)
setting pressure (2,986 ± 71)
MPa (kgf/cm2) (psi)
24.5 +1.0 +10
0 (250 0 ) Run engine at lowest
Steering line overload relief pressure (LI) +142
(3,555 0 ) possible speed while setting

✽ Low press.: 9.5 (97) (1,380)

Fan motor line relief pressure (HI) (Reference values)
❈ High press.: 18.1 (185) (2,625)

3.5 (36)
Pilot line reducing pressure (LI)
(512)

Fan Max. revolution Engine water temp. < 80 °C (176 °F) 1,120 ✽ Low press. 9.5 MPa
min-1 (rpm) Engine water temp. > 93 °C (200 °F) 1,600 ❈ High press. 18.1 MPa

03-4
Standard Measurement Values for Performance Check 115ZV MEASUREMENT FOR PERFORMANCE CHECK 03

Item Standard measurement values

for performance check Remarks
System Measurement item Normal Power
Shift lever Slowly increase the
2nd speed reverse
position 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 Before brake check,

3rd speed reverse
position be sure to disconnect
Performance of
↑ the cable connector of
parking brake
parking brake solenoid
Engine speed Maximum (HI)
valve.

11.8 ± 0.5 (120 ± 5)

Off (Cut-out)
(1,706 ± 71)
Unloader valve
setting pressure 6.9 ± 1.0 (70 ± 10)
On (Cut-in)
(995 ± 142)
Brake line setting
pressure Low-pressure alarm switch setting pressure 3.9 ± 0.3 (40 ± 3)
MPa (kgf/cm2) (psi) (For brake accumulator circuit) (569 ± 43)
Brake

12.3
Brake line reducing pressure (125)
(1,778)

3.5 (36)
Auto brake reducing pressure (512)

Accumulator charge The time from the low-pressure alarm

Engine speed
time is turned off till the unloading valve 16
(LI)
(sec) cuts off 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.) at least brake pedal as follows:
pedal applications Step on the brake pedal and release, and check the 11 times On: 5 sec.
number of times until the low-pressure alarm is turned on. Off: 5 sec.

Declutch 1/5 slope

Engine: Maximum speed / Inching pedal: Quick release
engagement 15 (6) or less (approx. 11°), unladen,
(Distance the loader rolls back before moving forward)
(cm) (in) 1st speed

03-5
Standard Measurement Values for Performance Check 115ZV MEASUREMENT FOR PERFORMANCE CHECK 03

For Europe specification (S/N 11C4-9001~9010)

Measurement conditions:
Temperature of torque converter oil : 50 to 80°C (120~180°F)
Temperature of hydraulic oil : 50 to 80°C (120~180°F)
Temperature of engine coolant : 50 to 80°C (120~180°F)
Item Standard measurement values
for performance check Remarks
System Measurement item Normal Power
Minimum no-load speed, Low Idle (LI) 775 ± 50
Maximum no-load speed, High Idle (HI) 2,250 ± 50
Engine

Engine speed Maximum speed in torque converter stall mode 2,130 ± 100
(min-1) (rpm) Maximum speed in multiple control valve relief mode 2,140 ± 100

Maximum speed in torque converter stall plus multiple

1,520 +150
- 100 1,650 +150
- 100
control valve relief mode

1st speed 2.2 ~ 2.3 (22 ~ 23) (313 ~ 327)

Low idle
Clutch pressure Except 1st speed 2.5 ~ 2.6 (25 ~ 26) (356 ~ 370)
Transmission

Engine speed
MPa (kgf/cm2) (psi) 1st speed 2.5 ~ 2.6 (25 ~ 26) (356 ~ 370)
High idle
Except 1st speed 2.6 ~ 2.9 (27 ~ 30) (384 ~ 427)

Clutch time lag Neutral → Forward 1st speed

0.3 ± 0.1 Before wheels move
(sec) (engine speed: 1,500 min-1 (rpm))

Cylinder drift (when

Boom cylinder 3 (1/8) or less
boom and bucket
are horizontal and
with no load) Bucket cylinder 4 (5/32) or less
(mm/min) (in/min)

Idling (LI) 23 ± 3.0

Boom rising time
(no load) Engine speed 1,500 min-1 (rpm) 10.5 ± 1.0
(sec) Maximum (HI) 8.4 ± 0.5
Idling (LI) 5.0 ± 0.5
Full steering time
Engine speed 1,500 min (rpm)
-1
3.9 ± 0.3
(sec)
Maximum (HI) 3.9 ± 0.3

20.6 ± 0.5 (210 ± 5)

Hydraulic line

Loading line main relief pressure (HI)

(2,986 ± 71)

23.5 ± 0.5 (240 ± 5) Run engine at lowest

Loading line overload relief pressure (LI)
(3,413 ± 71) possible speed while setting

Relief valve 20.6 ± 0.5 (210 ± 5)

Steering line main relief pressure (HI)
setting pressure (2,986 ± 71)
MPa (kgf/cm2) (psi)
24.5 +1.0 +10
0 (250 0 ) Run engine at lowest
Steering line overload relief pressure (LI) +142
(3,555 0 ) possible speed while setting

✽ Low press.: 9.5 (97) (1,380)

Fan motor line relief pressure (HI) (Reference values)
❈ High press.: 19.0 (194) (2,755)

3.5 (36)
Pilot line reducing pressure (LI)
(512)

Fan Max. revolution Engine water temp. < 94 °C (200 °F) 1,120 ✽ Low press. 9.5 MPa
min-1 (rpm) Engine water temp. > 94 °C (200 °F) 1,600 ❈ High press. 19.0 MPa

03-6
Standard Measurement Values for Performance Check 115ZV MEASUREMENT FOR PERFORMANCE CHECK 03

Item Standard measurement values

for performance check Remarks
System Measurement item Normal Power
Shift lever Slowly increase the
2nd speed reverse
position 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 Before brake check,

3rd speed reverse
position be sure to disconnect
Performance of
↑ the cable connector of
parking brake
parking brake solenoid
Engine speed Maximum (HI)
valve.

11.8 ± 0.5 (120 ± 5)

Off (Cut-out)
(1,706 ± 71)
Unloader valve
setting pressure 6.9 ± 1.0 (70 ± 10)
On (Cut-in)
(995 ± 142)
Brake line setting
pressure Low-pressure alarm switch setting pressure 3.9 ± 0.3 (40 ± 3)
MPa (kgf/cm2) (psi) (For brake accumulator circuit) (569 ± 43)
Brake

12.3
Brake line reducing pressure (125)
(1,778)

3.5 (36)
Auto brake reducing pressure (512)

Accumulator charge The time from the low-pressure alarm

Engine speed
time is turned off till the unloading valve 16
(LI)
(sec) cuts off 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.) at least brake pedal as follows:
pedal applications Step on the brake pedal and release, and check the 11 times On: 5 sec.
number of times until the low-pressure alarm is turned on. Off: 5 sec.

Declutch 1/5 slope

Engine: Maximum speed / Inching pedal: Quick release
engagement 15 (6) or less (approx. 11°), unladen,
(Distance the loader rolls back before moving forward)
(cm) (in) 1st speed

03-7
Standard Measurement Values for Performance Check 115ZV MEASUREMENT FOR PERFORMANCE CHECK 03

For Europe specification (S/N 11C4-9011~)

Measurement conditions:
Temperature of torque converter oil : 50 to 80°C (120~180°F)
Temperature of hydraulic oil : 50 to 80°C (120~180°F)
Temperature of engine coolant : 50 to 80°C (120~180°F)
Item Standard measurement values
for performance check Remarks
System Measurement item Normal Power
Minimum no-load speed, Low Idle (LI) 775 ± 50
Maximum no-load speed, High Idle (HI) 2,250 ± 50
Engine

Engine speed Maximum speed in torque converter stall mode 2,130 ± 100
(min-1) (rpm) Maximum speed in multiple control valve relief mode 2,140 ± 100

Maximum speed in torque converter stall plus multiple

1,520 +150
- 100 1,650 +150
- 100
control valve relief mode

1st speed 2.2 ~ 2.3 (22 ~ 23) (313 ~ 327)

Low idle
Clutch pressure Except 1st speed 2.5 ~ 2.6 (25 ~ 26) (356 ~ 370)
Transmission

Engine speed
MPa (kgf/cm2) (psi) 1st speed 2.5 ~ 2.6 (25 ~ 26) (356 ~ 370)
High idle
Except 1st speed 2.6 ~ 2.9 (27 ~ 30) (384 ~ 427)

Clutch time lag Neutral → Forward 1st speed

0.3 ± 0.1 Before wheels move
(sec) (engine speed: 1,500 min-1 (rpm))

Cylinder drift (when

Boom cylinder 3 (1/8) or less
boom and bucket
are horizontal and
with no load) Bucket cylinder 4 (5/32) or less
(mm/min) (in/min)

Idling (LI) 23 ± 3.0

Boom rising time
(no load) Engine speed 1,500 min-1 (rpm) 10.5 ± 1.0
(sec) Maximum (HI) 8.4 ± 0.5
Idling (LI) 5.0 ± 0.5
Full steering time
Engine speed 1,500 min (rpm)
-1
3.9 ± 0.3
(sec)
Maximum (HI) 3.9 ± 0.3

20.6 ± 0.5 (210 ± 5)

Hydraulic line

Loading line main relief pressure (HI)

(2,986 ± 71)

23.5 ± 0.5 (240 ± 5) Run engine at lowest

Loading line overload relief pressure (LI)
(3,413 ± 71) possible speed while setting

Relief valve 20.6 ± 0.5 (210 ± 5)

Steering line main relief pressure (HI)
setting pressure (2,986 ± 71)
MPa (kgf/cm2) (psi)
24.5 +1.0 +10
0 (250 0 ) Run engine at lowest
Steering line overload relief pressure (LI) +142
(3,555 0 ) possible speed while setting

✽ Low press.: 9.5 (97) (1,380)

Fan motor line relief pressure (HI) (Reference values)
❈ High press.: 18.1 (185) (2,625)

3.5 (36)
Pilot line reducing pressure (LI)
(512)

Fan Max. revolution Engine water temp. < 80 °C (176 °F) 1,120 ✽ Low press. 9.5 MPa
min-1 (rpm) Engine water temp. > 93 °C (200 °F) 1,600 ❈ High press. 18.1 MPa

03-8
Standard Measurement Values for Performance Check 115ZV MEASUREMENT FOR PERFORMANCE CHECK 03

Item Standard measurement values

for performance check Remarks
System Measurement item Normal Power
Shift lever Slowly increase the
2nd speed reverse
position 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 Before brake check,

3rd speed reverse
position be sure to disconnect
Performance of
↑ the cable connector of
parking brake
parking brake solenoid
Engine speed Maximum (HI)
valve.

11.8 ± 0.5 (120 ± 5)

Off (Cut-out)
(1,706 ± 71)
Unloader valve
setting pressure 6.9 ± 1.0 (70 ± 10)
On (Cut-in)
(995 ± 142)
Brake line setting
pressure Low-pressure alarm switch setting pressure 3.9 ± 0.3 (40 ± 3)
MPa (kgf/cm2) (psi) (For brake accumulator circuit) (569 ± 43)
Brake

12.3
Brake line reducing pressure (125)
(1,778)

3.5 (36)
Auto brake reducing pressure (512)

Accumulator charge The time from the low-pressure alarm

Engine speed
time is turned off till the unloading valve 16
(LI)
(sec) cuts off 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.) at least brake pedal as follows:
pedal applications Step on the brake pedal and release, and check the 11 times On: 5 sec.
number of times until the low-pressure alarm is turned on. Off: 5 sec.

Declutch 1/5 slope

Engine: Maximum speed / Inching pedal: Quick release
engagement 15 (6) or less (approx. 11°), unladen,
(Distance the loader rolls back before moving forward)
(cm) (in) 1st speed

03-9
Preparation for Performance Check 115ZV MEASUREMENT FOR PERFORMANCE CHECK 03

Preparation for Performance Check

WARNING CAUTION
Unexpected movement of the machine may Do not touch the fan or V-belt of the engine or a
cause an accident resulting in injury or death. hig-temperature section if the engine is running. An
Therefore, to provide repair service with the
accident resulting in injury may occur.
engine running, be sure to observe the following
items: Be sure to stop the engine before you open the side
- Park the machine on level ground. cover of the engine room. Keep all guards in place.
- Apply the parking brake. Avoid high temperature components even when the
- Block the tires with chocks to prevent the tires
engine is stopped.
from moving.
- Determine the signals between the service men.
- Prohibit any person from walking into
dangerous areas.
- Near articulation area of the machine
- Under the machine
- Around the engine
- In front of or behind the machine

Preparation of measurement units Cautions regarding measurement

- To measure pressure, be sure to prepare the hose, - Take safety precautions before starting measurement
adapter, and wrench for pressure port plug in addition work, and carefully measure and record the valves.
to the measurement instruments. - Measure a value three times or more. If the obtained
values greatly differs from each other, an error has
- Check operation of the measurement instruments. been made in measuring the value.
Carefully handle the instruments. If something comes Measure the value again.
in contact with an instrument or large shock is applied Calculate the average value from the various
to an instrument, the instrument may be damaged. In readings.
addition, periodic inspection of the instruments is also
important. If the zero point of an instruments is not Warm-up
properly adjusted, the value indicated by the - If the machine is too cold, measured values may be
instrument may be wrong. wrong. To prevent incorrect readings, be sure to warm
up the machine until the torque converter oil, hydraulic
oil, and engine coolant are heated to the specified
temperature.

03-10
Preparation for Performance Check 115ZV MEASUREMENT FOR PERFORMANCE CHECK 03

Procedure for warm-up (140°F) (176°F) (212°F) (230°F)

1) Torque converter oil temperature 60°C 80°C 100°C 110°C

Perform torque converter stall operation by referring

to "Stall speed measurement procedure". C H

Check the approximate temperature using the T/C OIL

TEMP

temperature gauge in the instrument panel.

2) Hydraulic oil temperature Torque converter oil temperature gauge

Perform multiple control valve relief operation by
referring to "Engine speed measurement procedure
in multiple control valve relief mode".
Check the approximate temperature using the (140°F) (176°F) (194°F) (230°F)
contact thermometer attached to the outside surface 60°C 80°C 100°C 110°C
of the hydraulic tank.
C H

3) Engine coolant temperature WATER

TEMP

Warming up the torque converter oil and hydraulic oil

also warms up the engine.
Check the engine coolant temperature using the Engine coolant temperature gauge
97ZV03001
temperature gauge in the instrument panel.

03-11
Measuring Engine Speed 115ZV MEASUREMENT FOR PERFORMANCE CHECK 03

Measuring Engine Speed

WARNING CAUTION
Unexpected movement of the machine may Do not touch the fan or V-belt of the engine or a
cause an accident resulting in injury or death. high-temperature section if the engine is
Therefore, to provide repair service with the running. An accident resulting in injury may
engine running, be sure to observe the following occur.
items: Be sure to stop the engine before you open the
- Park the machine on level ground. side cover of the engine room. Keep all guards
- Apply the parking brake. in place.
- Block the tires with chocks to prevent the tires Avoid high temperature components even after
from moving. the engine is stopped.
- Determine the signals between the service men.
- Prohibit any person from walking into
dangerous areas.
- Near articulation area of the machine
- Under the machine
- Around the engine
- In front of or behind the machine

Measurement instrument
- Tachometer drive port

Warm - up the engine before measuring the engine

speed

Standard measurement value (min-1) (rpm)

(S/N 11C4-0101~) (S/N 11C4-9001~)
Normal Power Normal Power
Minimum no-load speed (LI) 775 ± 50 Minimum no-load speed (LI) 775 ± 50
Minimum no-load speed (HI) 2,350 ± 50 Minimum no-load speed (HI) 2,250 ± 50

Maximum speed in torque converter stall Maximum speed in torque converter stall
2,130 ± 100 2,130 ± 100
mode mode

Maximum speed in multiple control valve Maximum speed in multiple control valve
2,140 ± 100 2,140 ± 100
relief mode relief mode

Maximum speed in torque converter stall 1,520 ± 150

1,650 ± 150 Maximum speed in torque converter stall 1,520 ± 150
1,650 ± 150
100 100 100 100
plus multiple control valve relief mode plus multiple control valve relief mode

03-12
Measuring Engine Speed 115ZV MEASUREMENT FOR PERFORMANCE CHECK 03

Stall speed measurement procedure Engine speed measurement procedure in multiple

control valve relief mode
WARNING
Unexpected movement of the machine for IMPORTANT
abnormal brake performance may cause an When the relief valve is activated, the oil
accident resulting in injury or death. temperature rises rapidly. Therefore, long relief
Before measuring, make sure that the machine operation may damage the seals or cause the
has sufficient brake performance. spool to stick inside the valve.
This is why relief operation should be limited to
10 seconds.
IMPORTANT To repeat the relief operation, be sure to wait
In the stall mode, the torque converter oil more than 10 seconds with medium engine
temperature rises rapidly. Therefore, long stall speed before next relief operation, and cool the
operation may damage the seals, and the inside of the valve.
damaged seal may cause oil leakage. Using this cycle safely warms up cold oil.
This is why stall test should be limited to 20
seconds. The torque converter oil temperature
1) Lower the boom to the lowest limit. Roll back the
should not be exceeded 120°C (250°F).
bucket fully until the bucket contacts to the stopper.
To repeat the stall operation, be sure to wait
2) Set the parking brake to the "ON" position.
more than 10 seconds with medium engine
3) Set the engine speed to HI.
speed before next stall operation so that the
4) Place the bucket control lever in roll back position.
torque converter oil is cooled enough.
Measure the engine speed.

1) Lower the boom to the lowest limit. Roll back the

bucket fully until the bucket contacts to the stopper.
2) Set the parking brake to the "OFF" position.
3) Set the clutch cut off switch to OFF.
4) Press the brake pedal all the way to the floor,
and then set the transmission shift lever to the
maximum forward speed position ("4").
Note : Cancel the auto shift mode.
As a result the transmission shift lever "A"
position works as "4" position.
5) Gradually increase the engine speed. Measure the
97ZV03002
engine speed when the accelerator pedal is fully
pressed down.
6) Record the engine speed at T/C stall.
(During stall speed measurement, do not operate
the steering system, boom, bucket, etc.)

03-13
Measuring Engine Speed 115ZV MEASUREMENT FOR PERFORMANCE CHECK 03

Cause of extremely high or low measurement value

and solution
Minimum no-load speed(LI) or maximum no-load speed(HI) low The engine speed is too high in multiple control valve relief mode.

Possible cause Solution Possible cause Solution

Insufficient warm up Warm up Adjustment or

Relief valve pressure too low
disassembly
Malfunctioning accelerator pedal Inspection & repair Disassembly
Defective pump / pump seals
Clogged fuel filter Clean & repair

Defective fuel pump Repair

Defective fuel injection nozzle Repair The engine speed is too low in multiple control valve relief mode.
Valve clearances incorrect Adjustment

Insufficient compression pressure Repair Possible cause Solution

Inspection
Engine low power
& repair
Extremely high relief pressure of
The engine speed is too high in torque converter stall mode. Adjustment
multiple control valve

Possible cause Solution

The engine speed is too high in torque converter stall plus multiple
Slipping transmission clutch or defect Disassembly control valve relief mode.
inside of transmission & repair
Disassembly
Defect inside torque converter Possible cause Solution
& repair
Slipping transmission clutch or defect inside Disassembly
of transmission or T/C & repair
Relief pressure too low Adjustment
The engine speed is too low in torque converter stall mode.
Disassembly
Defective pump / pump seals
& repair

Caused by reduction in engine power

Possible cause Solution The engine speed is too low in torque converter stall plus multiple
control valve relief mode.
Clogged air cleaner element Cleaning
Fuel
Improper type of fuel Possible cause Solution
replacement
Clean or Inspection
Clogged fuel filter or suction strainer Engine low power
replace & repair
Use antifreeze Extremely high relief pressure of multiple
Frozen fuel / wax build up Adjustment
mixture control valve or steering valve
Inspection
Malfunctioning accelerator pedal
& repair
Defective fuel pump Repair

Defective fuel injector nozzle Repair

Insufficient compression pressure Repair

03-14
Measuring Clutch Oil Pressure and Time Lag 115ZV MEASUREMENT FOR PERFORMANCE CHECK 03

Measuring Clutch Oil Pressure and Time Lag

- Standard measurement value
WARNING
2.2 – 2.3
Unexpected movement of the machine may 1st
(22 – 23)
cause an accident resulting in injury or death. speed
Low (313 – 327)
Therefore, to provide repair service with the idle 2.5 – 2.6
engine running, be sure to observe the following Except
(25 – 26)
1st
items: Clutch pressure Engine (356 – 370)
- Park the machine on level ground. MPa (kgf/cm2) (psi) speed 2.5 – 2.6
1st
- Apply the parking brake. speed
(25 – 26)
- Block the tires with chocks to prevent the tires High (356 – 370)
from moving. idle 2.6 – 2.9
Except
- Determine the signals between the service men. (27 – 30)
1st
(384 – 427)
- Prohibit any person from walking into
dangerous areas. Neutral→1st forward
Clutch time lag
speed (engine speed: 0.3 ± 0.1
- Near articulation area of the machine (sec)
1,500 min-1 (rpm))
- Under the machine
- Around the engine
- In front of or behind the machine 3rd speed clutch pressure Reverse clutch pressure

Measurement instruments:
- Pressure gauge: 4.9 MPa (50 kgf/cm2) (1,000 psi)
3 R
with 2 ~ 3 m (6 ~ 10 ft.) hose
Pressure measurement port: H

1st clutch PF1/4

2 L
Except 1st clutch PT3/8
- Tachometer
- Stop watch
2nd speed clutch pressure Low speed clutch pressure
115ZV33001
Warm-up the engine before measuring the clutch
oil pressure and time lag

Clutch oil pressure measurement procedure 3rd speed clutch Main clutch
pressure pressure
1) Lower the boom to the lowest limit, and lower the
bucket onto the ground. Solenoid
valve mount
2) Set the parking brake to the "ON" position. 2nd speed
clutch pressure
3) Set the transmission shift lever to the neutral position.
4) Stop the engine. Attach the pressure gauge to the
pressure measurement port. Place the gauge inside
the operator's area, start the engine.
5) As the clutch oil pressure rises just after the engine
is started, adjust the engine to the specified speed 1st speed
before the pressure measurement. clutch pressure

6) Measure and record the pressure in each speed range.

7) Change the transmission speed range while keeping
the shift lever at the neutral position. Check that the
115ZV33002
pressure instantaneously lowers just after speed
change, and then rises to the original pressure again. Transmission oil pressure test port location
03-15
Measuring Clutch Oil Pressure and Time Lag 115ZV MEASUREMENT FOR PERFORMANCE CHECK 03

Time lag measurement procedure:

1) Lower the boom to the lowest limit, and fully roll back
WARNING
the bucket until the bucket contacts to the stopper.
Unexpected movement of the machine may
2) Set the parking brake switch to the "OFF" position.
cause an accident resulting in injury or death.
Do not apply the service brakes.
To crawl under the machine, be sure to stop the
3) Set the transmission shift lever to the neutral 1st
engine, and block the tires with chocks to
speed.
prevent them from moving. Give signals to the
4) Keep the engine speed at 1,500 min-1 (rpm).
person in the cab during the work.
5) 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 low clutch oil pressure and

clutch time lag

Clutch oil pressure

Possible cause Solution

Malfunctioning modulator valve (1) Inspection

operation & repair

Malfunctioning modulator valve (2) Inspection

operation & repair

Defective controller Replacement

Disassembly
Oil leakage from clutch
& repair

Clutch time lag

Possible cause Solution

Defective pressure difference sensor Replacement

Malfunctioning modulator valve (1) Inspection

operation & repair

Malfunctioning modulator valve (2) Inspection

operation & repair

Defective controller Replacement

Disassembly
Defective clutch
& repair

03-16
Measuring Cylinder Drift 115ZV MEASUREMENT FOR PERFORMANCE CHECK 03

Measuring Cylinder Drift

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

Measurement instrument Reference :

- Scale : 150 to 300 mm (1 ft.) Drift rate depends on the viscosity of the hydraulic oil
- Stop watch and its temperature. In other words, high temperature
- Black vinyl "electrician's" type of the hydraulic oil reduces the viscosity. Reduction in
oil viscosity increases oil leakage through the seals,
Warm-up the hydraulic oil before measuring and increases the drift rate. Cold thick oil reduces the
cylinder drift drift rate.

Standard measurement value

(mm/min)(in/min)

Boom cylinder 3 (1/8) or less

Bucket cylinder 4 (5/32) or less

Measurement procedure
Mark
1) Unload the bucket.
2) Keep the boom and bucket horizontal. Scale
3) Set the parking brake switch to the "ON" position.
4) Lock the boom and bucket control levers using the 95ZV03012

safety lock.
5) Stop the engine.
IMPORTANT
6) Mark the cylinder rod at a point 100 to 150 mm (4~6
At the completion of measurement, if the vinyl
in) away from the cylinder head cover.
tape used for measurement is not removed from
7) Measure the accurate distance from the cylinder
the cylinder rod, the tape may be caught by the
head cover to the mark. This is distance "A" mm
rod seal. The tape will cause oil leakage from the
(in). Measure the distance again 5 minutes later.
rod seal. To prevent oil leakage, be sure to
This is distance "B" mm (in).
remove the vinyl tape.

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

(in/min) 5 (min)

03-17
Measuring Cylinder Drift 115ZV MEASUREMENT FOR PERFORMANCE CHECK 03

Possible causes of excessive cylinder drift:

Bucket cylinder Bucket cylinder
(RH)
Possible cause Solution

Damaged cylinder piston seal / barrel Disassembly & repair

Defective multiple control valve overload relief valve Disassembly & repair

Oil leakage from multiple control valve bucket spool Disassembly & repair

- Identifying defective part

(LH)
Pressure is applied to the bucket cylinder bottom side
to support the bucket. There should be no pressure
applied to the cylinder rod side. 115ZV03004

Bucket cylinder rod side flange

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

Boom cylinder
Possible cause Solution

Damaged cylinder piston seal / barrel Disassembly & repair

Oil leakage from multiple control valve boom spool Disassembly & repair

- Identifying defective part

Just like the bucket cylinder, no pressure should be
applied to the rod side of the boom cylinder when the (LH)

weight of the boom is resting on the boom cylinders.

(RH)
Carefully loosen the split flange (see the arrow) for
Boom cylinder
the pipe on the cylinder rod side.
115ZV03005
If the compressed oil spouts from the cylinder, judge
that the piston seal and/or barrel of the boom cylinder Boom cylinder rod side flange
is damaged. If the compressed oil spouts from the
pipe side, judge that the piston seal of the other
cylinder is defective.

If no oil spouts from the split flange, judge that oil is

leaking from the multiple control valve spool.

03-18
Measuring Boom Cycle Time 115ZV MEASUREMENT FOR PERFORMANCE CHECK 03

Measuring Boom Cycle Time

WARNING Possible causes of slow boom cycle time:

Standing under the boom or bucket during Possible cause Solution

Disassembly
service work is dangerous. An accident resulting Damaged main pump / seals
& repair
in injury or death may occur. Damaged steering pump / seals Disassembly
& repair
Stay out of the area around the raised boom. Multiple control valve spool sticking Disassembly
& repair
Measuring instrument How to determine the cause (damaged main pump or
- Stop watch steering pump):
- Tachometer Measure the full steering time. If normal the main
pump is damaged. If steering time is also slow the
Warm-up the engine before measuring boom rising steering pump is damaged.
time
Boom cylinder

Standard measurement value(sec) To steering line

Multiple control
Idling (LI) 23 ± 3.0 valve
Steering
Engine speed 1,500 min-1(RPM) 10.5 ± 1.0 valve
Steering pump
Maximum (HI) 8.4 ± 0.5

Main pump

Measurement procedure
1) Unload the bucket.
2) Lower the boom to the lower limit, and roll back the
Hydraulic oil tank
bucket.
95ZV03004
3) Set the parking brake switch to the "ON" position.
Stop the engine and install the tachometer.
4) Adjust the engine speed to the specified point.
5) Measure the time required for raising the boom from
the lowest limit to the highest limit.
Note : Even if the boom kick out system (optional) is
installed, the boom control lever should be
held in the UP position until the boom rises to
the highest limit.

97ZV03005

03-19
Measuring Full Steering Cycle Time 115ZV MEASUREMENT FOR PERFORMANCE CHECK 03

Measuring Full Steering Cycle Time

WARNING
Standing in the articulation area during service
work is dangerous. An accident resulting in injury
or death may occur.
During this test, prevent any person from walking
around the machine or in the articulation area.

Measuring instrument
- Stop watch
- Tachometer
97ZV03007

Warm-up the engine before measuring full steering Full steering

time

Standard measurement value(sec)

Idling (LI) 5 ± 0.5
Engine speed 1,500 min-1(RPM) 3.9 ± 0.3
Maximum (HI) 3.9 ± 0.3

Measurement procedure
1) Adjust the stopper bolts of the front chassis so that Possible causes for slow steering times:
the front chassis stopper contacts to the rear Possible cause Solution
chassis.
Damaged steering pump / seals Disassembly
2) Unload the bucket. & repair

3) Lower the boom to the lower limit, and roll back the Malfunctioning steering valve flow Disassembly
control plunger or steering spool & repair
bucket.
4) Set the parking brake switch to the "OFF" position
and release the brake pedal. Flow control plunger
5) Adjust the engine speed to the specified point. (G)
P
6) Measure and record the time required for full
steering.
- From full left to full right or MR

- From full right to full left

Turn the steering wheel as fast as possible during
Pb Pa
the test.

IMPORTANT
After measuring, return the stopper bolts.
(Refer to "Stop Valve" in Check & Adjustment.) Steering valve T
95ZV03005

03-20
Measuring Relief Valve Setting Pressures 115ZV MEASUREMENT FOR PERFORMANCE CHECK 03

Measuring Relief Valve Setting Pressures

WARNING CAUTION
Unexpected movement of the machine may Do not touch the fan or V-belt of the engine or a
cause an accident resulting in injury or death. high-temperature section if the engine is
Therefore, to provide repair service with the running. An accident resulting in injury may
engine running, be sure to observe the following occur.
items : Be sure to stop the engine before you open the
- Park the machine on level ground. side cover of the engine room. Keep all guards
- Apply the parking brake. in place.
- Block the tires with chocks to prevent the tires Avoid high temperature components even when
from moving. the engine is stopped.
- Determine the signals between the service man.
- Prohibit any person from walking into
dangerous areas.
2. Standard measurement value MPa
- Near articulation areas of the machine
(kgf/cm2) (psi)
- Under the machine
- Around the engine Loading line main relief pressure 20.6 ± 0.5
(at maximum speed) (210 ± 5) (2,986 ± 71)
- In front of or behind the machine
Loading line overload relief pressure 23.5 ± 0.5
(at idling speed) (240 ± 5) (3,413 ± 71)

Steering line main relief pressure 20.6 ± 0.5

CAUTION (at maximum speed) (210 ± 5) (2,986 ± 71)
Be careful, you may get burned if the high 24.5 +1.0
Steering line overload relief pressure 0

pressure oil spouts out. To prevent such an (at idling speed) (250 +10 +142
0 ) (3,555 0 )

accident, be sure to release the residual pressure Pilot line reducing valve pressure 3.5
from the pipe, and open the cap of the hydraulic (at idling speed) (36) (512)

oil tank before removing the plug and hose from

Hydraulic oil temp : 50~80 °C (120~180 °F)
the pressure measurement port.

Releasing residual pressure from tank and pipes.

1. Measurement instruments : Keep the bottom surface of the bucket horizontal,
Pressure gauge 34.3 MPa (350 kgf/cm2) (5,000 psi) (for and stop the engine when the bucket is
loading and steering lines) with 1.5~3 approximately 30 cm (1 ft.) above the ground.
m (4~10 ft.) hose Tilt down the bucket until it comes in contact with the
4.9 MPa (50 kgf/cm2) (1,000 psi) (for ground. Place the bucket control lever in the roll
pilot line) with 2~3 m (6~10 ft.) hose back position, and then lower the boom.
Push down on, then open the cap of the hydraulic oil
Note : For safety, route the gauge to an area where it tank to release the residual pressure.
may be safely read by the person doing the test.

03-21
Measuring Relief Valve Setting Pressures 115ZV MEASUREMENT FOR PERFORMANCE CHECK 03

Loading Circuit Bucket cylinder

1. Gauge port and port size
Gauge port location Port size
1
Main relief pressure ➀, ➁, ➂ ➀…Rc (PT) 1/4
➁
……➂
,
Overload relief G (PF) 1/4
pressure ➀, ➁, ➂ with O-ring
2
Note:
Pilot line pressure ➃…G (PF) 1/4 North America equipped
(Reducing valve) ➃ with O-ring M/c's have a quick connector
in port 3 for testing. 115ZV43001

Multiple control valve

Make-up valve
2. Measuring loading line main relief
pressure
Overload relief
1) Unload the bucket. valve
2) Lower the boom to the lowest limit.
3) Attach the pressure gauge 29.4 MPa (5,000 psi) to
the quick connector port (➂).
4) Set the parking brake switch to the "ON" position.
5) Move the bucket control lever to the roll back
position. Hold the lever at that position.
Overload relief Main relief valve
6) Increase the engine speed to the maximum, and valve
measure and record the pressure using the pressure 3
gauge. Valve assembly 95ZV43002
4
(PPI) (Z)
Adjusting main relief pressure :
(Z2)
Loosen the lock nut and adjust the pressure by the (PA)
(Z1)

ACF (ACCF) (ACCR)

adjusting screw. (PARKING)
(TA)
(PI)

Turn clockwise the adjusting screw to raise the set (T) (P)

pressure, or turn counterclockwise the adjusting

screw to lower the set pressure.
Reducing valve
(for pilot)

IMPORTANT 95ZV43003

At the completion of check and adjustment of

Main relief valve
main relief valve pressure, be sure to tighten the Cap
lock nut. Lock nut

Adjusting
screw

03-22 95ZV43004
Measuring Relief Valve Setting Pressures 115ZV MEASUREMENT FOR PERFORMANCE CHECK 03

3. Measuring loading line overload relief 4. Measuring pilot line pressure

pressure WARNING
1) Attach the pressure gauge to the port ➂
Trapped pressure in brake circuit could cause
2) Adjust the main relief valve pressure to 24.5 MPa
serious injury when the plug is removed.
(3,555 psi) + 1/4 additional turn, so the pressure is
Fully release all residual accumulator pressure
above the overload relief pressure.
before servicing.
Bucket cylinder bottom side :
(1) Lower the boom to the lowest limit.
(2) Move the bucket control lever to the roll back 1) Attach the pressure gauge to the port (➃).
position. 2) Keep the engine speed at low idle (when the brake
(3) Keep the engine speed at low idle. line pressure is normal) and then measure and
(4) Hold the bucket control lever at the roll back record the pressure.
position and record the pressure.
Bucket cylinder rod side : Adjusting pilot line pressure :
(1) Keep the boom horizontal. Loosen the lock nut and adjust the pressure by the
(2) Move the bucket control lever to the dump adjusting screw.
position, hold and then measure and record the Turn clockwise the adjusting screw to raise the pilot
pressure. line pressure.

Adjusting overload relief pressure :

IMPORTANT
Loosen the lock nut and adjust the pressure by the
After the completion of the adjustment of the
adjusting screw.
pilot line pressure, be sure to tighten the lock
Turn clockwise the adjusting screw to raise the set
nut.
pressure, or turn counterclockwise the adjusting
screw to lower the set pressure.
Reducing valve

IMPORTANT Lock nut

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

Overload relief valve Adjusting

screw
Lock nut

70ZV43006

Adjusting screw

95ZV43005

03-23
Measuring Relief Valve Setting Pressures 115ZV MEASUREMENT FOR PERFORMANCE CHECK 03

Steering Circuit
1. Gauge port and port size Steering cylinder
(RH)
Gauge port location Port size 2
Steering cylinder
(LH)
Main relief pressure Note:
G (PF) 1/4 North America equipped
➀, ➁ with O-ring M/c's have quick
Overload relief connectors at ports 1
pressure 1 and 2 . 115ZV43002

Reducing pressure ➂ Rc (PT 1/8)

Reducing valve

2. Measuring steering line main relief

pressure
1) Attach the pressure gauge to the gauge port (➀ or (A)

➁). 3
2) In case the pressure gauge is installed to ➀, steer
the machine to the left until the front and rear chassis 115ZV43006
(B)

contact each other.

Continue to hold the steering wheel fully turned. Steering valve Main relief valve
Note : Because the stop valve is installed into the
steering line, oil pressure does not reach the set
point when the steering is fully turned.
When measuring oil pressure, be sure to apply
the articulation stopper or screw the stopper
(bolt) in until the front and rear chassis contact
each other.

WARNING
If the machine begins to move with the Overload relief
valve
articulation stopper applied, it may cause an
accident resulting in injury or death. 95ZV43006

After the measurement, be sure to disconnect

Main relief valve
and store the articulation stopper.
Lock nut
Adjusting
3) Increase the engine speed to high idle, and measure screw
and record the pressure.

Adjusting steering line main pressure :

Loosen the lock nut and adjust the pressure by the
adjusting screw.
Turn clockwise the adjusting screw to raise the
steering line main pressure. 95ZV43007

03-24
Measuring Relief Valve Setting Pressures 115ZV MEASUREMENT FOR PERFORMANCE CHECK 03

3. Measuring steering line overload relief Overload relief valve

pressure Lock nut
1) Attach the pressure gauge to the port (➀ for the left
turn, ➁ for the right turn).
Adjusting
screw
2) Adjust the main relief valve pressure to 25.5 MPa
(3,697 psi) + 1/4 additional turn, so the pressure is
above the overload relief pressure.
3) Steer the machine until the front and rear chassis
contact each other. Continue to hold the steering
wheel fully turned.
Note : Because the stop valve is installed into the
steering line, oil pressure does not reach the set 95ZV43008

point when the steering is fully turned.

When measuring oil pressure, be sure to apply ● Cause of extremely high or low measurement
the articulation stopper or screw the stopper value and solution
(bolt) in until the front and rear chassis contact The pressure is too high.
each other.
4) Keep the engine speed at low idle, and measure and
Possible cause Solution
record the pressure.
Raise the engine speed to 1,000 min-1 if fail to do. Relief valve pressure not set properly Adjustment

Adjusting overload relief pressure : The pressure is too low.

Loosen the lock nut and adjust the pressure by the
adjusting screw.
Possible cause Solution
Turn clockwise the adjusting screw to raise the set
pressure, or turn counterclockwise the adjusting Relief valve pressure not set properly Adjustment

screw to lower the set pressure. Disassembly

Relief valve spring broken
& repair

Disassembly
WARNING Debris stuck in valve
& cleaning
If the machine begins to move with the Disassembly
Damaged pump / seals
articulation stopper applied, it may cause an & repair
accident resulting in injury or death.
If the inside of the pump is damaged, boom rising
After the measurement, be sure to disconnect
time and steering time may be also slow.
and store the articulation stopper.
The pilot pump damage may only reduce pilot pump
pressure.

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

03-25
Measuring Relief Valve Setting Pressures 115ZV MEASUREMENT FOR PERFORMANCE CHECK 03

4. Measuring pilot circuit relief pressure Adjusting screw

(Reducing pressure)
Lock nut
(S/N 0104~, S/N 9004~)
1) Attach the pressure gauge to the port (➂).
Gauge port plug width across flat : 5 mm
2) Move the bucket control lever to the roll back
position.
3) Keep the engine speed at low idle.
(T)
4) Hold the bucket control lever at the roll back position
and record the pressure.
(A)

Adjusting pilot line pressure :

3
Loosen the lock nut and adjust the pressure by the
(TS)
adjusting screw.
Turn clockwise the adjusting screw to raise the pilot
115ZV43007
(B)
line pressure.

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

03-26
Measuring Fan Revolution 115ZV MEASUREMENT FOR PERFORMANCE CHECK 03

Measuring Fan Revolution

(S/N 0101~0120, S/N 9001~9010)

IMPORTANT CAUTION
When adjusting the fan revolution, adjust not the pressure Be careful, you may get burned if the high
but the actual fan revolution. pressure oil spouts out. To prevent such an
Whenever the fan max. revolution is adjusted, always accident, be sure to release the residual pressure
adjust the high revolution first, because when the high from the pipe, and open the cap of the hydraulic
revolution is changed, the low revolution is also changed. oil tank before removing the plug and hose from
the pressure measurement port.
1. Measurement instrument
- Spanner: 22, 27, 32 mm (0.87, 1.06, 1.26 in) ● Possible causes of extremely high or low
- Pressure gauge: 29.4 MPa (5,000 psi gauge will work) measurement valve and solution
[Gauge port: PG port (PF1/4)] Fan speed is high and will not go down
- Tachometer (Photo tachometer)
Possible cause Solution

2. Measurement procedure Defective fan motor relay Replacement

Disconnected wiring between fan mortor relay

Install the pressure gauge. Inspection & repair
and solenoid valve
Pressure measurement point : PG port
Defective fan motor solenoid valve Disassembly & repair
port size : G(PF 1/4)with o-ring
Fan speed is low and will not go up

1) High revolution (High pressure) side Possible cause Solution

➀ Remove the solenoid valve connection wire. Defective fan motor relay Replacement
When the solenoid valve is OFF, the high revolution
Defective fan motor solenoid valve Disassembly & repair
can be adjusted.
Disconnected wiring between ECM and fan
➁ While the engine speed is at high idle, measure the motor relay
Inspection & repair

fan revolution.
High revolution too high (low)

2) Low revolution (Low pressure) side Possible cause Solution

➀ Confirm the radiator cooling water temperature is Inappropriate set two-step relief valve at high
Inspection & repair
pressure side
lower than 80°C (176°F), and then adjust the rpm's
keeping the solenoid valve connection wire installed Low revolution is too high (low)

on the relief block. Possible cause Solution

When the radiator cooling water temperature is low, Inappropriate set two-step relief valve at low
Inspection & repair
the solenoid valve is ON. pressure side

➁ While the engine speed is at high idle, measure the

fan revolution. P1 21 22

PG PX
3. Standard valve P2

Engine water
Fan revolution Set pressure
temperature B A
T1 23 24
9.5 MPa TG
<94 °C (200 °F) 1,120 min -1
(97 kgf/cm2) (1,379 psi)
19.0 MPa
>94 °C (200 °F) 1,600 min-1 T2
(194 kgf/cm2) (2,759 psi)

Solenoid
valve 95ZV42065

03-27
Measuring Fan Revolution 115ZV MEASUREMENT FOR PERFORMANCE CHECK 03

4. Adjustment procedure
- Whenever the fan max. revolution is adjusted, always
adjust the high revolution first, because when the high
revolution is changed, the low revolution is also
changed.
1) High revolution (High pressure) side
P1
➀ Remove the solenoid valve connection wire. 21 22

➁ Loosen the lock nut (21), adjust the rpm's (pressure) PG PX

P2
by turning the adjusting screw (22).
Turn the adjusting screw clockwise as viewed from
B A
the valve end to raise the rpm's (pressure). T1 23 24
TG
Note: Do not raise the pressure more than 18.6 MPa
(2,702 psi) during adjustment.
Set revolution 1,600 min-1 (rpm) T2
[Set pressure 19.0 MPa (194 kgf/cm2) (2,759 psi)]
➂ After adjusting the fan rpm's, tighten the lock nut
(21) while holding adjusting screw (22) so as not to Solenoid
valve 95ZV42065
turn it at the same time.
: Lock nut 45.1 N-m (4.6 kgf-m) (33.3 lb-ft)

2) Low revolution (Low pressure) side

➀ Confirm the radiator cooling water temperature is
lower than 80°C (176°F)
➁ Loosen the lock nut (23), adjust the rpm's (pressure)
by turning the adjusting screw (24).
Turn the adjustment screw clockwise as viewed from
the valve end to raise the rpm's (pressure).
Set revolution 1,120 min-1 (rpm)
[Set pressure 9.5 MPa (97 kgf/cm2) (1,379 psi)]
➂ After adjusting the fan rpm's, tighten the lock nut (23)
while holding the adjusting screw (24) so as not to
turn it at the same time.
: Lock nut #22: 31.4 N-m (3.2 kgf-m) (23 lb-ft)

03-28
Measuring Fan Revolution 115ZV MEASUREMENT FOR PERFORMANCE CHECK 03

(S/N 0121~, S/N 9011~)

WARNING Fan motor

Cooling fan

The residual oil pressure in the hydraulic line 90.0

Check valve
cm3/rev
could spout high pressure oil and cause serious
T1 P1
injury such as burn when a hose or plug is
T Ps
removed.
18.1 MPa (2,625 psi) Thermo-sensing
Make sure to release the residual pressure from Radiator valve
the line and the internal pressure from the tank
Pp
before starting adjustment. T2

Ts P High pressure set:

Measuring and adjusting the maximum number of 18.0 MPa (2,610 psi)
From unloader valve
Low pressure set :
revolutions 8.1 MPa (1,175 psi)
1) Remove hose and adapters from the ports Pp and Relief valve
TS, and attach plugs to the both ports.
Hydraulic circuit diagram
Port size … PF 1/4 115ZV03010

2) Remove the plug from the port Ps, and attach a

gauge. Adapter
Gauge … About 19.6 MPa (200 kgf/cm 2 ) PP
(3,000 psi) Relief valve
Port size … PF 1/4 P

3) Measure the number of fan revolution while the

engine is at high idle.
Set pressure
T
2,350±50 min-1 (rpm) (S/N 0121~)
Engine at high idle
2,250±50 min-1 (rpm) (S/N 9011~)
-1 (rpm)
Number of High 1,600 +75
–50 min

fan revolution Low 1,120 +75 -1 (rpm)

–50 min

Relief set pressure High 18.1 MPa (185 kgf/cm2) (2,625 psi)
(guideline) TS
Low 9.5 MPa (97 kgf/cm2) (1,380 psi) Plug 115ZV42043

4) If the maximum number of revolutions is not correct,

adjust it using the adjusting screw in the relief valve. Relief valve assembly
Turn the adjusting screw clockwise to increase both
the pressure and the number of fan revolution.

Note : - The relief valve on the low pressure side Adjusting screw
cannot be adjusted because it accommodates
a thermo-sensing valve. It can be only
confirmed.
- After replacing hose and adapters in the ports
Pp and TS to normal, measure the pressure Lock nut
while the fan is moving at low speed. At this
Relief valve 65ZV43007
time, the engine cooling water temperature
should be 80 °C (176 °F) or less (Engine at HI).
03-29
Checking Brake Performance 115ZV MEASUREMENT FOR PERFORMANCE CHECK 03

Checking Brake Performance

Service brake performance check IMPORTANT
1) Method 1 The following method is easy and simple, however
WARNING it is not an accurate way, because the braking force
and rim-pull may vary on each machine. Confirm
Separate the test course by using rope etc. and
engine & transmission performance via using a
keep persons away from the test course, or else
stall test. See page 03-12. Reconfirm the brake
an accident resulting in injury or death may
performance by the method 1 as soon as possible.
occur. In addition, post persons in several
positions near the course to warn others and
WARNING
avoid an accident while checking the service
Unexpected movement of the machine may
brake performance.
cause an accident resulting in injury or death.
Before starting brake performance check, be
- Condition sure to observe the following items:
(1) Test course - Place the machine on level ground.
Level, straight, dry and the paved ground. - Check that there is enough clearance for brake
(2) Run the machine and depress the brake pedal at performance check around the machine.
35 km/h (22 mph). - During performance check, prohibit any person
Measure and record the braking distance. to walking near the machine.
- Standard measurement valve - Confirm safe conditions around the machine
Braking distance......20 m (22 1/4 yd) or shorter
(1) Lower the boom to the lowest limit, and roll back
- Possible causes of extremely long braking distance the bucket fully until the bucket contacts to the
stopper.
Possible cause Solution
(2) Set the parking brake switch to the "OFF"
Low brake line pressure Check and repair
position.
Friction plate wear Check and repair
(3) Set the T/M (transmission) cut-off switch to OFF,
Brake valve malfunction Check and repair and then depress the brake pedal all the way to
the floor.
(4) Set the shift lever to 2nd reverse speed.
(5) Gradually increase the engine speed. The
machine should not move at the maximum
Note: The brake performance check methods 1 and engine speed.
2 are based on the law and the regulation in - Possible cause of machine moving during brake
Japan. performance check.
When checking the service brake Possible cause Solution
performance, follow the law and/or local
Low brake line pressure Check and repair
regulation in your country.
Friction plate wear Check and repair

Brake valve malfunction Check and repair

2) Method 2
If no test course available as described "Method 1",
carry out the following method.

03-30
Checking Brake Performance 115ZV MEASUREMENT FOR PERFORMANCE CHECK 03

Parking brake performance check

1) Method 1
IMPORTANT
WARNING The following method is easy and simple, however
During the brake performance check on a slope, it is not an accurate way, because the braking force
unexpected movement of the machine may and rim-pull may vary on each machine. Confirm
cause an accident resulting in injury or death. engine & transmission performance via using a
Before starting brake performance check, be stall test. See page 03-12. Reconfirm the brake
sure to observe the following items: performance by the method 1 as soon as possible.
- Check that there is enough clearance for brake
performance check around the machine. WARNING
- During performance check, prohibit any person Unexpected movement of the machine may
to walking near the machine. cause an accident resulting in injury or death.
- Confirm safe conditions around the machine. Before starting brake performance check, be
sure to observe the following items:
- Condition
- Place the machine on level ground.
(1) Test course
- Check that there is enough clearance for brake
1/5 slope (Approx. 11° 19')
performance check around the machine.
(2) Bucket empty
- During performance check, prohibit any person
(3) Parking switch ON
to walking near the machine.
- Standard measurement
- Confirm safe conditions around the machine
No movement on 1/5 slope.
(1) Set the parking brake switch to the "ON" position.
- Possible cause of machine moving during brake (2) Disconnect the cable connector of parking brake
performance check solenoid valve.
(3) Place the shift lever to the 2nd forward position.
Possible cause Solution
(4) Gradually increase the engine speed. The
Clearance between brake drum and
Clearance adjustment machine should not move at the maximum speed.
shoe too large
Improperly adjusted spring chamber link Check and adjustment IMPORTANT
Broken spring chamber spring Check and repair If the machine begins to move with the parking
Parking brake solenoid valve malfunction Check and repair brake applied, the brake shoes are burnt or
misadjusted.
Note: The brake performance check methods 1 and
At the completion of parking brake test, be sure
2 are based on the law and the regulation in
to connect the connector of electrical line to the
Japan.
solenoid valve again.
When checking the service brake
performance, follow the law and/or local Possible cause Solution
regulation in your country, state or province. Clearance between brake drum and shoe too large Clearance adjustment

Improperly adjusted spring chamber link Check and adjustment

2) Method 2
Broken spring chamber spring Check and repair
If no test course available as described "Method 1",
Parking brake solenoid valve malfunction Check and repair
carry out the following method.

03-31
Measuring Brake Line Oil Pressure 115ZV MEASUREMENT FOR PERFORMANCE CHECK 03

Measuring Brake Line Oil Pressure

WARNING CAUTION
Unexpected movement of the machine may cause an Be careful, you may get burned if the high pressure oil
accident resulting in injury or death. Therefore, to spouts out. To prevent such an accident, be sure to
provide repair service with the engine running, be sure release the residual pressure from the pipe, and open
to observe the following items: the cap of the hydraulic oil tank before removing the
- Park the machine on level ground. plug and hose from the pressure measurement port.
- Apply the parking brake.
- Block the tires with chocks to prevent the tires from moving.
- Determine the signals between the service men.
- Prohibit any person from walking into dangerous areas.
(PPI) (Z)
- Near articulation area of the machine
- Under the machine (Z2) (Z1)

- Around the engine (PA)

ACF (ACCF) (ACCR)
- In front of or behind the machine (PARKING)

(TA) (PI)

(T) (P)

1. Brake line main pressure

Brake line main pressure is regulated by the unloader valve.
1) Measuring unloader valve setting pressure
ACF port
- Measurement instrument
Hydraulic pressure gauge: 24
22
21
19.6 MPa (200 kgf/cm2) (3,000 psi) Fan motor port

- Gauge measuring port Valve assembly

ACF port on valve assembly......Rc (PT) 1/8
- Measuring pressure
(1) Lower the boom to the lowest limit, and tilt the
bucket down to the ground.
Pump port
Then set the parking brake switch to the "ON"
position. Unloader valve
(2) Stop the engine. Repeatedly depress and release 95ZV03006

the brake pedal till you feel light brake to 2) Adjusting unloader valve setting pressure
discharge accumulator pressure. - Adjusting procedure
(3) Remove the ACF port plug on the valve assembly (1) Remove the cap nut (24) and loosen the lock nut
and attach the pressure gauge to the port. (22).
(4) Start the engine, and keep the speed at low idle. (2) Adjust the pressure by the adjusting screw (21).
Measure and record the pressure when the Turn the screw clockwise to raise the pressure.
pointer of the pressure gauge stops rising (cut- Note: In a case that the "ON" or "OFF" pressure does
out pressure). not match the standard setting pressure, set the
(5) Keep the engine at low idle, and repeatedly "ON" (cut-in) pressure to the standard setting
depress and release the brake pedal to reduce the pressure.
accumulator pressure. Measure and record the Tightening torque
pressure when the pointer of the pressure gauge : N-m (kgf-m) (lb-ft)
stops and then starts rising again (cut-in pressure). ACF port plug......11.3 (1.15) (8.3)
- Setting pressure #22......16.7 (1.7) (12)
Cut-out 11.8 ± 0.5 MPa (120 ± 5 kgf/cm2) (1,706 ± 71 psi) #24......78.5 (8.0) (58)
Cut-in 6.9 ± 1.0 MPa (70 ± 10 kgf/cm2) (995 ± 142 psi)
03-32
Measuring Brake Line Oil Pressure 115ZV MEASUREMENT FOR PERFORMANCE CHECK 03

2. Measuring and adjusting accumulator

line pressure
Accumulator line pressure is regulated by the unloader
valve. However, the reducing valve also may affect (PPI) (Z)

brake manifold pressure or accumulator pressure, as it

is installed between the unloader valve and brake (Z2) (Z1)
(PA)
manifold. Measure pressure at the ACF ports to
ACF (ACCF) (ACCR)
(PARKING)
determine the manifold pressure when there is a brake
(TA) (PI)
pressure problem.
(T) (P)

1) Measuring reducing valve setting pressure

- Measurement instrument
Hydraulic pressure gauge:
19.6 MPa (200 kgf/cm2) (3,000 psi) ACF port
- Gauge measuring port
ACF port on valve assembly......Rc (PT) 1/8
- Measuring pressure
Valve assembly
Measure the pressure in the same way of
measuring the unloader setting pressure. 95ZV03014

Note: In case the pressure is lower than the

unloader cut-in pressure, adjust the reducing Adjusting screw
valve setting pressure to see if this may affect
the pressure setting. It may have a stuck
Lock nut
plunger or another malfunction.

2) Adjusting reducing valve setting pressure

(1) Raise the setting pressure of the unloader valve
to 12.7 MPa (130 kgf/cm2) (1,849 psi).
(2) Loosen the lockout of the reducing valve and
adjust the pressure by the adjusting screw. Turn
clockwise the screw to raise the pressure.
C
A

Note: After raising the pressure to check function of

valve, be sure to reset the unloader valve
pressure to the original setting pressure.

Tightening torque
: N-m (kgf-m) (lb-ft)
Lock nut......7.8 (0.8) (5.8)
B

Reducing valve 70ZV53003

03-33
Measuring Brake Line Oil Pressure 115ZV MEASUREMENT FOR PERFORMANCE CHECK 03

● Possible cause of extremely high or low

measurement valve and solution

Unloader valve
The pressure is too low.

Possible cause Solution

Inappropriate set unloader valve pressure Adjustment

Disassembly
Debris stuck in pilot valve (poppet)
& clean

Disassembly
Pilot spring broken
& repair

Disassembly
Defect inside pilot pump
& repair

Inspection
Inappropriate set reducing valve pressure
& repair

The pressure is too high

Possible cause Solution

Inappropriate set unloader valve pressure Adjustment

Reducing valve

The pressure is too low.

Possible cause Solution

Inappropriate set reducing valve pressure Adjustment

Disassembly
Debris stuck in ball seat face
& clean

Disassembly
Spring broken
& repair

The pressure is too high.

Possible cause Solution

Inappropriate set reducing valve pressure Adjustment

Disassembly
Debris stuck in orifice
& clean

Disassembly
Sticking plunger
& clean

03-34
Measuring Accumulator Circuit Charging Time 115ZV MEASUREMENT FOR PERFORMANCE CHECK 03

Measuring Accumulator Circuit Charging Time

WARNING CAUTION
Unexpected movement of the machine may Be careful, you may get burned if the high
cause an accident resulting in injury or death. pressure oil spouts out. To prevent such an
Therefore, to provide repair service with the accident, be sure to release the residual pressure
engine running, be sure to observe the following from the pipe, and open the cap of the hydraulic
items: oil tank before removing the plug and hose from
- Park the machine on level ground. the pressure measurement port.
- Apply the parking brake.
- Block the tires with chocks to prevent the
tires from moving.
- Determine the signals between the service
men. (PPI) (Z)
- Prohibit any person from walking into dangerous
areas.
(Z2) (Z1)
- Near articulation area of the machine
(PA)
- Under the machine
ACF (ACCF) (ACCR)
- Around the engine (PARKING)

- In front of or behind the machine (TA) (PI)

● Measurement instrument (T) (P)

- Hydraulic pressure gauge :

19.6 MPa (200 kgf/cm2) (3,000 psi)
- Stop watch
● Gauge installation position ACF port
- Valve assembly ACF port : size Rc (PT) 1/8
● Standard measurement valve (sec)
Engine speed : Low idle Valve assembly
Unloader valve pressure
95ZV03014
3.9 MPa 11.8 MPa
↑

16
(40 kgf/cm2) (120 kgf/cm2) ● Possible causes of extremely high measurement
(569 psi) (1,706 psi)
value and solution
● Measurement procedure
1.Lower the boom to the lowest limit, and tilt down
The accumulator charging time is too long
the bucket to the ground.
2.Set the parking brake switch to the "ON" position.
Possible cause Solution
3.Stop the engine. Repeatedly depress and release the
brake pedal to discharge accumulator pressure. Disassembly
Defective unloader valve
& repair
4.Attach the pressure gauge to the valve assembly
ACF port. Check and
Oil leakage from pipe
repair
5.Start the engine, and keep the engine speed at low
Disassembly
idle speed. Defective pilot pump
& repair
6.Measure and record the time from the low pressure
alarm is turned off 3.9 ± 0.5 MPa (40 ± 5 kgf/cm2) (569
± 71 psi) till the pointer of the pressure gauge stops
rising 11.8 ± 0.5 MPa (120 ± 5 kgf/cm2) (1,706 ± 71
psi).
03-35
Measuring Number of Brake Pedal Applications 115ZV MEASUREMENT FOR PERFORMANCE CHECK 03

Measuring Number of Brake Pedal Applications

WARNING CAUTION
Unexpected movement of the machine may Do not touch the fan or V-belt of the engine or a
cause an accident resulting in injury or death. hig-temperature section if the engine is running. An
Therefore, to provide repair service with the accident resulting in injury may occur.
engine running, be sure to observe the following Be sure to stop the engine before you open the side
items: cover of the engine room.Keep all guards in place.
- Park the machine on level ground. Avoid high temperature components even when the
- Apply the parking brake. engine is stopped.
- Block the tires with chocks to prevent the
tires from moving.
- Determine the signals between the service
men.
- Prohibit any person from walking into dangerous
areas.
- Near articulation area of the machine
- Under the machine
- Around the engine
- In front of or behind the machine

● Standard measurement value ● Possible causes of extremely low measurement

value and solution
Run engine 1 minute high idle, then stop the engine.
Step on the brake pedal and release, and check the 11 times
number of times until the low pressure alarm is or more
Possible cause Solution
turned on 3.9 ± 0.5 MPa (40 ± 5 kgf/cm2) (569 ± 71 psi)
Insufficient accumulator pressure due to Check and
● Measurement procedure defective unloader valve repair
1.Lower the boom to the lowest limit, and tilt down Insufficient accumulator pressure Charging
the bucket to the ground.
Insufficient accumulator pressure due to Check and
2.Set the parking brake switch to the "ON" position. defective pilot pump repair
3.Run engine 1 minute high idle, then stop the engine. Check and
Defective brake valve
4.Turn the starter switch to "ON". repair
5.Depress the right brake pedal all the way to the Check and
Defective service brake piston seal
floor, and hold down the pedal for 5 seconds. repair

Release the pedal, and wait for 5 seconds to Check and

Oil leakage from pipe
repair
depress the pedal again. Repeat.
6.Count and record the number of pedal applications
until the low pressure alarm buzzer starts to sound.

03-36
Measuring Declutch Engagement 115ZV MEASUREMENT FOR PERFORMANCE CHECK 03

Measuring Declutch Engagement

WARNING
Brake performance check on a slope is dangerous
work. An accident resulting in injury or death may
occur.
Before starting declutch engagement test observe
the following:
- Check that the slope is smooth.
- Check that the brake works well.
- Prohibit any person from walking into the
dangerous
- Determine the signs between the service men.
- Do not enter the area near the moving machine.

● Measurement instrument
- Chalk
- Scale (approx. 1 m) (3 ft.) or tapemeasure 97ZV03010
- Thin rod (approx. 1 m) (3 ft.) used as measurement Measurement rod attached to step
rod
- Vinyl tape
- Assistant / operator
- Nylon tie straps (2 or 3)

● Warm-up the engine before measuring declutch

engagement ● Measurement procedure
1) Park the machine on level ground.
● Standard measurement value 2) Attach the measurement rod to the step.
3) Position the boom approximately 50 cm (11/2ft.)
1/5 slope (approx. 11°19'), unloaded
bucket, engine maximum speed at 1st 15 cm (6 in) above the ground. Roll the bucket fully back until
speed position, quickly released inching or less the bucket contacts to the stopper.
pedal
4) Stop the machine on a 1/5 slope (approx. 11°19')
so that the machine is in the climbing direction
● Cause of extremely high measurement value and (bucket up hill) .
solution 5) Set the inching cut-off switch to ON.
Possible cause Solution
6) Set the parking brake switch to the "OFF" position.
7) Press the inching brake pedal (left pedal) all the
Too much delay in resetting Check and replace
declutch switch declutch switch way to floor.
Refer to "Time lag 8) Mark the ground at the pointer position with chalk
Too much time lag in engaging
measurement
clutch procedure". or tape. Increase the engine speed to its
maximum, and set the transmission shift lever to
the 1st forward speed.
9) Quickly release the inching brake pedal, and mark
the point at which the machine stops rolling back
(using the pointer) and starts moving up the slope.
10) Measure and record the distance on the slope.

03-37
MEMO
Notes
Notes
Notes
Notes