50ZV (Ex F&S) A4 (93205 00151)
50ZV (Ex F&S) A4 (93205 00151)
50ZV (Ex F&S) A4 (93205 00151)
June 2009
Foreword
To ensure good machine performance, reduce failures or problems, and prolong the service life of each component,
it is necessary to operate the machine as is directed in the Operator and Maintenance Manual.
To effectively diagnose and repair the machine, it is important to follow the guidelines laid out in this 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.
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
50ZV General Information ..................................................................................................................................... 00-1
How to Use Manual ........................................................................................................................................... 00-2
Safety precautions ...................................................................................................................................... 00-2
Symbols ...................................................................................................................................................... 00-3
Outline ............................................................................................................................................................... 00-4
Layout of main components ........................................................................................................................ 00-4
Inspection and maintenance table .............................................................................................................. 00-5
Recommended lubricants ........................................................................................................................... 00-8
Coolant ..................................................................................................................................................... 00-10
Lubrication chart ........................................................................................................................................00-11
Weight of main components ..................................................................................................................... 00-12
Bolt tightening torque ................................................................................................................................ 00-13
Hose band tightening torque ..................................................................................................................... 00-17
Liquid gasket and screw lock agent .......................................................................................................... 00-18
Cautions regarding welding repair service ................................................................................................ 00-20
50ZV Measurement for Performance Check ......................................................................................................... 03-1
Cautions on Safety ............................................................................................................................................ 03-2
Standard Measurement Values for Performance Check ................................................................................... 03-3
50ZV Function & Structure Chassis Group ........................................................................................................... 12-1
Front Chassis .................................................................................................................................................... 12-2
Loading linkage ........................................................................................................................................... 12-2
Loading linkage pin ..................................................................................................................................... 12-3
Rear Chassis .................................................................................................................................................... 12-4
Fuel tank ..................................................................................................................................................... 12-4
Floor board mount ....................................................................................................................................... 12-5
Center Pin ......................................................................................................................................................... 12-6
Upper center pin ......................................................................................................................................... 12-6
Lower center pin ......................................................................................................................................... 12-6
Dust seal ..................................................................................................................................................... 12-7
50ZV Check & Adjustment Chassis Group ........................................................................................................... 13-1
Linkage Pin ....................................................................................................................................................... 13-2
Liner ............................................................................................................................................................ 13-2
Center Pin ......................................................................................................................................................... 13-4
Adjusting shim (#5) ..................................................................................................................................... 13-4
Installing bearing cover (#3) ........................................................................................................................ 13-4
50ZV Function & Structure Power Group .............................................................................................................. 22-1
Power Line ........................................................................................................................................................ 22-2
Engine / Transmission ....................................................................................................................................... 22-3
Engine / transmission mount ....................................................................................................................... 22-3
Accelerator pedal ........................................................................................................................................ 22-4
Fuel control ................................................................................................................................................. 22-5
Radiator ............................................................................................................................................................. 22-6
Radiator mount ............................................................................................................................................ 22-7
Propeller Shaft .................................................................................................................................................. 22-8
Second propeller shaft assembly ................................................................................................................ 22-9
Third propeller shaft assembly .................................................................................................................. 22-10
Axle Assembly ................................................................................................................................................. 22-11
Axle Support .................................................................................................................................................... 22-12
Differential Gear .............................................................................................................................................. 22-14
Function of T.P.D ....................................................................................................................................... 22-15
Operation of T.P.D ..................................................................................................................................... 22-16
50ZV 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 ............................................................................................................................................................. 23-5
Differential gear ........................................................................................................................................... 23-6
50ZV Function & Structure Torque Converter and Transmission Group ............................................................... 32-1
Torque Converter .............................................................................................................................................. 32-2
Torque converter structure .......................................................................................................................... 32-2
Power flow path ........................................................................................................................................... 32-2
Torque multiplication ................................................................................................................................... 32-2
Torque Converter Gear Pump ........................................................................................................................... 32-3
Gear pump specifications ............................................................................................................................ 32-3
Transmission ..................................................................................................................................................... 32-4
Gear arrangement ....................................................................................................................................... 32-4
Valve location .............................................................................................................................................. 32-5
Clutch Pack ....................................................................................................................................................... 32-6
Forward and 2nd speed clutch .................................................................................................................... 32-6
Reverse and 1st speed clutch ..................................................................................................................... 32-7
3rd speed clutch .......................................................................................................................................... 32-8
Clutch specifications ................................................................................................................................... 32-8
Power Flow Path in the Transmission ............................................................................................................... 32-9
Forward ....................................................................................................................................................... 32-9
Reverse ..................................................................................................................................................... 32-10
Hydraulic System Diagram ..............................................................................................................................32-11
Hydraulic Circuit Diagram ............................................................................................................................... 32-12
Oil Flow ........................................................................................................................................................... 32-13
Oil flow in the torque converter line ........................................................................................................... 32-13
Oil flow to the clutch .................................................................................................................................. 32-13
Shift Lever ....................................................................................................................................................... 32-14
Control Valve ................................................................................................................................................... 32-15
System diagram ........................................................................................................................................ 32-16
Oil port layout ............................................................................................................................................ 32-17
Modulation Mechanism ................................................................................................................................... 32-19
Clutch control oil pressure curve ............................................................................................................... 32-19
Before the shift lever is moved (travelling or stop condition) .................................................................... 32-20
When the shift lever is moved (1) ............................................................................................................. 32-21
When the shift lever is moved (2) ............................................................................................................. 32-22
Accumulator .................................................................................................................................................... 32-23
Accumulator for 1st speed clutch .............................................................................................................. 32-23
Solenoid Valve ................................................................................................................................................ 32-25
Clutch cut-off solenoid valve ..................................................................................................................... 32-25
50ZV Check & Adjustment Torque Converter and Transmission Group ............................................................... 33-1
Clutch Oil Pressure ........................................................................................................................................... 33-2
50ZV 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 .................................................................................................................................. 42-9
Hydraulic Tank ................................................................................................................................................. 42-10
Hydraulic tank breather valve (tank cap) ................................................................................................... 42-11
Hydraulic tank specifications ..................................................................................................................... 42-12
Hydraulic oil level check ............................................................................................................................ 42-12
Hydraulic Pump ............................................................................................................................................... 42-13
Hydraulic pump specifications ................................................................................................................... 42-13
Hydraulic pump principle ........................................................................................................................... 42-14
Hydraulic pump wear plate ........................................................................................................................ 42-15
Hydraulic pump bushing lubrication .......................................................................................................... 42-15
Hydraulic Cylinder ........................................................................................................................................... 42-16
Boom cylinder ........................................................................................................................................... 42-16
Bucket cylinder .......................................................................................................................................... 42-17
Steering cylinder ....................................................................................................................................... 42-17
Hydraulic cylinder specifications ............................................................................................................... 42-18
Return Filter .................................................................................................................................................... 42-19
Return filter specifications ......................................................................................................................... 42-19
Loading System .............................................................................................................................................. 42-20
Multiple Control Valve ..................................................................................................................................... 42-21
Multiple control valve specifications .......................................................................................................... 42-23
Multiple control valve main relief valve ..................................................................................................... 42-24
Multiple control valve overload relief valve (with make-up function) ......................................................... 42-26
Multiple control valve make-up valve ........................................................................................................ 42-28
Multiple control valve bucket spool ........................................................................................................... 42-29
Multiple control valve boom spool ............................................................................................................. 42-31
Valve Control ................................................................................................................................................... 42-34
Steering System .............................................................................................................................................. 42-35
Priority Valve ................................................................................................................................................... 42-37
Priority valve specifications ....................................................................................................................... 42-37
Priority valve operation ............................................................................................................................. 42-38
Safety precautions - Contact tire manufacturer's local dealer for tire ser-
vicing and changing.
The most important point in providing repair service is - Always store the tools in good condition, and use
safety. To ensure safety, observe the general cautions them properly.
described below.
- Keep the work area clean. Clean up spills immedi-
- This manual is intended for properly trained and ately.
equipped service technicians.
- Avoid the use of flammable solvents and cleaners.
- Any work on the machine must be performed by the
trained personnel only. - When working outdoors keep work areas, ladders,
steps, decks and work platforms clear of snow, ice,
- Carefully read this manual to thoroughly understand and mud.
the operation method before you operate or repair
the machine. - Use safe work platforms to reach higher areas of the
machine.
- Be sure to wear appropriate clothes and protectors,
such as safety boots, hard hat and goggles.
Symbols
For safe and effective service work, the following sym-
bols are used for notes and useful information in this
manual.
Oil or
Shows the oil or water supply port and the refill
water
amount.
supply
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.
Outline
3 14
4 5 2 1 7 8 9
10 12 6 13 11 15
50ZVA00001
IMPORTANT
Severe applications require more frequent mainte-
nance.
Severe conditions include heavy dust, extremely
abrasive material, caustic chemicals, extremely wet
conditions or abnormally hot or cold ambient temper-
atures.
Clean or Replace Air Cleaner Element After six cleanings or once a year
Greasing
Replace Air Conditioner Receiver Dryer (option) Every 3 years or 6000 hours
Recommended lubricants
∗1 ISO VG32
Hydraulic tank 48.3 liter Hydraulic oil ISO VG46
2,000
Engine Use oil that meets engine oil classification API CH4 or CG4.
∗3. Change engine oil every 250 hours unless CH4 is used.
Engine oil drain intervals need to be reduced by 50% when fuel sulfur content exceeds
0.5 %.
Transmission Use engine oil classification API CD or A.T.F. (Auto Transmission Fluid).
Never mix engine oil and ATF.
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.
Differential & Use class API CD engine oil with 5% "Antichatter" additive or friction modifier.
Planetary
Brake oil Use engine oil classification API CD, SAE 5W or 5W-20 only.
Coolant
Coolant specification
Expected Minimum
-35ºC -30ºC -25ºC -20ºC -15ºC
Ambient Temperature
Pure Water liter 19.7 21.8 23.9 26.0 28.1
IMPORTANT
Do not mix different brands of antifreeze because
they each contain special additives.
Careless mixing often diminishes the effect of these
additives and causes packing damage or water leak-
age.
00-11
50ZV General Information
Outline
Lubrication chart
LINK STEERING
SYSTEM SYSTEM TO
EVERY DAY
HO BO GO
EVERY 250Hr
G G
EVERY 50Hr
G EVERY 50Hr
EO
G G AXLE SUPPORT
EO G G EVERY 250Hr
BUCKET CENTER PIN
ENGINE OIL PAN 3RD
PROPELLER SHAFT
2ND
PROPELLER SHAFT
60ZV00002
G HO
Grease point Multipurpose grease Hydraulic oil
GO TO
Check and add if necessary Gear oil Engine oil
EO
Oil replacement Engine oil
00-12
50ZV General Information
Outline
(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.
00-14
50ZV 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.
00-15
50ZV 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.
00-16
50ZV General Information
Outline
(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
00-17
50ZV General Information
Outline
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
To reassemble the disassembled parts, be sure to use Completely remove the hardened lock agent from the
the specified liquid gasket or screw lock agent or the screw and the threaded hole before reassembling the
equivalent according to the following lists: screw.
Caution
65ZV00004
Blind hole
H
Abt 1/3H
65ZV00003
00-20
50ZV General Information
Outline
Cautions
1. Turn the starter switch OFF. 4. 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. The spark may damage the cylinder
3. Ground the welder near the section to be welded. rod.
Example 1
Section to be welded
35C00002
Example 2
35C00006
00-21
50ZV General Information
Outline
35C00005
Pin
Note
The weld spattered on the plated sections causes corro-
sion.
Section to
be welded
1m or more
35C00004
MEMO
03-1
50ZV Measurement for Performance Check
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 tank before removing
the plug from the pressure measurement port so that
the internal pressure of the hydraulic tank is released
and burst of the high pressure oil can be prevented.
WARNING
Entering the articulation area of the machine body
while the engine is running may cause severe acci-
dents.
Make sure to stop the engine, pull out the starter key,
and attach a "DO NOT OPERATE!" tag to the cab
before entering the articulation area.
03-3
50ZV Measurement for Performance Check
Standard Measurement Values for Performance Check
Engine speed
(min-1) (rpm) Maximum speed in multiple control valve relief mode 2,170±100
Engine speed
MPa (kgf/cm2) (psi) Maximum (HI) 1.3~1.6 (13~16) (185~228)
20.6±0.5 (210±5)
Loading line main relief pressure (HI)
(2,986±71)
Front Chassis
Loading linkage
4 5
50ZV12001J
1. Bucket
2. Link
3. Lever
4. Bucket cylinder
5. Boom
6. Boom cylinder
12-3
50ZV Function & Structure Chassis Group
Front Chassis
7 8 4
11
3
10
1 50ZV12001
12-4
50ZV Function & Structure Chassis Group
Rear Chassis
Rear Chassis
Fuel tank
EMPTY
FULL
1
25
4 2 5
30
3
6 7
(140 L)
217
View A
50ZV12003a
1. Fuel tank
2. Fuel level sensor
3. Fuel tank filler assembly
4. Drain plug
5. Inspection hole cover
6. Suction pipe
7. Fuel return pipe
12-5
50ZV Function & Structure Chassis Group
Rear Chassis
Floor board
1
1
2
60ZV12007
5
1. Floor board
2. Viscous mount
6
7
8 9
70ZV12007
1. Stud
2. Cushion rubber
3. Case
4. Cap
5. Damping plate
6. Plain washer
7. Head bolt
8. Silicon oil
9. Plug
12-6
50ZV Function & Structure Chassis Group
Center Pin
Center Pin
1 4 10
3
8 1 4
Front chassis
6
2
Front
7 chassis Rear
chassis
2 11
9 Rear chassis
Upper 50ZV12004 Lower 50ZV12005
Upper Lower
Dust seal
Center
pin
When installing the dust seal, check that the lip faces
toward the outside. If the lip faces toward the outside,
the dust will not be drawn through the seal.
12-8
50ZV Function & Structure Chassis Group
MEMO
13-1
50ZV Check & Adjustment Chassis Group
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
50ZV13001
Adjustment
1 2 3 4 5
portion
Liner hole dia. 51 71 56 61 36
mm (in) (2.00) (2.80) (2.20) (2.40) (1.42)
13-3
50ZV Check & Adjustment Chassis Group
Linkage Pin
Adjustment
* *
95ZV12005
Center Pin
1 4 10
8
3 Front
Grease hole
6 60ZV13001
Front
7 chassis Rear
chassis Install the bearing cover so that the grease nipple
2 11 mounting hole is positioned as shown in the figure.
9
Upper 50ZV12004
Power Line
2 1 9 10 3
6 4 8 5 7 11
50ZVA22001
Engine / Transmission
A
Rear axle C/L
4
Flexible
plate
3
Trans-
mission Front Rear
1
Flywheel
1 2
Clearance 1 mm Clearance 1 mm
2
50ZV22002
Accelerator pedal
1
25
2 11
10
10
12
9 13
2
7
3
8
3
8
4
4
6
Stroke
5 44.5 6 5
(1.8 in)
(mm)
1. Accelerator pedal (in)
44.5
2. Rod 40 (1.8)
3. Lever (1.6)
Lever stroke
4. Plate 30
(1.2)
5. Cable support 20
6. Clevis (0.8)
7. U bolt 10
(0.4)
8. Nut
9. Return spring
0 10 20
10. Bellows
Pedal angle
11. Adjusting bolt
12. Lock nut
13. Bearing 65ZV22003
22-5
50ZV Function & Structure Power Group
Engine / Transmission
Fuel control
Idling
B
Full
A
50ZV22003
12 mm (0.5 in)
Rotational (cable screw
de pth)
center
Full stroke
65ZV22005
Radiator
2 Coolant IN
3
1 5
C
B
50ZV22005
1. Radiator assembly The radiator incorporates the engine coolant and torque
2. Cap converter oil cooler. For the engine coolant, the air-cool-
3. Upper tank (Soldered) ing system is used. For the torque converter oil, the
4. Lower tank (Soldered) watercooling system is used.
5. Fan shroud
6. Torque converter oil cooler
22-7
50ZV Function & Structure Power Group
Radiator
Radiator mount
60ZV22021
Capacity in radiator:
Cooling water 30 L (8 gal)
Torque converter oil 1 L (1/4 gal)
Propeller Shaft
1 3 4 2
50ZV22006
1. 2nd propeller shaft The engine power transmitted to the torque converter,
2. 3rd propeller shaft (fixed type) the transmission and is then transmitted to the second
3. Pillow block and the third propeller shafts to the front and the rear
4. Slip joint axle.
Transmission
5 1
2
Front
differential
50ZV22007
1. Flange yoke
2. Journal spider assembly
IMPORTANT
3. Sleeve yoke assembly Never reuse universal joint or driveline bolts or locks.
4. Propeller shaft assembly Always use new bolts and secure with loctite® 262
5. Journal spider assembly and primer.
6. Pillow block
22-10
50ZV Function & Structure Power Group
Propeller Shaft
2
2
1
Rear differential
Transmission
50ZV22008
1. Flange yoke
2. Journal spider assembly
IMPORTANT
3. Coupling yoke Never reuse universal joint or driveline bolts or locks.
Always use new bolts and secure with loctite® 262
and primer.
22-11
50ZV Function & Structure Power Group
Axle Assembly
Axle Assembly
24
9
11 14
14 1
19 21
22 8
6
22
21
7 18
26
16
14 20 17
15
14 3 15
5 10
2
4
10
15
12
13
23
24
25
50ZV22010
Axle Support
Front
10
1
2 3
A-A
7
Grease pipe (Front) (Rear)
5 8
connection port
Large Small
6 chamfer chamfer Large Small
chamfer chamfer
4 9
11
A A
4 11 5 6
2
3
9
#9 mounting method
50ZV22013
10
7
9
6
8
Grease piping
9 3
Grease piping
5
1 Rear differential
11
4
50ZV22012
1. Rear differential
2. Rear axle support (front)
3. Rear axle support (rear)
4. Seal
5. Seal
6. Bushing
7. Plate
8. Bolt
9. Seal
10. Breather
11. Bushing
22-14
50ZV Function & Structure Power Group
Differential Gear
Differential Gear
21 15 12
14
13
16
29
18
20 17
5 11
17
19 8
22 7
10 6
4
3 23
50ZV22003J
The differential gear used for the machine is the torque T.P.D. Conventional
proportioning type. Compared with the conventional dif- differential
ferential, the torque proportioning differential (T.P.D.)
can reduce tire slippage on sandy or muddy ground.
R2
R1
Difference in gear shapes Shaft center of side gear
95ZV22018
Conventional differential
Conventional
differential There is little change in distance from the shaft center of
the side gear.
T.P.D.
The contact point varies as the gear rotates. The dis-
tance between the contact point and the shaft center of
the side gear also varies in the range of R1~R2.
T.P.D. 95ZV22014
Conventional differential
Standard bevel gear
T.P.D.
Special bevel gear
The gear width is 35~50% longer than the conventional
differential.
22-16
50ZV Function & Structure Power Group
Differential Gear
Operation of T.P.D
Rotational direction
Pinion
Pinion
Side gear
R2
L R L R2 R1 R L R1 R
R1 R2
95ZV22015
The function of the T.P.D. is as follows: If the surface (slipping occurs), the driving force of the right wheel
resistance values of the right and left wheels differ from will be increased to limit the reduction in the total
each other, engagement position of the pinion gear with amount of the driving force.
the side gears will be automatically shifted to transmit
different torque to the right and left wheels. Different Assuming that the driving torque of the right wheel is TR,
torque in right and left wheels prevents the tires from and that of the left wheel is TL, the relation between TR
slipping. and TL can be expressed as follows:
1. When the traction of the right and left wheels are The value obtained from the above formula is referred
identical to each other, the pinion and side gears to as the bias ratio. The limit of the bias ratio is 1.4. In
will be engaged as shown in figure [A]. In this case, other words, until the difference in the surface resis-
the torque arms of both side gears are identical to tance between the right and left tires is increased to 40
each other (R1 = R2). As a result, identical driving %, the pinion gear will be properly engaged with the
force will be applied to both the right and left shifted side gears, and driving force will be properly
wheels. applied to both the side gears to prevent the tires from
slipping.
2. If the left wheel loses traction the engagement posi-
tion between the pinion and side gears will be 3. If the surface resistance of the right wheel is
shifted as shown in figure [B] to quickly rotate (spin) reduced, the engagement position between the pin-
the left wheel. As a result, the torque arms of the ion and side gears will be shifted as shown in figure
both side gears differ from each other (R1> R2), and [C] above. In this case, the right and left sides are
the driving force of the left wheel is small. As a reversed compared with the above description.
result, tire slipping can be reduced.
When the driving force of the left wheel is reduced
23-1
50ZV Check & Adjustment Power Group
Engine
Measuring engine oil pressure
WARNING
Measurement instrument
Unexpected movement of the machine may cause an
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 Install position
moving.
- Determine the signals between the service men. 1. Location (A)
- Prohibit any person from walking into dangerous Remove the oil pressure switch and install the pres-
areas. sure gauge.
- Near articulation area of the machine
- Under the machine 2. Measuring port: PF 1/8
- Around the engine
- In front of or behind the machine 3. Oil pressure gauge: 1.0 MPa (10 kgf/cm2) (142 psi)
CAUTION
Do not touch the fan or V-belt of the engine or high- Standard measurement value
temperature section if the engine is running.
An accident resulting in injury may occur. Engine speed Service standard
Be sure to stop the engine before you open the side Idle 0.18 MPa (1.8 kgf/cm 2) (26 psi)
cover of the engine room. Full 0.36 MPa (37 kgf/cm2) (53 psi)
Keep all guards in place. [Engine coolant temperature 50ºC (120ºF)]
Avoid high temperature components even when the
engine is stopped.
A
Use a photo tachometer when checking engine revo-
lution.
- Tachometer
Propeller Shaft
95ZV22007
Top view
Side view
95ZV22008
Tightening torque
IMPORTANT
Never reuse universal joint or driveline bolts or locks.
Always use new bolts and secure with loctite® 262
and primer.
1. 80 (8.15) (59)
2. 142 (14.5) (105)
3. 137 (14.0) (101)
4. 230 (23.5) (170)
Axle
Axle
16 7 4 20 11 9 6 1
17
26
13 5 2 24
23
10
15
12
25•B
21 8 22 14 (A) 18
3 19
50ZV23003
Differential gear
21 15
12
28, 29
29
18
20 17
5 11
17
27
25
9
19
8
22
26 7
10 6
4
1 3 23
50ZV23004
A Correct
2
Ring gear is too far from the
C Do the reverse adjusting as B.
drive pinion
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
Note
Single sale of the bevel gear or the drive pinion is not
possible.
32-1
50ZV Function & Structure Torque Converter and Transmission Group
Torque Converter
Torque multiplication
P T 1
95ZV32002
0.5 1.0
Speed ratio (e)
95ZV32003
Torque converter structure
If the engine speed/pump impeller speed stays the
The torque converter is between the engine and trans- same but the turbine impeller speed is reduced due to
mission, and consists of three impellers as shown in the the transmission load-output torque is increased. This is
figure. The three impellers are pump (P), turbine (T), "torque multiplication". Heat is also generated.
and stator (S) impellers.
Turbine impeller speed (min –1 ) (rpm)
Speed ratio(e)= ------------------------------------------------------------------------------------------------
-
Pump impeller speed (min – 1 ) (rpm)
Actual discharge
pump rev. 1,800 min-1 (rpm)
oil temp. at 50ºC 54 L/min (14.4 gal/min.)
(discharge pressure 2.9 MPa
(30 kgf/cm2) (427 psi))
6 5 7 9 4 6
60ZV32002
1. Front frame
2. Rear frame
3. Drive gear
4. Driven gear
5. Side plate
6. Metal bushing
7. O-ring
8. Oil seal
9. Pin
10. Snap ring
32-4
50ZV Function & Structure Torque Converter and Transmission Group
Transmission
Transmission
Gear arrangement
16 17 13 12 11 10 9
22 24
19
25
28
26
30
60ZV32003
No. Gear name Number of teeth No. Gear name Number of teeth
9 P.T.O. gear 35 19 Forward clutch gear 26
10 P.T.O. idler 52 22 Counter gear B 46
11 P.T.O. drive gear 41 24 Counter gear C 61
12 Input shaft gear 32 25 2nd speed clutch gear 22
13 Reverse clutch gear 26 26 3rd speed clutch gear 42
16 Counter gear A 46 28 Counter gear D 49
17 1st speed clutch gear 32 30 Output shaft gear 42
32-5
50ZV Function & Structure Torque Converter and Transmission Group
Transmission
Valve location
Accumulator
(for 1st speed)
T/C oil
temperature
switch
T/C inlet pressure
regulator valve Clutch pressure
T/C outlet pressure
regulator valve regulator valve
50ZV32001E
32-6
50ZV Function & Structure Torque Converter and Transmission Group
Clutch Pack
Clutch Pack
11
8 16 7 6 1 4 5 2 12 3 9 14
2ND F
10
15
13
60ZV32006
10 8 15 7 6 1 4 5 2 11 3 9 13
1ST R
14
12
60ZV32005
13 10 2 5 4 1 6 14 12
3RD
3 8 7 9 11
60ZV32007
Clutch specifications
Friction plate Steel plate Conical plate Return spring
Kind Quantity Kind Quantity Thickness (mm) Quantity Set load N (kgf) (lbs)
Forward clutch 6 6 1
Reverse clutch 6 Same dia. 6 1
1,765
Paper same dia. (Thickness: 2.8
1st speed clutch 6 6 1 (180)
(ø158 mm) 2 mm) (0.11 in)
(396 lbs)
2nd speed clutch 6 (0.08 in) 6 1
3rd speed clutch 6 6 1
32-9
50ZV Function & Structure Torque Converter and Transmission Group
Power Flow Path in the Transmission
3
4 1st R
2
1st R
7 5
8
6
7 2nd F
5
2nd F
10
10
3rd
3rd
11
11
60ZV32009
60ZV32008 - When the forward clutch and the 2nd speed clutch
are engaged, power from the torque converter is
- When the forward clutch and the 1st speed clutch transmitted via the input shaft gear (1) to the forward
are engaged, power from the torque converter is clutch gear (5) and 2nd speed clutch gear (7), then
transmitted via the input shaft gear (1) to the forward to counter gear D (10). Because the forward clutch
clutch gear (5), and via the counter gear (6) to and the 2nd speed clutch are the only clutches
counter gear A (3) and the 1st speed clutch gear (4). engaged, the power is then transmitted via the out-
From there, it is transmitted via counter gear C (8) to put shaft gear (11) to the output shaft.
the 2nd speed clutch gear (7). Because the forward
clutch and the 1st speed clutch are the only clutches
engaged, the power is then transmitted via counter
gear D (10) to the output shaft gear (11), then to the
output shaft.
Note
In the illustration here, the input shaft gear (1) and for-
ward clutch gear (5) are not meshed. But as shown ear-
lier in the "Gear Arrangement" diagram, the input shaft
gear (1) is meshed with the forward clutch gear (5) as
well as the reverse clutch gear (2).
32-10
50ZV Function & Structure Torque Converter and Transmission Group
Power Flow Path in the Transmission
1st R 4
2
6 1st R
5
8
2nd F 7
2nd F
10 9
3rd 10
3rd
11
11
60ZV32014
- When the forward clutch and the 3rd speed clutch 60ZV32015
Fixed orifice
13
From regulator valve
15
16
11 12
To reverse clutch
14
To F clutch
To 2nd speed clutch
To 3rd speed clutch
17
7
3
10
8
4
To T/C outlet
To T/C inlet
5 6
R
F
1
Note
Numbers below correspond to page 32-12.
60ZV32001E
32-12
50ZV Function & Structure Torque Converter and Transmission Group
Hydraulic Circuit Diagram
17
4 7 12
10
8
14
9
R 1st 16 15
6 Temp.
3 switch
F 2nd
3rd
2
1
Clutch
60ZV32002E
1. Transmission case
2. Suction strainer
3. Torque converter pump
4. Line filter
5. Regulator valve
6. Torque converter inlet pressure regulator valve
7. Torque converter
8. Torque converter outlet pressure regulator valve
9. Oil cooler
10. Lubricating-oil valve
11. Pressure detection valve
12. Accumulator
13. Solenoid valve
14. Clutch cut-off valve
15. Forward/Reverse selection spool
16. Speed selection spool
17. Accumulator (For 1st speed, installed separately)
32-13
50ZV Function & Structure Torque Converter and Transmission Group
Oil Flow
Oil Flow
Note
From cooler to lubrication circuit The engine will not start if the shift lever is set to the for-
ward or reverse position. The shift lever must be set to
Oil cooled by the oil cooler (9) flows through the lubrica- the neutral position to start the engine. Therefore, the
tion oil passages in the transmission housing to lubri- machine will not move when the engine is started.
cate all the bearings and to cool the clutch plates. After
that, the oil is drained into the oil pan. When the 1st speed position, which involves a high
reduction ratio, is selected, a certain amount of shock
would occur.
Shift Lever
A A
1
1 R
FN
5 R
(Yellow ring)
3
2
1
K60V2J72001
When shift lever (4) is moved forward, control cable (6) Turn shift lever (4) to select the desired machine speed.
pushes the T/M control valve spool in. As a result, the Control cable (5) pushes and pulls the transmission
transmission forward clutch is engaged. speed selection spool by turning shift lever (4).
The machine does not move when shift lever is in N One of the speed clutches is always engaged when
(neutral) position. starting the engine.
32-15
50ZV Function & Structure Torque Converter and Transmission Group
Control Valve
Control Valve
Identification mark
Identification mark
Section B-B
D D 1 2 3
Back light switch
C C
60ZV32003E
32-16
50ZV Function & Structure Torque Converter and Transmission Group
Control Valve
System diagram
From
regulator valve
11
12
To reverse clutch
15
13
To F clutch 14
60ZV32004E
B B B
d 3 2 1 D
P c D
D a
b
From regulator valve
B B
D R g F D
D D
B B B
Sub-plate
B B B
D To 3rd speed
clutch Plate installation
hole
To 1st speed clutch
From
D
To 2nd regulator valve
speed clutch D
B B
To forward To reverse
clutch clutch
D
D
D
D
B B B
60ZV32006E
32-19
50ZV Function & Structure Torque Converter and Transmission Group
Modulation Mechanism
Modulation Mechanism
When forward/reverse or speed changing, the modula- Clutch control oil pressure curve
tion mechanism works to reduce the time required for
clutch engagement (time lag), to prevent the shock at
clutch engagement, to improve the work efficiency and
durability of the power system, and to ensure operator's
comfort.
Clutch pressure
For such effects, the modulation mechanism controls MPa (kgf/cm2)
the clutch oil pressure rising time as follows:
P3
P2
P1
t1 t2 Time (sec)
70ZV32020
Orifice A
Accumulator
60ZV32020a
Orifice A (C)
Accumulator (discharging)
60ZV32021a
When the shift lever is moved, the circuit pressure Under this condition, oil from the regulator valve flows
between the fixed orifice A and the clutch drops until oil through the fixed orifice A, passage (1) and orifice (C) in
fills the piston chamber of the clutch that is engaged the spool, passage (3) and the fixed orifice B and into
and force the piston against the clutch plates. the clutch piston chamber, and this keeps the low oil
pressure in the piston chamber.
This drop in circuit pressure causes a drop in the pres-
sure forcing the accumulator piston to the right, so the
spring moves the piston to the left, and the oil in the
accumulator is directed to the piston chamber of the
clutch that is engaged.
Orifice A (C)
60ZV32022
After oil from the accumulator initially fills the clutch pis-
ton chamber, the oil from the regulator valve flows
through passage (1) and orifice (C) in the spool, pas-
sage (3) and the fixed orifice B, and into the accumula-
tor, filling it.
Accumulator
Accumulator for 1st speed clutch During shifting to 1st speed (A)
1 1st accumulator 4 3 2
Oil from the 1st speed solenoid valve flows through the
pressure detection valve (4) and passage [1] into the 1st
5
speed accumulator, pushing the piston (1) to the right
against the stopper (3). (Charging of the accumulator.)
Pressure
detection valve
During shifting to 1st speed (B) When shifting to 1st speed is completed
1 4 3 4
[1]
[2]
To 1st clutch From 1st speed solenoid 60ZV32012 To 1st clutch From 1st speed solenoid 60ZV32013
When the piston of 1st speed accumulator (1) has been After the oil in the accumulator has been discharged
stopped by the stopper (3), oil from passage [2] starts to into the drain port, there is still oil pressure in the clutch
move the spool of the pressure detection valve (4) to port. Therefore, the spool of the pressure detection
the right. valve (4) remains at the right with the oil pressure and
the force of spring (5) balanced.
Consequently, the oil filling the accumulator flows
through passage [1] and the pressure detection valve
(4) and drains into the drain port. (Discharging of the
accumulator.)
32-25
50ZV Function & Structure Torque Converter and Transmission Group
Solenoid Valve
Solenoid Valve
P
During travel
T
Port (A) of the solenoid valve is open to port (T), and oil
leaking from the cut-off valve drains to the tank.
32-26
50ZV Function & Structure Torque Converter and Transmission Group
MEMO
33-1
50ZV Check & Adjustment Torque Converter and Transmission Group
5
6
9
4
7
2
9
8 3
50ZV33001E
WARNING
Unexpected movement of the machine may cause an
accident resulting in injury or death.
Therefore, to provide repair service with the engine
running, be sure to observe the following items :
- Park the machine on level ground.
- Apply the parking brake.
- Block the tires with chocks to prevent the tires from
moving.
- Determine the signals between the service men.
- Prohibit any person from walking into dangerous
areas.
- Near articulation area of the machine
- Under the machine
- Around the engine
- In front of or behind the machine
Purpose of flushing
Debris
To tank
95ZV42001
Work procedure
(a) Before installing pipes, pour new oil into the pump
or the cylinder.
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.
Working (1)
hydraulic Fixed
line displacement,
Hydraulic pump
(1) Unidirectional (2)
Pilot line (2) Bidirectional
Drain line
(1)
Lines Variable
joining displacement,
Non-compensating
hydraulic pump (2)
Flexible (1) Unidirectional
line (2) Bidirectional
(1)
Lines Fixed
passing 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)
(1) (2)
Rotary joint Single
(1) one line acting cylinder
(Unidirectional) (without spring)
(2) three line (2)
(Bidirectional)
(1) (2)
Single
acting cylinder
(with spring)
(1) (2)
Double
acting cylinder
(single rod)
(1) (2)
Double
acting cylinder
(double rod)
Single flow
Spring path valve,
Normally closed
Single flow
Adjustable spring path valve,
Normally open
Control methods
Pressure
Lever
relief valve
Push button
Unloading valve
Pedal or treadle
Mechanical
control
Sequence valve
Plunger
Pressure
Spring
reducing valve
Solenoid
control
Single acting
solenoid Flow control valve
Double acting Flow control
solenoid valve, Adjustable
non-compensated
Electric motor
control Pressure
compensated flow
control valve
Unidirectional M
fixed
Bidirectional M
variable
Detent
Flow dividing
valve
42-6
50ZV Function & Structure Hydraulic Group
Hydraulic Circuit Symbols
Two position
Check valve
Two ports
Four ports
Shuttle valve
with restrictor
Two position
Two ports
Mechanical
control
Spring offset
Pressure
control
Two position
Three ports
Pressure control
Spring offset
Solenoid
control
Restrictor
Two ports
Three ports
Four ports
Servo valve
42-7
50ZV Function & Structure Hydraulic Group
Hydraulic Circuit Symbols
(1)
Hydraulic tank
(1) Vented
(2) Pressurized (2)
Manual
shut off
valve
Pressure
switch
Accumulator
Electric
motor M
Internal
combustion M
Power source
Filter or
strainer
Heater
Cooler
Pressure
gauge
Temperature
gauge
Flow meter
42-8
50ZV Function & Structure Hydraulic Group
Hydraulic System Operation
Loading system Oil from pump (1) flows to Orbitrol® (3) through the pri-
ority valve (2).
The loading system consists of the following compo-
nents. All numbers base on page 92-4. When the steering wheel is turned, an amount of oil pro-
portional to the turning speed is sent from the pump (1)
- Hydraulic pump (1) to the steering cylinder (7)(8) through the priority valve
- Priority valve (2) (2) and the Orbitrol® (3).
- Multiple control valve (4)
- Boom cylinders (5) When the steering wheel is not operated, almost all of
- Bucket cylinder (6) the hydraulic oil discharged from the pump (1) is sup-
plied to the loading circuit.
Oil from pump (1) flows to priority valve (2). The priority
valve functions to distribute oil discharged from only one Priority valve (2) detects the resistance of the hydraulic
pump adequately to both steering and loading circuits oil passing through the Orbitrol® (3), namely the speed
plus relieve excessive hydraulic pressure for steering. of the steering wheel’s rotation and the amount of oil,
and then distributes oil to the loading and steering cir-
When the steering wheel is not operated, almost all cuits.
hydraulic oil discharged from pump (1) is sent to multi-
ple control valve (4) through priority valve (2). Cushion valve (12) is provided to prevent shock at the
time of starting and stopping the steering wheel.
When the steering wheel is turned, an amount of oil pro-
portional to the turning speed is sent from pump (1) to While the steering wheel is not turned, almost all
steering cylinders (7)(8) through priority valve (2) and hydraulic oil from the steering pump (1) is sent to the
Orbitrol® (3). loading line by the action of the flow control spool.
Excessive oil is sent to multiple control valve (4). Oil returns from the steering cylinders (7)(8) flows
through Orbitrol® (3) and returns to the hydraulic tank.
Oil from pump (1) is then directed through multiple con-
trol valve (4) to boom cylinders (5) and bucket cylinder Finally it returns to the tank through the return filter (9).
(6).
5 6 1 2 7 4 2
7
50ZV42001E
Hydraulic Tank
2
2
Pump
Return
4
4
5
1. Oil tank
2. Oil level gauge
3. Breather valve (tank cap)
4. Drain plug
5. Inspection port 50ZV42003J
42-11
50ZV Function & Structure Hydraulic Group
Hydraulic Tank
Hydraulic tank breather valve When the pressure inside the hydraulic tank drops
below the outside air pressure, the outside air flows
(tank cap) through the filter element (6). The suction valve (3) is
then opened to let the air flow into the tank.
6 1
2 When the air pressure inside the hydraulic tank rises to
3 a certain point 78.5 kPa (0.8 kgf/cm2) (11.4 psi), the dis-
charge valve (2) is lifted (opened) so that the air can
flow out of the tank through the filter element (6).
7
One cycle (down and up) of the boom applies pressure
to the inside of the tank.
50ZVA42010
1. Cap
2. Discharge valve
3. Suction valve
4. Strainer
5. Key (Allen 4 mm (5/32 in))
6. Filter element
7. Knob
42-12
50ZV Function & Structure Hydraulic Group
Hydraulic Tank
50ZV42003
42-13
50ZV Function & Structure Hydraulic Group
Hydraulic Pump
Hydraulic Pump
4 5 1
5
6
10
8 9
60ZV42005J
Type SAR2-45A
Theoretical discharge cm3/rev 34.7
Maximum operation pressure MPa (kgf/cm2) 20.6 (210)
-1
Maximum speed min (rpm) 2,420
Measurement conditions:
Inlet Outlet
Inlet Outlet
Inlet Outlet
95ZV42040
When the gear teeth mesh again, the oil is extruded out
of the tooth cavities and forwarded to the outlet.
42-15
50ZV 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
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.
115ZV42006
42-16
50ZV Function & Structure Hydraulic Group
Hydraulic Cylinder
Hydraulic Cylinder
Boom cylinder
9,10 15 11 12
1
9 6 3 2 13,14
7
8
5
4 A B
15 11
5, 23 8 7 9 9 10 6
Bucket cylinder
8 6 22 9 8
9
7
4 21
5
A-Detail
4 3 2 1 11 6 11 12
A B
B-Detail
50ZVA42005
Steering cylinder
8 4 7 20 9 10 2 3 1 15 16 17 18
19
13, 14 13, 14
50ZV42006
Return Filter
Return filter
50ZV42003E
2 3
Return filter specifications
Type Cartridge type
Filtration area 5,100 cm2 (791 in2)
Filtration degree 10 µ
IN OUT
0.15±0.03 MPa
Bypass valve cracking pressure (1.5±0.3 kgf/cm2)
1 (21.3±4.3 psi)
60ZV42007
1. Filter cartridge
2. Head cover
3. Bypass valve
42-20
50ZV Function & Structure Hydraulic Group
Loading System
Loading System
When the control lever is operated, the multiple control
valve spool is moved by the control cable.
Control lever
Control
cable
Multiple
control valve
Steering Priority
circuit valve
Return
P filter
60ZV42009J
42-21
50ZV Function & Structure Hydraulic Group
Multiple Control Valve
8 9 11
7 10
1 5
A2 B2 Boom spool
A1 B1 Bucket spool
2
4 P T
3
6
IN OUT
OU
T
K60V2J42005
A2 B2
A1 T P B1
Bucket Bucket
cylinder cylinder
4 4
60ZV42010J
The bucket priority line is used for the multiple control Multiple control valve specifica-
valve, and consists of the following units:
tions
1. Main relief valve
Model 2000H-2-MD
Relieves the pressure when the working pressure 20.6 MPa
exceeds the relief setting pressure. Main relief valve setting pressure (210 kgf/cm2)
(2,986 psi)
Chamber A
Main poppet Orifice1 Orifice2 Pilot poppet
Sleeve
Main poppet
To tank Sleeve
Adjusting screw
From pump
Lock nut
Main poppet Chamber A
Passage B Pilot poppet
60ZV42021
2. When the oil pressure exceeds the set point Adjusting set pressure
- When the oil pressure in the pump port exceeds the Loosen the lock nut and adjust the pressure by the
set spring force of the pilot poppet, the pilot poppet is adjusting screw. Turn clockwise the adjusting screw to
opened, and the oil in the chamber A flows through raise the set pressure, or turn counterclockwise the
the passage B and along the sleeve and escapers to adjusting screw to lower the set pressure.
the tank port. As a result, the oil pressure in the
chamber A rapidly lowers. After adjustment, be sure to tighten the lock nut.
The main poppet is pushed to the right. Then it
opens the port to the tank port and the pressurized Set pressure
oil in the pump port escapes to the tank port. 20.6 MPa (210 kgf/cm2) (2,986 psi)
42-26
50ZV Function & Structure Hydraulic Group
Multiple Control Valve
Sleeve
Adjusting screw
Cylinder
Piston
Lock nut
Main poppet Orifice2 Pilot poppet
60ZV42022
ber A side and the piston is pressed against the pilot Adjusting set pressure
poppet. Therefore the oil flows from the cylinder to
the chamber A through only annular clearance
between the main poppet and piston and through the
orifice (2), as a result the pressure difference
between the cylinder port side and chamber A Adjusting screw
becomes greater. The main poppet opens and the
pressurized oil in the cylinder port escapes to the
tank port.
2. As make-up valve
Lock nut
Sleeve 60ZV42023
Tank
B
A
When the cylinder pressure becomes less than tank
pressure, the make-up valves is opened.
Cylinder
Main poppet
Tank
Cylinder
60ZV42024
D
B1 A1
Main relief
From pump
C valve
50ZVA42001
On the other hand, the oil on the rod side of the bucket
cylinder returns from the B1 port to the tank.
D
B1 A1
From pump
C 50ZVA42002
D
B2 A2
Make-up valve
On the other hand, the oil on the rod side of the boom
cylinder returns from the B2 port to the tank.
D
B2 A2
From pump
C
50ZVA42004
From pump
60ZV42019J
Valve Control
B A
Down Raise
Boom operation Roll back Dump
(Forward/Rearward)
3
3
Front chassis
Floor board
Ball joint-Detail
B-Detail
60ZV42020J
42-35
50ZV Function & Structure Hydraulic Group
Steering System
Steering System
Orbitrol®
Steering
cylinder
Cushion valve
To loading circuit
Priority valve
P Pump
Tank 60ZV42032
60ZV42002E
1. Priority valve
2. Cushion valve
3. Steering cylinder
4. Orbitrol®
42-37
50ZV Function & Structure Hydraulic Group
Priority Valve
Priority Valve
CF EF
LS
To the Orbitrol®
LS port
1 To the tank
T
P
4 2 3
From the pump
Hydraulic symbols
LS CF EF
P
2 4 5 1
50ZVA42006
Co
To loading circuit
P LS T
CF EF
Spring (2)
Chamber B
LS
From pump
50ZVA42007
The priority valve functions to distribute oil discharged orifice Co). So, in the CF circuit and also in the pres-
from only one pump adequately to both steering and sure chamber A the pressure will increase.
loading circuits plus relieve excessive hydraulic pres-
sure for steering. - On the other hand, only a small amount of the pres-
sure remains in the pressure chamber B, because it
1. When the steering wheel is not operated is connected to the tank through the Orbitrol® ports
LS and T.
- Spool (1) moves right and left depending upon the
difference in the pressure between the pressure - Accordingly, when a large difference in the pressure
chambers A and B and the force of the spring (2). arises between the pressure chambers A and B, the
spool moves from the left to the right and is held in
- When the steering wheel is not operated, the oil dis- that position. Now the EF circuit is almost fully
charged from the pump flows into the Orbitrol® port P opened and the CF circuit is only slightly opened.
through the priority valve ports P and CF.
- The pressure in the steering circuit is equal to the
- When the Orbitrol® is in the neutral state, P and T spring force, namely about 0.7 MPa (6.9 kgf/cm2) (98
ports in the Orbitrol® are nearly closed (indicated by psi) regardless of the pressure in the loading circuit.
42-39
50ZV Function & Structure Hydraulic Group
Priority Valve
C1
P LS T To loading circuit
CF EF
Pressure
chamber B
LS
P: Pump
T T: Tank
Pressure
chamber A Co: Controlled orifice
LS: Line signal
CF: Controlled flow
P
EF: Excess flow
From pump
50ZVA42008
- When the steering wheel is turned clockwise, the oil - So, the spool housed in the priority valve always
passage is changed in the Orbitrol® as shown below. works to keep the amount of oil discharged from the
Oil supplied to the Orbitrol® flows into the cylinder pump adequate to the speed of turning the steering
through control orifice C1 and the rotor. wheel.
LS
Pressure
chamber A
P
3
From pump 2
50ZVA42009
Note
Actual adjustment procedure is shown in the inspection
and adjustment section of this manual.
42-41
50ZV Function & Structure Hydraulic Group
Orbitrol®
Orbitrol®
A sensing-type Orbitrol® is used in this model in combi- Orbitrol® construction
nation with the priority valve, which regulates the oil flow
from the pump in proportion to the rotating speed of the
1. Spool 6. Centering spring
steering wheel.
2. Sleeve 7. Cross pin
3. Stator 8. Emergency check valve
4. Star 9. Inlet check valve
5. Drive shaft
Valve part
T
6
7 L
Valve part
1 9
2 R
3
4
Rotor part
60ZV42037
42-42
50ZV Function & Structure Hydraulic Group
Orbitrol®
Rotor part
1 2
Oil groove
To tank
To steering cylinder
To steering cylinder
Oil hole
From priority
valve (pump)
To priority valve LS port 60ZV42038
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 To priority
2 9 valve
R P LS port
From priority
3 70ZV42025
valve
4 CF port
1. Spool 6. Centering spring
2. Sleeve 7. Cross pin
3. Stator 8. Emergency check valve
60ZV42039
4. Star 9. Inlet check valve
5. Drive shaft
- 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.
Turn
(When the steering wheel is being turned)
T
6
7 L
1
2 9
R
60ZV42041
65ZV42036
42-45
50ZV Function & Structure Hydraulic Group
Orbitrol®
Steering cylinder
Steering cylinder
60ZV42042
- 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, the hydraulic circuit is opened, and oil starts and the sleeve, oil continues flowing into the
flowing. Oil from the pump enters the Orbitrol® and Orbitrol®, and the star can continue rotating. Due to
turns the star; this oil flows into the steering cylinder. this rotation, the sleeve catches up with the spool,
At this time, the star rotation is transmitted to the and closes the hydraulic circuit. Finally, the centering
sleeve by the drive shaft and the cross pin. spring returns the spool and the sleeve to the neutral
position and flow of oil is completely stopped.
- As a result, the sleeve starts rotating slightly behind
the spool as if to follow its rotation. This way the
spool can continue rotating, allowing the steering
wheel to be turned and the machine to be turned.
42-46
50ZV 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
star, 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 star is
small, so the star turns slowly.
- For this reason, the spool rotates faster than the star,
and the displacement angle reaches a maximum
point, and the spool turns the star by means of the
cross pin and drive shaft. At that time, the star works
as a hydraulic pump, and the steering wheel is
70ZV42028 harder to turn.
1. Spool
2. Sleeve
3. Centering spring
6 3
6 3 6 3
5 4 5 4 5 4
7 2
6 3
5 4
- Inside the star there is a stator with 7 internal gears - The star makes a 1/6 turn per rotation of the star,
that is fixed to the housing and a 6-tooth star that is pushing out oil equivalent to 7 chambers. When the
engaged with the stator. star 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 star
is connected to the high-pressure side and the other - For the motor, it has 6 times larger torque or a 1/6
half to the low-pressure side. reduction effect.
When high-pressure oil flows into the chamber, the
star is forced to turn in the direction that will expand
the area of the chamber (by means of pressure dif-
ference).
Auxiliary valves
2
D
L R
1
D
A
LS
4
D
3
T P
A-A
C
C
C
C
60ZV42044
®
The Orbitrol housing contains 2 overload relief valves,
2 make-up valves, 1 inlet check valve, and 1 emergency
check valve.
42-49
50ZV Function & Structure Hydraulic Group
Orbitrol®
Overload relief valve and make-up valve When the steering wheel is not being turned, the oil
between the Orbitrol® and the cylinder is sealed in.
When the overload relief valve opens and causes the oil
in the cylinder to escape to the tank, the pressure in the
External force
opposite section of the cylinder (the rod end of the cylin-
der in the figure) becomes negative. When that hap-
pens, the make-up valve opens and directs the oil from
Overload Make-up valve the tank into the cylinder, cancelling the suction pres-
relief valve sure in the cylinder.
Note
Unless the Orbitrol® is removed, it is impossible to
Orbitrol® adjust the overload relief valve.
Check ball
Tank port
Cylinder port
60ZV42045
42-50
50ZV Function & Structure Hydraulic Group
Orbitrol®
Emergency To prevent this reverse flow of oil, the inlet check valve
check valve
is installed between the priority valve and the Orbitrol®.
60ZV42046
42-51
50ZV Function & Structure Hydraulic Group
Cushion Valve
Cushion Valve
To steering cylinder L port To steering cylinder R port To steering cylinder L port To steering cylinder R port
B A
3
Section B-B
B A
Section A-A
4 1
2
1. Main spool L R
2. Pilot poppet
3. Check valve
4. Plug
5. Orifice
13 5
60ZV42047
42-52
50ZV Function & Structure Hydraulic Group
Cushion Valve
CAUTION
Be careful, you may get burned if the high pressure
oil spouts out. To prevent such an accident, be sure
to release the residual pressure from the pipe, and
open the cap of the hydraulic tank before removing
the plug from the pressure measurement port.
CAUTION
Do not touch the fan or V-belt of the engine or a high-
temperature section if the engine is running. An acci-
dent resulting in injury may occur.
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.
43-3
50ZV Check & Adjustment Hydraulic Group
Loading/Steering Circuit Relief Valve
Standard measurement value MPa Measuring loading circuit main relief pres-
(kgf/cm2) (psi) sure
Steering line overload relief pressure 20.6±0.7 4. Apply the parking brake.
(at idling speed) (210±7) (2,986±100)
5. Move the bucket control lever to the roll back posi-
tion. Hold the lever at that position.
Hydraulic oil temp
50~80ºC (120~180ºF)
6. Increase the engine speed to the maximum, and
measure and record the pressure using the pres-
Reference
sure gauge.
Releasing residual pressure from tank and pipes
Adjusting main relief pressure
Keep the bottom surface of the bucket horizontal,
Loosen the lock nut and adjust the pressure by the
and stop the engine when the bucket is approxi-
adjusting screw.
mately 30 cm (1 ft.) above the ground.
Turn clockwise the adjusting screw to raise the set pres-
Tilt down the bucket until it comes in contact with
sure, or turn counterclockwise the adjusting screw to
the ground. Place the bucket control lever in the
lower the set pressure.
roll back position, and then lower the boom.
(1)
1. Lower the boom to the lowest limit.
60ZV43001
2. Move the bucket control lever to the roll back posi-
tion.
Multiple control valve
3. Keep the engine speed at low idle.
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.
Adjusting screw
60ZV43004
43-5
50ZV Check & Adjustment Hydraulic Group
Loading/Steering Circuit Relief Valve
Lock nut
Adjusting screw
60ZV43005
43-6
50ZV Check & Adjustment Hydraulic Group
Loading/Steering Circuit Relief Valve
CAUTION
Be careful, you may get burned if the high pressure
oil spouts out. To prevent such an accident, be sure Standard measurement value MPa
to release the residual pressure from the pipe, and (kgf/cm2) (psi)
open the cap of the hydraulic tank before removing
the plug from the pressure measurement port.
Steering line main relief pressure 17.2±0.5
(at maximum speed) (175±5) (2,489±71)
Measuring steering circuit main relief pres- Adjusting steering line main pressure
sure
(1)
1. Attach the pressure gauge to the gauge port ((1) or
(2)).
(2)
Priority valve
(3) (4)
Relief valve
60ZV43011
(7)
60ZV43009
Note
Unless the Orbitrol® is removed from the cab floor, it is
impossible to adjust the overload relief valve.
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.
43-9
50ZV Check & Adjustment Hydraulic Group
Valve Control
Valve Control
Left Right
Dump
Forward Rearward
back
Roll N
Down
Raise
78 78
Float
N
78 78 78
A-Detail
Boom operation Bucket operation
Raise
Down
Float
N
8 8 8 Control cable
B Control cable
Boom 12
Multiple Standard screw
Dump
back
engagement length
Roll
control valve N
spool 8 8 (Max. 13.5 mm
Bucket
Min. 5 mm)
12
B-Detail
60ZV43010J
43-10
50ZV Check & Adjustment Hydraulic Group
Hydraulic Cylinder
Hydraulic Cylinder
Note
Warm-up the hydraulic oil before measuring cylinder
drift.
Reference
Vinyl tape
Scale
70ZV43012
IMPORTANT
At the completion of measurement, if the vinyl tape
used for measurement is not removed from the cylin-
der rod, the tape may be caught by the rod seal. The
tape will cause oil leakage from the rod seal. To pre-
vent oil leakage, be sure to remove the vinyl tape.
43-12
50ZV Check & Adjustment Hydraulic Group
MEMO
52-1
50ZV Function & Structure Brake Group
2
3
4
50ZVA52002
Brake Circuit
T/C pump
50ZVA52001
11
From T/C pump To T/M C/V From brake
13 oil reservoir
12
27
27 From brake
oil reservoir
4
23 To front brake 22 21 To rear brake
3
piston chamber piston chamber
5 2 24 25
8
9 10 26
1 6 7 Drain port
Hydraulic servo section Master cylinder section
27
1
12
Drain port 21
View A
60ZV52006J
Performance diagram
Oil pressure in master cylinder MPa (kgf/cm2)
2.84 +0.20
- 0.49
(29 +2
-5 )
Oil flow amount at 0 L/min
+0.49
0.91 - 0.10
(9.3 +5
-1 )
0
[196] 355.1 43.6 916
+21.7 (20) (36.2 4.4) (93.5)
121.3 - 43.6
(12.4 +2.2
- 4.4 )
Force on pedal N (kgf)
60ZV52014J
52-6
50ZV Function & Structure Brake Group
Hydraulic Servo Master Cylinder
Push rod
G 23 F 25 C 22
24 D
6 9 8 B 10 26
A 7
50ZVA52003
When the brake pedal is released from the applied posi- When the brake pedal is depressed, spool (2) moves to
tion, spool (2), power piston (7) and connector (8) are the right. It reduces the clearance at the notch (E)
moved back to cylinder cover (6) side by spring (9). between the spool (2) and power piston (7). The built-up
pressure in the chamber A becomes larger than the
Primary piston (22) and secondary piston (23) are also pressure in the chamber B.
moved back to the initial position by spring (26). The
chambers C and D are connected to the brake oil reser- Consequently power piston (7) moves to the right and
voir through the release port. Oil in the chamber C and also connector (8) and secondary piston (23) move to
D returns through the release port to the brake oil reser- the right. It builds up pressure in the chamber C. The
voir, releasing the brake. Oil from T/C pump flows into pressure in the chamber C pushes primary piston (22)
the chamber A and flows out from the chamber B to T/C to the right and it builds up pressure in the chamber D.
C/V through the notch (E) between spool (2) and power The pressure in the chamber C and D is transferred to
piston (7). the brake piston chamber in the axle housing, applying
the brake.
52-7
50ZV Function & Structure Brake Group
Hydraulic Servo Master Cylinder
When the brake is in the hold (balanced) Braking in case of pump failure
position
If the engine and thus the hydraulic pump stop,
When the brake pedal is depressed with a certain force depressing the pedal moves the spool (2) and the con-
and held there, the pressure is created in the chamber nector (8) of the hydraulic servo master to the right,
A and C like at the time of brake application. which in turn moves the secondary piston (23) and pri-
mary piston (22) of the master cylinder, creating pres-
The pressure in the chamber C transfers to the chamber sure in proportion to the force on the pedal, and thereby
G through the passage F. It pushes reduction piston applying the brake.
(24) to the left. This reaction force moves rod (10) and
spool (2) to the left and it transfers to the brake pedal
through the push rod. Because of that rod (10) and
spool (2) move to the left, the notch E between spool (2)
and power piston (7) becomes larger and the pressure
in the chamber B decreases. When the pressure in the
chamber B decreases, power piston (7) moves to the
right and the pressure in the chamber B is increased.
Service Brake
Service brake operation
Differential gear
assembly
10 6 1 7 5 4 3
When stepping on the brake pedal, the brake oil from
the differential gear housing oil inlet enters the brake
piston chamber and presses the brake piston (3) to the
left. Then the brake piston presses the steel plate (4)
against the friction plate (5).
Since the friction plate (5) rotating with the sun gear (6)
is placed between the brake retainer (7) and the steel
plate (4), it makes the rotation speed of the sun gear
decrease or makes it stop.
12
11
2 9 8
60ZV52010
1. Axle housing
2. Internal gear
3. Brake piston
4. Steel plate
5. Friction plate
6. Sun gear
7. Brake retainer
8. O-ring (for brake piston inner)
9. O-ring (for brake piston outer)
10. Spider
11. Planetary gear
12. Pin
1
0.4 mm (0.016 in)
or more
1 + 0.3
0
1 (0.039 + 0.012
0 in)
2
5.7 0.3
(0.224 0.012 in)
Detailed drawing of groove
60ZV52015
1. Plate
2. Lining
6 0- 0.2 mm
0
(0.236 - 0.008 in)
282 (11.102 in)
210 (8.268 in)
170 (6.693 in)
60ZV52016
52-10
50ZV Function & Structure Brake Group
Service Brake
Brake circuit air bleeding proce- 1. Connect a vinyl tube to the air bleeder nipple of the
hydraulic servo master.
dure
IMPORTANT
Cap Air bleeder nipple
Do not use vegetable oil or DOT 3 brake fluid for the
brake. The seals between the hydraulic servo master
and the brake piston may be deteriorated or dam-
aged. Be sure to use mineral oil or Mobil Delvac 1 for
the brake.
60ZV52012
3. Repeat the above procedure until no air is in the
brake oil. At the completion of air bleeding, close
the air bleeder nipple.
WARNING : Air bleeder nipple of hydraulic
Unexpected movement of the machine may cause a servo master: 10.8 N-m (1.1 kgf-m) (8 lb-ft)
severe accident. To prevent such an accident, take
the following safety measures when performing air Note
bleeding with the engine running. During air bleeding, enough oil should be in the brake
- Park the machine on level ground. oil tank. Be sure to check the oil level of the brake oil
- Apply the parking brake. tank frequently, and add oil into the tank.
- Block the tires with chocks to prevent wheels from
moving.
- Determine the signals between the persons related
to the work.
- When raising the boom, install a safety support
under the boom.
- Apply the articulate stopper.
52-11
50ZV Function & Structure Brake Group
Service Brake
60ZV52011
52-12
50ZV Function & Structure Brake Group
Parking Brake
Parking Brake
Mounting
face
ar
ge
fo rum
d
ar
in d
rw
n of
tio n
ta tio
ro irec
D
X X
60ZA5218
Brake Control
1
2
8
B B
A A
9 4
8 7
3 A-A
2
4
9
5
6
5
B-B
60ZV52013
1. Brake pedal 6. Arm Because the brake pedal (1) is operated together with
2. Inching pedal 7. Arm the inching pedal (2), the stop lamp switch (5) is actu-
3. Hydraulic servo master 8. Pillow block ated and the stop lamp lights up.
4. Inching switch 9. Ball joint
5. Stop lamp switch When only brake pedal (1) is depressed the moment the
brake is applied, stop lamp switch (5) is actuated and
When the inching pedal (2) is depressed with the clutch the stop lamp lights up. No forward/reverse clutches
cut-off (declutch) select switch ON, inching switch (4) is disengaged even the clutch cut-off (declutch) select
actuated, the forward/reverse clutches are disengaged, switch is ON.
and the brake is applied simultaneously.
52-14
50ZV Function & Structure Brake Group
Brake Control
1 5
4 6
Turn buckle
3
4
5
31 Float
MIN
Alarm oil level Alarm float level
48 40
Level sensor
65ZA5216
Note
- When installing the cap, tighten it until the cap stops
turning.
: 3.4 N-m (2.5 lb-ft)
- Securely insert the level sensor.
- Fill the brake oil to the MAX level.
52-16
50ZV Function & Structure Brake Group
MEMO
53-1
50ZV Check & Adjustment Brake Group
2.84 +0.20
- 0.49
(29 +2
-5 )
Oil flow amount at 0 L/min
+0.49
0.91 - 0.10
(9.3 +5
-1 )
To front brake To rear
(A) brake 0
(B) [196] 355.1 43.6 916
+21.7 (20) (36.2 4.4) (93.5)
121.3 - 43.6
(12.4 +2.2
- 4.4 )
WARNING
60ZV53001J
Unexpected movement of the machine may cause an
accident resulting in injury or death. Therefore, to
provide repair service with the engine running, be
Air bleeder
sure to observe the following items.
nipple - Park the machine on level ground.
- Apply the parking brake.
- Block the tires with chocks to prevent the tires from
moving.
- Determine the signals between the service man.
- Prohibit any person from walking into dangerous
areas.
- Near articulation areas of the machine
- Under the machine
- Around the engine
65ZA5217 - In front of or behind the machine
Note
A
Before inspecting the performance of the hydraulic
servo master, it is necessary to confirm that the trans-
mission oil pressure is between 1.3~1.6 MPa (13~16
kgf/cm2) (185~228 psi).
Pressure gauge
5 MPa (50 kgf/cm2) (1,000 psi)
Port size
M12 x 1
Measuring procedure
Service Brake
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 Unexpected movement of the machine may cause an
Level, straight, dry and the paved ground. accident resulting in injury or death.
Before starting brake performance check, be sure to
2. Run the machine and depress the brake pedal at observe the following items:
20 km/h (13 mph). - Place the machine on level ground.
Measure and record the braking distance. - Check that there is enough clearance for brake
performance check around the machine.
- During performance check, prohibit any person to
walking near the machine.
Standard measurement value
1. Lower the boom to the lowest limit, and roll back
Braking distance the bucket fully until the bucket contacts to the
5 m (5 1/2 yd) or shorter stopper.
Possible causes of extremely long braking distance 2. Release the parking brake lever to the "OFF" posi-
tion.
Possible cause Solution
Hydraulic servo master defective Check and repair 3. Set the T/M (transmission) cut-off switch to OFF,
Friction plate wear Check and repair and then depress the brake pedal all the way to the
Improperly adjusted service brake linkage Check and adjustment floor.
Measuring procedure*
Parking Brake
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
accident resulting in injury or death.
Condition Before starting brake performance check, be sure to
observe the following items:
1. Test course - Place the machine on level ground.
1/5 slope (Approx. 11º 19') - Check that there is enough clearance for brake
performance check around the machine.
2. Bucket empty - During performance check, prohibit any person to
walking near the machine.
3. Fully pull up the parking brake lever to engage the
parking brake. 1. Apply the parking brake.
Adjusting
screw
Screw
driver
50ZV53001
For replacement of shoe assembly refer to Section 54.
ing items:
- Park the machine on level ground. 1. To rotate the brake drum during adjustment, lift the
- Block the tires with chocks to prevent the wheels front and rear wheels on one side (or both sides)
from moving. using safety jacks, cribbing, etc..
- Place the bucket to the ground.
- Stop the engine, and then remove the starter key. 2. Turn the inspection hole of the brake drum approxi-
Place "DO NOT OPERATE!" tag on the steering mately 15º clockwise from the vertical position as
wheel. shown in the figure.
- Prohibit any person from walking into the danger- After that, use a screw driver or brake tool to turn
ous area. the adjusting screw to adjust the clearance.
Turn the adjusting screw counterclockwise (down)
If the machine moved during parking brake performance to expand the brake shoes until the linings come in
check, the clearance between the brake drum and the contact with the brake drum.
lining is too large. After that, turn the adjusting screw 8 notches clock-
wise (up). The clearance will be adjusted to 0.2
mm. (0.008 in)
Adjustment range
0.15~0.25 mm (0.006~0.010 in)
Shoe Rivet
B Abrasion limit
Lining
80ZV53004
Brake Control
3
Brake pedal assembly
50ZV53003
48º
0
-5
218
5 60ZV53008J
Note
The elbow joint (5) std. thread engagement to the rod
(4) is minimum 9 mm (0.354 in).
53-10
50ZV Check & Adjustment Brake Group
Brake Control
5 Brake pedal
Std. thread engagement
4
Min: 11 mm
9
16 mm 15 mm
6 Inching pedal
7 5 Hydraulic servo
8 master
10 10
6
115 mm 8
60ZV53009J
9 14
13
3. The distance between hydraulic servo master (6)
and elbow joint (7) is to be fixed temporarily to 115 D
15
mm (4.528 in).
C
Note
The hydraulic servo master (6) and elbow joint (7) std.
12
thread engagement to the rod (8) is minimum 11 mm
(0.43 in) respectively.
50ZV53006
4. After the above adjustment, confirm that there is a
play of 0.5~1.5 mm (0.02 in~0.06 in) to the direction
of hydraulic servo master shaft (6) at elbow joint The linkage must be adjusted with rod (14) so that the
(7), and secure it with the lock nut (9)(10). rod and elbow joint assembly (comprised of items 14 &
15) drive C block on bellcrank (12) to push against lever
IMPORTANT D on the right side bellcrank (13).
Inching pedal 1
Std. mounting
distance 29.5
6 in)
(1.1
Inching switch
3
4
50ZV53007 6
Brake pedal
WARNING
Unexpected movement of the machine may cause
serious injury or death. Adjusting parking brake clear-
ance requires the parking brake to be released. So,
to prevent accidental movement, observe the follow-
ing items:
Std. mounting 24 - Park the machine on level ground.
distance (0.945 in) - Block the tires with chocks to prevent the wheels
from moving.
Stop lamp switch
- Place the bucket to the ground.
- Stop the engine, and then remove the starter key.
50ZV53008
Place "DO NOT OPERATE!" tag on the steering
wheel.
Install the stop light switch so that the mounting dis- - Prohibit any person from walking into a dangerous
tance is 24.0 mm (0.945 in). At this position, check that area.
another 1~2 mm (0.039~0.079 in) still remains as a
clearance allowance for the stop light switch.
Lock nut
Turn buckle
(1 27
in)
Plate
in)
6
.0
Rod
5
.1
(0
(1 27
in)
13
6
.0
Turn buckle
50ZV53010
Limit switch
A
1. Before adjusting the control cable, adjust the clear- Limit switch
ance between the parking brake lining and drum.
50ZV53011
4. Adjust the control cable by turning the turnbuckle. 3. Fix the limit switch (3) to the bracket so that the
Turning the turnbuckle clockwise makes the control mounting distance (A) is 2.3 mm (0.09 in).
cable shorter.
When adjusting the control cable, do not make the
control cable too tight.
(This causes the parking brake to drag.)
62-1
50ZV Function & Structure Electrical Group
10 6 5 1
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
21
40 39 32 31
40 36 35 31
WIDTH LAMP RIDE CONTROL NEUTRAL BACK LAMP HORN RELAY CONTROLLER
RELAY RELAY RELAY RELAY FAULT RELAY
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
(3) 95ZV62001
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
G (green) GY G GL GW GR GB GO
W (white) WY WG WL W WR WB WO WP WV
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
V (violet) V
Insulation color
Stripe color
70ZV62001
62-4
50ZV Function & Structure Electrical Group
Electrical Circuit Symbols
Conductors
Mechanical coupling
(Not connected)
Relay contact
Terminal
("a" contact)
Relay contact
Ground
("b" contact)
Positive -negative-
Battery or Direct voltage source
positive (PNP) transistor
62-5
50ZV Function & Structure Electrical Group
Sensor Mount
Sensor Mount
Engine water
temperature sensor
Air cleaner
indicator
Transmission oil
temperature
switch
Transmission oil
temperature
switch
Fuse
The following fuses are provided to protect electrical cir- Fuse box
cuits.
For chassis
Fusible link
30 A x 1, 50 A x 1, 70 A x 1, Fuse
Fuse No. capacity Protective circuit
(A)
Fuse box 1 20A LIGHTING HEAD LIGHT
15 fuses x 2 (for chassis and cab) 2 15A R. WORK LIGHT 20A
BOOM KICKOUT
(For installation positions, refer to "Electrical Equipment 3 10A
BUCKET POSITIONER
Layout".) BACK LAMP SPARE
4 15A STOP LAMP
TURN SIGNAL
CAUTION 5 10A SPARE 15A
Possible burn hazard. Before replacing a fuse, be 6 15A FUEL VALVE
SPARE
sure to turn off the starter switch. 7 10A SPARE
8 15A SPARE 10A
9 15A SPARE
IMPORTANT 4WAY FLASHER SPARE
10 15A
Replace a fuse with the same capacity. HORN
If a fuse blows immediately after replacement, the 11 10A MONITOR 5A
electric system is defective. Locate the defective part, 12 15A WORK LIGHT
SPARE
and then repair it. 13 5A FUEL RELAY
14 5A NEUTRAL RELAY
15 5A BATTERY RELAY
For cab
Fuse
Fuse No. capacity Protective circuit
(A)
16 5A FL. WIPER
17 5A FR. WIPER 20A
18 5A R. WIPER
SPARE
19 10A F. WIPER
20 10A CIGAR LIGHTER 15A
21 15A SPARE
SPARE
22 3A RADIO
23 10A SPARE 10A
24 10A SPARE
SPARE
25 20A AIRCON (OPTION)
26 5A SPARE 5A
27 5A AIRCON (OPTION)
SPARE
28 10A SPARE
29 20A AIRCON (OPTION)
30 20A SPARE
62-7
50ZV Function & Structure Electrical Group
Fuse
G1.25
BATTERY
F14
5A
WR1.25 RELAY
G1.25
STARTER
70A
F11
B C
MAGNETIC
[R5]
S/W
BW5
RL1.25 [WG]
NEUTRAL
SWITCH
(Lg) (WG) VOLTAGE
F11 RELAY
CHARGE LAMP
R5X6 WL1.25
R2
ALTERNATOR
15 R
50A B
E
15
FUEL VALVE
F6 W2 FR BW2
WB F13 15A
FR
5A WB
HEATER
BW RELAY
15 15
AIR HEATER
(BG)
Starter switch
B BR ACC R1 R2 C
Preheat
Off Fusible link
Battery (24 V)
On
Start 30A
Fuel solenoid
F13
5A
F11 F15
Monitor lamp Battery
10A 5A relay F6 15A
Fuel solenoid relay
70A
Diode unit
Starter motor
From alternator B
F14
5A
Heater
Magnetic S/W
relay
Air heater
Neutral switch
Preheat lamp
Voltage relay
neutral current
Alternator
Alternator
1 2 3
Neutral
switch R N F
50ZV62003E
62-9
50ZV 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.
Starter switch
OFF
35º 30º
Preheat Run
35º
Start
B
C
C
AC
BR
R1
R2
Connection table
B BR ACC R1 R2 C
W3 W5 Preheat
Off
BW R1 BR WRx2
On
B ACC WBx2
R2 Start
BG C G
To neutral switch
To battery relay,
To heater relay
monitor lamp
From battery
To fuel relay
BW WR WR G W
BG WB WB W
50ZV62020a
Off Preheat
Enables insertion and removal of the starter key. Preheats the intake air to ensure smooth starting in cold
All the electrical circuits (except the horn and hazard weather.
flasher [OPT.]) will be turned off. Setting the fuel sole-
noid to this position activates the engine stopper that
stops the engine.
On
Supplies power to the charge, lamp, monitor and fuel
solenoid circuits.
Start
Starts the engine.
62-11
50ZV Function & Structure Electrical Group
Engine Start Circuit
Starter switch
From AC B
charge
Terminals for coil circuit Battery relay
Moving contact
energizing current (B)
(4 mm) Main contacts
To main (E)
circuit
Battery
BR
Terminals for
main current Suppression
Coil for energizing (8 mm) diode 65ZV62028a
95ZV62017
Battery relay
When the starter switch is placed to the ON position or
Rated voltage DC 24 V
the start position, the battery relay is turned on. When
the starter switch is set to the off position, the alternator Minimum operating voltage 20 V or less
stops generating power, and the battery relay is auto- Release voltage 9 V or less
matically turned off so that the electrical circuits will not
function. When current flows from the starter switch terminal AC,
the coil will be energized, and the moving contact will
If the battery relay was not used, a large amount of cur- lower to close the main contact. As a result, current will
rent would be directly sent through the starter switch flow from the battery to the main circuit.
when it is turned on. However, use of the battery relay
reduces the amount of current because this relay needs
only a small amount of current to energize it.
62-12
50ZV Function & Structure Electrical Group
Engine Start Circuit
12V 12V
30A
(2) BATTERY
R1 BR F15 WR WL
B AC
R2 C 5A [WV] WV:To battery relay
WV
BATTERY
(3) (1) WR:To starter switch terminal ACC (VIA F15)
WL: To alternator
F14
5A
RELAY WR WL
Heater From
B
E
F11
Voltage relay
50ZV62006E 50ZVA62008
Engine motion-active circuit (1) The diode unit is incorporated in the milky white connec-
tor near the battery relay. It is provided for the following
When the starter switch is turned OFF, the battery relay purpose.
is automatically turned OFF since the command current
from the starter switch terminal AC stops flowing and 1. Diode (2)
the coil is demagnetized. Then the charging circuit from This diode is provided to prevent the roundabout
the alternator is shut down. current from the alternator to the engine stop motor
relay.
However the alternator is still generating power and the
load dump surge may be generated. This may damage 2. Diode (3)
the related circuits and equipment. In order to prevent This diode is provided to prevent the roundabout
this trouble, this circuit (1) is provided to hold the battery current from the starter switch AC to the alternator
relay in the "ON" position. R terminal.
62-13
50ZV Function & Structure Electrical Group
Engine Start Circuit
1 2 3
Neutral
switch R N F
(A) (B)
60ZV62023E
Magnet switch
C C’
M’
M’ C’
70ZV62019
Note
The illustrations show the de-energized condition.
Voltage relay
Blue
K70V2J62005
Voltage relay
Contact point closed 6V
Contact point open 8V
Note
The illustrations show the de-energized condition.
operation
For
battery relay
operation
Starter
Load circuit operation
switch
Battery charge
<Load>
Battery
Stator coil
Rotor
Slip ring
Brush
N
Voltage DC 24 V
Fuel
solenoid Resistance 36 Ω (22ºC)
Min. operation voltage 18 V
1 2
WB
B
1
2
5
BW
5 3
Chassis side
Elec. circuit coupler
50ZV62016
Instrument panel
1 14 16 4 15 2 17 3 8 9
10
20 19
22
11
21 12
13
18 6 7 5
50ZV62004E
CN4
CN1 CN3
1 4 L11 L13 29 48
L12
8P L20 12P 16P
L1 58 57
5 8 L14 L10 35 56
Hour L10 L10
L2 meter
L10 L15 S
L21
L3
L16 E V
L4 S S
L17 L10
L5 E V E V
Fuel gauge Engine water temperature Speedometer
L18
sensor
L6 L10 L10
L19
L7
CN2
L8 9 18 L22 L23 L24 L25 L26 L27
20P
L9 19 28
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
60ZV62059
Gauge circuit
Controller
E V 15V
Note
If a gauge is removed from the panel, the resistance
between the terminals will differ from the standard value
shown in the table.
97ºC 100ºC
103ºC
35ºC
Indication
Resistance
120~125 115~120
between S and E (Ω)
Resistance
120~125 115~120
between S and V (Ω)
Resistance
170~190 165~170
between E and V (Ω)
62-22
50ZV Function & Structure Electrical Group
Instrument Panel and Switch
Flat terminal
Thermister
Terminal
95ZV62066
Terminal
48.5 (1.909 in)
Terminal
(ground)
(88.5 (3.484 in))
FULL
167.5 (6.594 in)
3/4
(233.5 (9.193 in))
286.5 (11.280 in)
Contact
1/4
Float arm
50ZV62019
The sending unit float arm in the fuel tank moves by the
fuel level movement in the tank. The contact installed on
the float arm axis also moves by contacting the resis-
tance wire. The contact position is fixed, based on the
Fuel gauge
F11 float position and the fuel level.
When the fuel level becomes low, the resistance value
10A rises accordingly.
The position of the fuel gauge pointer is decided by this
Sending unit resistance value, and the fuel gauge shows the fuel
amount left in the tank.
E
Sending unit circuit Float position FULL 3/4 1/2 1/4 EMPTY
60ZV62052 Resistance (Ω) (10 +1.0
- 0.5 ) (19) 32±3 (49.5) 80 +12
-2
Note
Figure in ( ) is for the reference resistance.
62-24
50ZV Function & Structure Electrical Group
Instrument Panel and Switch
Monitoring system
If a problem of a unit is detected while the engine is run-
ning, a monitor lamp lights to inform the operator.
11 13 7 12 1 2
Bulb check switch
3
4
5
6
14 9 10 8
50ZV62005E
62-25
50ZV Function & Structure Electrical Group
Instrument Panel and Switch
Monitor lamp
No. Item to be monitored Operation condition Buzzer Lamp test Remarks
Lighting Symbol
color
Monitor lamp
No. Monitor item Lighting condition Remarks
Lighting Symbol
color
Pointer axis
IMPORTANT Gauge pointer
Axis hole
When storing the instrument panel individually, make Main body
sure that the panel face (transparent face) faces frame
upward.
If the panel face faces below the vertical direction, the
damper oil may leak from meter pointer axis holes.
Damper
oil Magnet
Meter
70ZV62039
62-27
50ZV Function & Structure Electrical Group
Transmission Electrical Circuit
Transmission cut off (Declutch) When cut off select switch (1) is OFF
switch Even when declutch/brake pedal is depressed and the
inching switch (3) is actuated, the solenoid valve in the
transmission control valve does not operate and the
clutch is not disengaged.
Solenoid valve
60ZV62009E
62-28
50ZV Function & Structure Electrical Group
Transmission Electrical Circuit
COM NC
NO
60ZV62011E
COM NO NC 60ZV62038
Solenoid valve specification
Cut-off valve
Torque converter
Hyd. line pump
Elec. line
60ZV62010E
62-29
50ZV Function & Structure Electrical Group
Electrical Detent Circuit
Rod
50ZVA62007 Sensor
Bucket positioner
Proximity switch
main B 2
Multiple control valve
circuit L detent coil
3
+24V
Detection part
Operation indicator lamp (LED)
1(Br)
Detected View Z
object
3(L) 2(B)
5±2 mm 85ZV62015
Voltage DC 24 V
Power 4 W or less (at 24 V)
Release force 147~245 N (15~25 kgf) (33~35 lbs)
62-31
50ZV Function & Structure Electrical Group
Diode Unit Circuit
Diode unit
Diode inspection
A B C D
E I
F G
60ZV62013E
If any problem occurs, the conductivity of each of the Do not use a high-voltage insulation resistance tester
individual diodes must be inspected with a circuit tester. for these checks.
The diodes should conduct in the positive direction only.
If any diode conducts in both positive and negative
directions or does not conduct in either direction, the
diode is defective.
62-32
50ZV Function & Structure Electrical Group
Diode Unit Circuit
Specifications
B C D E F G H i B C E F G D i
A B C D A B C D
E F G H i E F G H i
6 10 6 10
GyL LgL SbW LgBr SbY
A301 A302 A512 E802 A307
G604 G605 C902 G606
YR Gy SbY LgR Gy
A107 A306 A307 B802 A306
G603 G606 G512 G603
5 (GREEN) 1 5 1
D5 D6
Wiring diagram
60ZV62024E
AC E
(LgY)
i
H D
LgBr
BUZZER G
F
E
C
A B
(Lg)
DIODE UNIT (WHITE)
BRAKE
SbY
AIR CLEANER
LgL
YR
B A LAMP BULB CHECK SWITCH
C
D
E
F
G E
H
i
DIODE UNIT (GREEN)
60ZV62014E
62-34
50ZV Function & Structure Electrical Group
Stop Light Switch Circuit
Rated voltage DC 24 V
Stop light switch Stop light Current 2.2 A
Contact B
F4
15A
E
Elec. diagram
60ZV62015E
Brake pedal
Stop light
switch
60ZV62016E
Parking Switch
(Identical with stop light switch)
Parking brake E
Parking lamp switch
F11
10A
Inching solenoid
Elec. diagram
60ZV62018E
Parking
brake lever
Parking switch
60ZV62019E
5A
Elec. diagram
60ZV62020E
Horn Circuit
Horn switch
(GL)
F10 GW
15A G
Horn relay Horn
E
Elec. diagram
60ZV62021E
Horn relay
1 2
3 4
Elec. diagram
Body black
60ZV62022E
Voltage 24 V
Resistance 320 Ω
62-38
50ZV Function & Structure Electrical Group
Diode
Diode
Symbols Open circuit, failed in open position.
Snap!
+24V
Switch
+ Solenoid
[Anode] [Cathode]
Surge voltage
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.
12V 12V
Diode check mode
30A
ECM Battery
(1)
R1 BR F15 WR (2) (3) WP
B AC
R2 C 5A
(2)(3): Diode unit
Suppression diode
F14
F13
5A
5A
R1
Charge From
circuit alternator
R terminal
B Neutral
relay
115V2E62005
Forward check
Continuity is detected in the status shown in the figure.
Normal Continuity is not detected when tester terminals are con-
nected in opposite way.
Continuity is not detected in either way Disconnection
Abnormal
Continuity is detected in either way Short-circuit
Note
When the circuit tester is the digital (number indication)
type, exchange the positions of the terminals of the
tester during the check. Some solenoid coils contain
diodes inside the solenoid coil pack.
Backward check
85V2E62036
R1>0 R2=
0 0
R1>0 R2=
R1
Electromagnetic field
forms when switch closes. Coil
Current direction
Coil
Voltage
Battery
Current
Switch or
Current [A]
Voltage [V]
transistor
Some electrical parts such as solenoid valves are During the coil is being activated by the transistor, when
equipped with a coil. the excruciating high voltage is loaded on the transistor,
the transistor may be broken.
When a coil is energized, an electromagnetic field is
formed. See fig. 1. In order to absorb this surge voltage, connect the diode
parallel to the coil in the reverse direction against the
Fig. 2 power supply.
Snap!
When the switch opens, the When the switch is off, the same amount of electric cur-
field collapses across the rent, that was flown till now, flows through the diode.
coil windings.
Coil
Voltage This electric current is attenuated gradually and finally it
Battery
Surge voltage
Load
115ZVE62033
MEMO
63-1
50ZV Check & Adjustment Electrical Group
80ZV63007
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.
63-4
50ZV Check & Adjustment Electrical Group
Cautions Regarding Electric Circuit Check
1. Square connector
Bucket positioner electrical cir- <Step 3> Checking detent magnet solenoid
cuit check
Detected View Z
object
3(L) 2(B)
Proximity switch
Magnet coil
+24V Multiple control valve detent section
LED Br 1
Switch Coil for detent
main. B 2 inside 50ZVA62007
circuit L pilot valve
3
+24V
90ZV63009
Check the continuity between coupler pins for the multi-
ple control valve detent magnet solenoid.
Though the clearance between the proximity switch and
the rod (detecting element) is 5±2 mm (0.197±0.079 in), If wire breakage is detected, repair it.
the operation indicator lamp (LED) is not lit, judge that
the proximity switch is defective, or the cable at the Detent coil specification
chassis side is disconnected or a wire broken.
Rated voltage DC 24 V
<Step 1> Checking proximity switch Resistance 141 Ω
<Solution>
A
Green A
White H
B C D E F G H i B C E F G D i
A B C D A B C D
E F G H i E F G H i
Connection diagram
A B C D
Green
E I
F G
+
(Analog type meter) K60V2J63001
Note
When the circuit tester is the digital (number indication)
type, exchange the positions of the terminals of the
tester during the check.
63-8
50ZV Check & Adjustment Electrical Group
Electrical Circuit Check
Resistance
between terminal 56.3 29.5 16.5 10
INSTRUMENT PANEL and body (Ω)
+ ES DD WTM
(+) FM GND
11 20
Fuel level sensor
RB YBr B
B206 G608 Ground
Lg O O YB
C106 B601 B602 G609
A4
E/G water temp.
Resistance between
G6 80 32 10
two terminals (Ω)
FUEL LEVEL
E/G WATER SENSOR
TEMP.
SENSOR <Step 2> Checking gauge
G608
Controller
B
YBr
YB
G609 1 2
E V 15V
60ZV63002E
97ºC 100ºC
103ºC
35ºC
Indication
Resistance
120~125 115~120
between S and E (Ω)
Resistance
120~125 115~120
between S and V (Ω)
Resistance
170~190 165~170
between E and V (Ω)
CN4
CN1 CN3
1 4 L11 L13 29 48
L12
8P L20 12P 16P
L1 58 57
5 8 L14 L10 35 56
Hour L10 L10
L2 meter
L10 L15 S
L21
L3
L16 E V
L4 S S
L17 L10
L5 E V E V
Fuel gauge Engine water temperature L18
sensor Speedometer
L6 L10 L10
L19
L7
CN2
L8 9 18 L22 L23 L24 L25 L26 L27
20P
L9 19 28
60ZV63016
63-10
50ZV Check & Adjustment Electrical Group
MEMO
72-1
50ZV Function & Structure Operator Station Group
Cabin (OPT)
4
6
A A
B
D
D
3
B
1
2
5 5
C
C
8
B-B A-A
Strip seal
Glass Glass
1. Door (left side)
2. Door (right side)
3. Front wiper Catch
4. Window washer jet nozzle
5. Rear view mirror Outside chassis
6. Rear view mirror Washer
7. Duct (outside air suction port) D-D
8. Door stopper
Duct Strip seal
C-C
60ZV72001J
72-3
50ZV Function & Structure Operator Station Group
Cabin (OPT)
ACC’ E
Wiper motor
F19 OR
M F Wiper
10A
Wiper switch
S2 S3
WASH B
Sint S1
5 3
1
Washer motor Intermittent 6
2
wiper relay
PB
M 4
Wiper motor
F18 OL
M R Wiper
5A
E S1 S2
B
WASH
Washer motor
PL Wiper switch
M
G
F10 Room lamp
ACC’ E
Cabin
50ZVA72010
72-4
50ZV Function & Structure Operator Station Group
Cabin (OPT)
Wiper motor
Front
(Y)
(R) 2
(R) 10
11 (W) (L)
6
1
5
4
3 (A)
Ro
tati
ng
dire
c tion
1. Wiper motor
2. Link assembly
3. Washer C
4. Nut Circuit breaker
5. Cap
6. Nut C
7. Bolt
8. Crank arm assembly
9. Spring washer
10. Nut
11. Connector
24V
Wiper motor (front) specifications
Rated voltage DC 24 V
Circuit diagram
Locked rotor current < 16 A
= 60ZV72005J
Wiping angle 52º
72-5
50ZV Function & Structure Operator Station Group
Cabin (OPT)
Rear (OPT)
Wiping angle 91º±3º Automatic
stop position
1 (L) (LR)
(B) (LW)
3 4 5
2
Cabin 6
1. Wiper motor
2. Washer Circuit breaker Motor
3. Packing B
4. Nut
5. Cap
6. Nut
7. Connector
LR LW L
Wiper motor (rear) specifications
+1 S +
Operator Seat
Seat assembly
2
2
ke
g stro
l i ni n
Rec
3
1
4
8
4
1
6 7
5
10 9
11
A-Detail
50ZVA72001
Suspension assembly
2
11 5
4
19
Suspension stroke
16
7
40
40
6
3
1
2
4 20 6
19 11
18
17
Section A-A
Section B-B
11 View P
7
13 14 10 3 9 14 15
15
12
3 8 9 5 Detail-10
60ZV72010J
Suspension adjustment
1. Lower body 11. Adjusting knob
2. Upper body 12. Bearing
Sit on the seat and turn adjusting knob (11) to adjust
3. Main arm 13. Spring pin
seat height.
4. Sub arm 14. Castle nut
5. Spring 15. Sprit pin
- Clockwise to raise seat
6. Sock absorber 16. Rubber stopper
7. Hook assembly 17. Bolt
- Counter-clockwise to lower seat
8. Shaft 18. Nut
9. Spring pin 19. Shaft
10. Adjuster bolt 20. Nut
72-8
50ZV Function & Structure Operator Station Group
Air Conditioner (OPT)
Air duct
Air conditioner cover
Air damper
Air conditioner
60ZV72011J
6 3
s s.
p re
w
Lo
H ig
hp
1 res
s.
Ho t
wa t
er
4
2
5
urn
r re t
a te
tw
Ho 50ZV72001J
2 4
5
11
14
13
8 15
10
12
A
Air damper
unit side
60ZV72013J
A
Air conditioner
unit side
60ZV72014J
60ZV72015J
2
1
60ZV72016J
1. Compressor
2. Magnetic clutch
72-13
50ZV Function & Structure Operator Station Group
Air Conditioner (OPT)
Condenser unit
2 4
3
1
60ZV72017J
1. Condenser core
2. Condenser fan motor
3. Fan
4. Fan shroud
5. Motor resistor
6. Wire harness
72-14
50ZV Function & Structure Operator Station Group
Air Conditioner (OPT)
Control unit
Control amplifier
Control panel
A/C
OFF LO HI
50ZVA72003
72-15
50ZV Function & Structure Operator Station Group
Air Conditioner (OPT)
Function of cooling mechanism contain some minor gas fractions, it is routed into the
receiver drier. There it dries the refrigerant by use of a
material we term a "desiccant", which means drying
Principle of cooling
agent. A down tube in the receiver drier is submerged
into the heavier liquid that is now at the bottom of the
Expansion
receiver drier. This tube will permit passage of only the
Indoor valve heavier liquid that is at the bottom of the receiver drier.
Expansion Condenser
Then the high-pressure liquid passes through the ther-
Evaporator
mal expansion valve that provides a restriction or throt-
Evaporation Releases
Condensation heat to the tles the flow of refrigerant. This restriction reduces the
outside. pressure of the liquid refrigerant thus reducing its boiling
Deprives heat
Compression Refrigerant point. The expansion valve also meters the amount of
of the adjacent
area.
refrigerant to the evaporator, by modulating the valve
from wide open to closed, which varies with the heat
Compressor
load. The expansion valve separates the high-pressure
Basic cooling cycle side from the low-pressure side.
97ZV72029
Note
HFC 134A is a very effective "vehicle" to carry away
heat.
Refrigerant
IMPORTANT
Make sure to use the specified refrigerant (R134a). If
any other refrigerant is used, following problems may
occur:
- The air does not become cool enough.
- The equipment may be damaged.
And never mix R134a with any other refrigerant.
Refrigerant characteristics Generally, fluid (which is the generic name for com-
pressed / condensed non-gas liquid) has following prop-
erties.
100
(212)
80
(176)
decreases, the gas starts to condense and change
60
(140)
into liquid at a certain temperature. For each sub-
stance (liquid), this temperature is fixed at a given
40
(104)
35
pressure. This temperature determined by a given
(95)
20
pressure is called the "saturated temperature".
(68)
15
(59)
0
2. On the contrary when the temperature is deter-
mined, the pressure at which liquefication starts is
(
20
4) fixed. This pressure is called the "saturated pres-
(
30
22)
sure".
0 3.6 5 8 10 15 20 25 30 35 40 (kgf/cm )
2 The figure on the left shows the relationship
353 490 785 981 1,471 1,961 2,452 2,942 3,432 3,923 (kPa)
51 71 114 142 213 284 355 426 497 568 (psi) between the saturated temperature and the satu-
Gauge pressure (kgf/cm2G) rated pressure of refrigerant R134a.
Relationship between saturated pressure At the temperature and the pressure below at the
and saturated temperature of R134a 85V2U72002
lower right side of the curve, the refrigerant is liquid.
At the temperature and the pressure above at the
upper left side of the curve, the refrigerant is gas.
Cooling circuit The figure on the left shows the cooling circuit of the air
conditioner.
In this circuit diagram, the area which cools down the air
inside the cab is the evaporator. The cooling circuit uti-
lizes the fact that the refrigerant absorbs heat (latent
heat of evaporation) from the adjacent area when evap-
orated, and cools down the air inside the cab. The area
Inside cab where the refrigerant is evaporated is the evaporator.
Pressure bulb
The "cooling" effect can be obtained only when the air to
be cooled down is continuously fed to the area around
the evaporator by the blower fan and the liquid refriger-
Evaporator Expansion valve
ant (wet evaporation refrigerant with low degree of dry-
Blower ness) is supplied into the evaporator.
Control amplifier
Control panel
Ventilation mode Air conditioner operation lamp Air conditioner Air intake control switch
selection lamp switch
Ventilation mode
selection switch
A/C
Ventilation temp. Blower operation lamp
Indication lamp
OFF LO HI
OFF OFF switch - Turn OFF blower fan and air conditioner.
Ventilation switch Face - This selects ventilation Face and lights indication lamp.
Ventilation switch Face/Foot - This selects ventilation Face/Foot and lights indication lamp.
Ventilation switch Foot - This selects ventilation Foot and lights indication lamp.
Ventilation switch Def/Foot - This selects ventilation Def/Foot and lights indication lamp.
Ventilation switch Def - This selects ventilation Def and lights indication lamp.
LO
Blower switch LO - This changes blower fan to LO and lights indication lamp.
Blower switch Me1 - This changes blower fan to Me1 and lights indication lamp.
Blower switch Me2 - This changes blower fan to Me2 and lights indication lamp.
HI
Blower switch HI - This changes blower fan to HI and lights indication lamp.
Inside air circulation selection switch - It changes to inside air circulation and lights indication lamp.
Outside air introduction selection switch - It changes to outside air introduction and lights indication lamp.
- When the starter switch is ON, operation mode starts at the same mode just
Starter switch Starter switch
before the starter switch is OFF.
72-21
50ZV Function & Structure Operator Station Group
Air Conditioner (OPT)
Control amplifier
[Maximum cooling]
Air mixing damper B
Heater radiator r
Blower motor at e
He
tor
Evaporator
dia
Ra Blower
Fan
Cold air motor
Cold air
Cold
Air mixing damper A air
[Maximum heating]
Evaporator Air mixing damper B
Evaporator
dia
Ra Hot air Blower
motor
Link rod B
Supporting (between dampers
Air mixing damper B point B A and B)
Evaporator
50ZVA72006
ate
r
Blower
He Fan motor
Link rod A During maximum cooling, the air mixing damper B is
(for water valve) completely closed, and the air mixing damper A is com-
Supporting point pletely opened. As a result, the air cooled by the evapo-
rator does not go through the heater radiator but is
blown off.
Water valve Supporting
selection point A Water valve
servo motor
Air mixing damper A
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-
50ZVA72005 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.
(Evaporator) Diaphragm
Evaporator
Spring
Temperature
sensing rod
Diaphragm
The expansion valve offers the following two functions. The temperature sensing rod detects the temperature of
the refrigerant which has gone through the evaporator,
1. By injecting the liquid refrigerant at high tempera- and transfers the detected temperature to the refriger-
ture and high pressure which has gone through the ant gas chamber located in the upper portion of the dia-
receiver from a small hole, the expansion valve phragm chamber.
expands dramatically the liquid refrigerant into mist
refrigerant at low temperature and low pressure. The gas pressure changes in accordance with the
detected temperature, the temperature sensing rod
2. Promptly in accordance with the vaporized status of directly connected to the diaphragm is moved, then the
the refrigerant inside the evaporator, the expansion needle valve opening is adjusted.
valve adjusts the refrigerant quantity.
In order to ensure that the evaporator offers its full - When the temperature at the exit of the evaporator is
performance, the liquid refrigerant should be kept in low or when cooling load is small, following occurs.
a state in which it deprives heat of the adjacent
area and its evaporation is always completed at the The gas pressure inside the diaphragm chamber
exit of the evaporator. becomes low, the volume decreases, the temperature
To realize this, the expansion valve automatically sensing rod moves to the right, and the needle valve is
adjusts the refrigerant quantity in accordance with closed.
fluctuation of the temperature inside the cabin
(cooling load) and fluctuation of the rotation speed - When the temperature at the exit of the evaporator is
of the compressor. high or when cooling load is great, following occurs.
The expansion valve consists of a needle valve, a
diaphragm and a temperature sensing rod. The gas pressure inside the diaphragm chamber
The temperature sensing rod detects the tempera- becomes high, the volume increases, the temperature
ture of the refrigerant which has gone through the sensing rod moves to the left, the needle valve is
evaporator, and transfers the detected temperature opened, and more quantity of refrigerant is supplied to
to the refrigerant gas chamber located in the upper the evaporator.
portion of the diaphragm chamber.
72-25
50ZV Function & Structure Operator Station Group
Air Conditioner (OPT)
Heater radiator
UT
te rO
Wa
Water IN
Fin
Heater core
60ZV72027J
Water valve
Valve lever
[Operating angle]
Closed
72
OUT
Opened
Valve lever
IN
60ZV72028J
COOL
Stop position
set at delivery
Spa
re
HOT
Servo motor
Circuit diagram
50ZVA72007
This servo motor operates in accordance with manipula- Air mix servo motor specifications
tion of the switches on the control panel. The servo
motor rotates only while the control amplifier applies the Voltage DC 24 V
power between the terminals A and B. The servo motor Load torque 0.3 N-m (3 kg-cm)
rotates in the normal direction or reverse direction in Rotating speed 5 min-1
accordance with the direction of the power applied Current 75 mA
between the terminals A and B. Terminal A HOT side
Voltage application terminal
Terminal B COOL side
While the servo motor rotates, the moving contact slides
in the resistor area on the fixed plate. When the
detected position (electric potential) of the moving con-
tact (which is connected to the control lever) becomes
equivalent to the indication on the control panel, the
power to the servo motor turns OFF. As the result, the
servo motor stops.
Ventilation selection duct The ventilation selection duct changes the ventilation to
Face, Face/Foot, Foot, Def/Foot and Def. It is controlled
by the ventilation mode selection switch on the control
To Face panel.
To Def
Foot
60ZV72031J
Face
Link
Foot
Link
Ventilation selection
servo motor
Foot damper
60ZV72032J
72-30
50ZV Function & Structure Operator Station Group
Air Conditioner (OPT)
Spare
Spare Spare
Voltage
between
C and E
Stop position
Servo motor
This servo motor operates in accordance with manipula- Ventilation selection servo motor specifications
tion of the switches on the control panel. The servo
motor rotates only while the control amplifier applies the Voltage DC 24 V
power between the terminals A and B. The servo motor Load torque 0.3 N-m (3 kg-cm)
rotates in the normal direction or reverse direction in Rotating speed 10 min-1
accordance with the direction of the power applied Current 75 mA
between the terminals A and B. Terminal A Face side
Voltage application terminal
Terminal B Def side
While the servo motor rotates, the moving contact slides
in the resistor area on the fixed plate. When the
detected position (electric potential) of the moving con-
tact (which is connected to the control lever) becomes
equivalent to the indication on the control panel, the
power supplied to the servo motor turns OFF. As the
result, the servo motor stops.
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
Blower resistor
Me1 Hi
Resistor Lo Me2
Fuse Fuse
Hi Me2 Me1 Lo
60ZV72037J
Appearance of thermistor
8,000
7,000
6,000
Resistance (Ω)
5,000
4,000 Thermistor
3,000
30A Fuse
2,000
20A Fuse
1,000
Compressor
0 clutch relay
10 5 0 5 10 15 20 25 30
Temperature (ºC)
Characteristics curve between temperature
and resistance of thermistor 97ZV72055
Control amplifier Compressor
To battery relay
Temp. clutch
sensor
The thermistor, a kind of semi-conductor, offers the circuit
3C ON
OFF
characteristics as shown in the curve on the above. 4C
Air filters and air damper box [Outside air introduction mode]
The air filter for outside air is provided on the outside air Air outlet
introduction side, and the air filers for inside air are pro-
vided on the top face and side of the inside air circula-
tion side to remove dusts from the air.
Outside air inlet Inside air inlet
on side (closed)
Air damper box 60ZV72042J
Inside air
Inside/outside
air selection damper
Outside air
60ZV72040J
Air outlet
a Spare
(FRS)
MRFB
(REC)
Outside air MRFA
introduction Servo motor
position
Circuit diagram
Inside air
circulation
position
50ZVA72009
This servo motor operates in accordance with manipula- Inside/outside air selection servo motor specifica-
tion of the switches on the control panel. The servo tions
motor rotates only while the control amplifier applies the
power between the terminals A and B. The servo motor Voltage DC 24 V
rotates in the normal direction or reverse direction in Load torque 0.1 N-m (1 kg-cm)
accordance with the direction of the power applied Rotating speed 20 min-1
between the terminals A and B. Current 75 mA
Outside air introduction
Terminal A
Voltage application mode side
terminal Inside air circulation
Terminal B
mode side
Catch
Air duct
Air filter
Stopper
60ZV72046J
60ZV72047J
Discharge valve
60ZV72048J
Model L50T
S
Voltage DC 24 V
Pulled
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
60ZV72050J
Condenser specifications
Voltage DC 24 V
Power consumption 132 W x 2 %
Air quantity 1,100 m3/Hr x 2
IN Tube Number of rotations of motor 2,400 min-1
Resistor
Resistance 2.8 Ω
Fan
Condenser
fan motor
Desiccant specifications
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
Strainers
Contact area
Tube accessory
60ZV72054J 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.
Flow rate
(L/min)
113
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
Service valve Pressure relief valve 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
Low press. (2.0 kgf/cm2) or less. As a result, the compressor
side charging does not work.
valve It means that the pressure switch for low pressure
detection functions also as a thermostat which
detects the outside air temperature.
60ZV72053J
72-45
50ZV Function & Structure Operator Station Group
Air Conditioner (OPT)
Relay A Relay B
97ZV72072 97ZV72099
Refrigerant hose
WARNING
Burst hazard
These hoses operate at high pressure for HVAC sys-
Outer layer tems and must not be replaced with substandard
hoses.
Reinforcing layer
Use only OEM replacement hoses or hoses of the
same rating as OEM replacement hoses.
Mouth ring
Inner layer
Intermediate layer
97ZV72073
97ZV72074
Region Material
Outer layer Ethylene propylene rubber
Reinforcing layer Polyester
Intermediate layer Chlorinated butyl rubber
Inner layer Nylon
IMPORTANT
Never use any other hose or any other refrigerant.
Otherwise, refrigerant may leak.
72-47
50ZV Function & Structure Operator Station Group
Air Conditioner (OPT)
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 (104ºF) or less.
ing work. Make sure to keep the can away from hot objects
- If the refrigerant comes into contact with your eyes, or fire.
you may lose your eyesight. Make sure to wear - During storage, make sure to avoid direct sunlight,
protective goggles. and store the can in a dark and cool place.
- The refrigerant in the liquid status is at low temper- - Inside the closed cab (including trunk), the air tem-
ature (approximately -30ºC (-22ºF)). If it splashes perature may rise considerably due to solar heat,
on your skin, you may suffer from frostbite. Pay etc., and may become dangerously temperature
close attention when handling it. even in winter if the closed cab is exposed to direct
- If the refrigerant (Refrigerant R134a) touches a hot sunlight. Never put the can inside the cab.
object (approximately +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 (104ºF) or less (tem- - If the compressor oil (ND-OIL 8) adheres to the
perature at which you feel warm when putting your painting face or the resin area, the painting may
hand into it). peel off or the resin may be damaged. If so, wipe it
Never warm the can with boiling water or overheat off soon.
it with open fire. If the can is treated in such a way, - Tighten the piping at the specified torque.
it may burst.
- When charging the refrigerant after having started
the engine, never open the high pressure (Hi)
valve. If it is opened, the high pressure gas may
flow in the reverse direction, and the service can
and the hose may burst.
72-48
50ZV Function & Structure Operator Station Group
Air Conditioner (OPT)
The refrigerant charging process is mainly divided into 1. Charge the system with the required amount of gas
"refrigerant evacuation procedure" and "gas charging by weight, and check for leaks by letting the HVAC
procedure" as shown below. system sit static and permit pressure to equalize.
2. Check the system pressure in comparison to the
ambient temperature. If acceptable, go to next step
Refrigerant evacuation procedure (3).
3. Turn on the engine, run at 1,200~1,500 rpm.
The "refrigerant evacuation process"* eliminates mois- 4. Turn on the HVAC air condition system, making
ture present inside the cooling circuit. If the moisture sure that the heat is off and A/C is set with fan on
remains inside the circuit, it may cause varied problems high.
even if its quantity is extremely small: The moisture may 5. Let the HVAC system run on coldest setting until all
freeze inside the expansion valve during operation, and parts are cold saturated; this should take about 30
may block the circuit or generate oxidation. To prevent minutes or more.
such problems, the refrigerant containing air inside the 6. Check the temperature that is coming from the
cooling circuit should be evacuated, and the moisture vents of the HVAC system inside the cab. Check
inside the circuit should be boiled and evaporated so the performance in the operating pressure and tem-
that all moisture is eliminated before pure refrigerant is perature chart.
recharged into the circuit. 7. Either remove or install more refrigerant depending
upon the findings.
*May be referred to as "air evacuation procedure" since it contains air
which also contains water that can cause system damage as noted.
Observe the work procedure and cautions shown
below, and charge the refrigerant correctly.
Gas charging procedure
The system should operate within about 5% of the
The "gas charging procedure" charges the refrigerant parameters. Be sure that the condenser is clear, evapo-
as gas into the circuit while in a vacuum state. The gas rator is clean and the fans are all working as they should
charging process not only affects the cooling ability of with good airflow in the system.
the air conditioner but also affects the system compo-
nent life.* Note
If the inside of the cab become cold during the charging
If the refrigerant is charged too quickly or in a liquid process, the compressor magnetic clutch turns off and
state, pressure inside the circuit may become extremely system charging is disabled.
high and the cooling ability may deteriorate. If the refrig-
erant charging volume is too low, the lubricating oil for When charging, completely open the cab doors.
the compressor may not circulate smoothly and com-
pressor pistons may seize and lock up the compressor. This will keep the system from turning off and on.
*Note
Liquid charging destroys a compressor. Never permit
entry of liquid refrigerant.
72-49
50ZV Function & Structure Operator Station Group
Air Conditioner (OPT)
Start evacuation.
Gauge manifold*
Low pressure
charging hose High pressure
(blue) charging hose
95ZV72024
(red)
Quick connector
(Lo)
It is against Federal Regulations* in the United States to
release refrigerant to atmosphere. A recovery and recy-
cling unit must be used to capture the refrigerant so as
not to release it into the atmosphere.
Center charging hose
(green or yellow)
*Refer to section 609 of the clean air act at www.epa.gov.
Quick connector
(Hi)
It is used for the following;
85V2U72007
Low pressure High pressure
gauge gauge
A leak detector find areas where refrigerant traces are
leaking and sounds an alarm to alert the technician of
areas of leakage.
Gauge manifold
Low pressure
valve High pressure
valve
Low pressure
charging hose Center valve High pressure
mounting nipple Center charging charging hose
hose mounting mounting nipple
nipple 97ZV72078
Screwdriver, etc.
Sleeve "Click" sound (OK)
Valve pin
(A)
Spring
97ZV72082
97ZV72080
IMPORTANT
Slide the sleeve upward, push the quick connector If you push the valve pin with a considerable force
against the charging valve, press and hold securely [294 kPa (3 kgf/cm2) (43 psi)] with a screwdriver, etc.,
part (A) until a click is heard, then slide the sleeve the spring may come off and the refrigerant may leak.
downward. Never do this.
IMPORTANT
- Push quick connector against charging valve verti-
cally.
- If refrigerant remains inside the charging hose, the
quick connector may not be easily connected.
(A)
(B)
97ZV72081
(Hi)
Recovery and recycling unit
(Lo)
Charging valve
on high pressure
side (located on
receiver dryer)
Vacuum pump shown
Compressor (stopped)
A refrigerant recycle and recovery unit
may be used.
95ZVE72045
IMPORTANT
Connect quick connectors to both the high pressure
and low pressure sides before starting air evacuation.
The check valve of a quick connector cannot hold
vacuum status. If a side of quick connector is not con-
nected, a vacuum condition cannot take place.
72-54
50ZV Function & Structure Operator Station Group
Air Conditioner (OPT)
2a. Evacuating the system with a vacuum pump 2b. Evacuating the system with a recycling and recove-
ry unit.
When pulling a vacuum with a vacuum pump on a sys-
tem that has been open due to replacing major compo-
nents.
Valve setting
After air evacuation Valve setting
Lo Hi for 30 minutes Lo Hi
OpenedOpened Closed Closed
(red)
(blue)
Each manufacture of recycling and recovery units pro-
(green) vide operating instructions for their units. Read, under-
stand and closely follow operating instructions as
provided.
(Hi)
(Lo)
Charging valve
on high
pressure side
95ZVE72046
(a) Open both the high pressure (High) valve and the
low pressure (Low) valve of the gauge manifold.
IMPORTANT
If you stop the vacuum pump before closing each
valve of the gauge manifold, refrigerant from vacuum
unit and tank is released to the atmosphere. It is
important to first close both high and low side valves.
72-55
50ZV Function & Structure Operator Station Group
Air Conditioner (OPT)
3. Checking for leaks after vacuum has been drawn Refrigerant charging process
IMPORTANT
Make sure to tighten the connection areas of the pip-
IMPORTANT
ing at a specified tightening torque. Never purge or vent refrigerant to atmosphere. (EPA)
For the tightening torque, refer to the volume "Mainte-
nance Standard".
72-56
50ZV Function & Structure Operator Station Group
Air Conditioner (OPT)
IMPORTANT
IMPORTANT
Make sure to tighten the connection areas of the pip-
If you charge refrigerant with refrigerant canister ing at a specified tightening torque.
placed upside down liquid will exit canister, refrig- For the tightening torque, refer to the volume "Mainte-
erantis sucked into the compressor in a liquid state. nance Standard". Do not overtighten or it will worsen.
This will damage the compressor. Charge only with
refrigerant gas.
72-57
50ZV Function & Structure Operator Station Group
Air Conditioner (OPT)
3. Charging the refrigerant - low pressure side - e/g (c) Start the engine, and increase the number of rota-
"ON". tions to approximately 1,500 min-1(rpm).
Charge the refrigerant (d) On the control panel, set the fan speed to high and
Valve setting until air bubbles seen Valve setting set the air flow volume to maximum cold, and set
through the sight glass
Lo Hi disappear. Lo Hi the vent port temperature switches to the coldest
Opened Closed Closed Closed
status.
(red)
IMPORTANT
When replacing service canister while charging
refrigerant, connect the line as described earlier so
(blue) (green) (Hi)
as to not have air in the line.
(Lo)
Charging valve (f) After charging, close the low pressure valve of the
on high pressure gage manifold and the service can valve. Then,
side stop the engine.
97ZV72066
(a) Make sure that the high and low pressure valves of
the gauge manifold and service canister valve are
closed.
- Doors
<Low pressure side> <High pressure side>
Completely open
215~275 kPa 1,470~1,765 kPa
(2.2~2.8 kgf/cm2) (15~18 kgf/cm2) - Inside/outside air selection
(31~40 psi) (213~255 psi)
Inside air
- Blower speed
High
97ZV72091
When the refrigerant charge quantity is insuffi- When the refrigerant does not circulate (due to
cient clogging in the cooling circuit)
<Low pressure side> <High pressure side> <Low pressure side> <High pressure side>
49~98 kPa 686~981 kPa Negative value 490~588 kPa
(0.5~1.0 kgf/cm2) (7~10 kgf/cm2) (5~6 kgf/cm2)
(7~14 psi) (100~144 psi) (71~85 psi)
97ZV72092 97ZV72093
When the moisture has entered into the cooling When the compression in compressor is defec-
circuit. tive.
97ZV72095
When there is too much refrigerant or cooling When air has entered into the cooling circuit
in the condenser is insufficient
<Low pressure side> <High pressure side> <Low pressure side> <High pressure side>
245~343 kPa 1,961~2,452 kPa 245~294 kPa 1,961~2,452 kPa
(2.5~3.5 kgf/cm2) (20~25 kgf/cm2) (2.5~3.0 kgf/cm2) (20~25 kgf/cm2)
(35~50 psi) (284~355 psi) (35~43 psi) (284~355 psi)
97ZV72096 97ZV72097
97ZV72098
Spring
Temperature sensing
97ZV72049
72-64
50ZV Function & Structure Operator Station Group
MEMO
73-1
50ZV Check & Adjustment Operator Station Group
Air Conditioner
IMPORTANT
- When replacing components of the air conditioner,
if the lubricant oil quantity is too small, the com-
pressor may seize. And if the lubricating oil quan-
tity is too much, the cooling ability may lessen.
Use the correct amount of compressor lube oil.
- When connecting a joint, apply compressor oil
(ND-OIL 8) on the O ring before tightening (Fig. 1).
Fig. 1
97ZV73002 - If the compressor oil (ND-OIL 18) is applied to
paint, paint may peel or otherwise be damaged. If it
gets on a painted surface, quickly wipe it off.
- Tighten the piping, etc. at the recommended
torque.
Nut type
1/2 pipe 24.5 (250) (18)
(Fig. 2)
Fig. 2
97ZV73003 5/8 pipe 34.3 (350) (25)
Fig. 3 97ZV73004
73-3
50ZV Check & Adjustment Operator Station Group
Air Conditioner
IMPORTANT
- Oil (180 cm3; or 0.76 cup) required for the cooling
circuit is sealed inside a new compressor.
Prior to replacing the compressor, excess oil
should be drained from the new compressor.
- The compressor oil can come to absorb moisture.
Seal the compressor immediately after adjusting
the oil quantity with a plastic cap.
- Never use ester based oil. Use only PAG oil.
73-4
50ZV Check & Adjustment Operator Station Group
Air Conditioner
IN
1
OUT
Evaporator
2 50ZVA73002
50ZVA73001
1
50ZVA73003
At the next time the dryer is replaced and from then on,
add 20 cm3 (0.7 oz) of compressor oil (ND-OIL 8) to a
new receiver dryer.
Link rod B
Supporting
(between damper
2. Confirm that the water valve is completely closed.
Air mix damper B point B Unless that the water valve is closed completely,
A and B)
remove clamp A link stopper and adjust the link rod
A position.
Evaporator
ate
r
Blower
He Fan motor
Link rod A
(for water valve)
Air mix damper B adjustment
Supporting point Heater
radiator
core 1. Confirm that the air mix damper B closes the heater
Water valve radiator core completely.
Supporting
selection
point A Water valve
servo motor 2. Remove clamp B link stopper and adjust the link
Air mix damper A
rod B position, unless that the air mix damper B
Link • damper position at lowest ventilation temperature closes the heater radiator core completely.
50ZVA73004
Link rod A
Water valve
Link rod B
Water valve
Clamp B
servo motor
Air mix damper A
60ZV73003J
73-6
50ZV 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 dimension A between rotor end face and
magnetic clutch hub end face while magnetic clutch is "OFF".
Hub
Head bolt
Washer plate
Rotor
95ZVE73002
WARNING
Shut off the engine to do this procedure.
Front
L.H R.H
10
1
8
3
4 6
2 7
50ZVA73005
7. Bracket
8~10m
8. Bolt
9. Bolt
10. Bolt
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
Cleaning
Once/1 month
Replacement
Once/3 years
S U
Safety precautions ........................................................... 00-2 Upper center pin ...............................................................12-6
Screw lock agent application procedure ........................ 00-19
Seat assembly .................................................................. 72-6
V
Second propeller shaft alignment ..................................... 23-3
Valve Control .........................................................42-34, 43-9
Second propeller shaft assembly ..................................... 22-9
Valve location ................................................................... 32-5
Sensor Mount ................................................................... 62-5
Valve part .......................................................................42-41
Service Brake .......................................................... 52-8, 53-4
Viscous mount ..................................................................12-5
Service brake friction plate ............................................... 52-9
Voltage relay ...................................................................62-15
Service brake friction plate wear measurement ............... 53-5
Service brake linkage ..................................................... 52-13
Service brake operation ................................................... 52-8 W
Service brake performance check .................................... 53-4 Water valve adjustment ....................................................73-5
Service brake steel plate .................................................. 52-9 Water valve and air mix damper adjustment ....................73-5
Shift Lever ...................................................................... 32-14 Weight of main components ...........................................00-12
Shift lever forward/reverse (F/R) position ......................... 62-9 When shifting to 1st speed is completed ........................32-24
Shift lever neutral (N) position .......................................... 62-9 When the brake is in the hold (balanced) position ............52-7
Sight glass ...................................................................... 72-43 When the compressor is replaced ....................................73-3
Solenoid Valve ............................................................... 32-25 When the condenser is replaced ......................................73-4
Solenoid valve ................................................................ 62-28 When the evaporator is replaced ......................................73-4
Solenoid valve operation table ....................................... 62-28 When the pedal is depressed a second time ....................52-7
Solenoid valve specification ........................................... 62-28 When the shift lever is moved (1) ...................................32-21
Speed selection .............................................................. 32-14 When the shift lever is moved (2) ...................................32-22
Standard measurement value ........................ 23-2, 53-4, 53-6 Wiper motor ......................................................................72-4
Standard measurement value (mm/min)(in/min) ............ 43-10 Work procedure ..............................................................72-48
Standard measurement value MPa (kgf/cm2) (psi)
............................................................................. 43-3, 43-6
Starter switch ................................................................. 62-10
Steering circuit relief valve setting pressures ................... 43-6
Steering cylinder ............................................................ 42-17
Steering speed and flow rate control .............................. 42-46
Steering System ............................................................. 42-35
Steering system ............................................................... 42-8
Stop Light Switch Circuit ................................................ 62-34
Sub-plate ........................................................................ 32-18
Surge voltage and surge suppression diodes ................ 62-41
Suspension adjustment .................................................... 72-7
Suspension assembly ...................................................... 72-7
Symbols ........................................................................... 00-3
System diagram ............................................................. 32-16
T
Third propeller shaft assembly ....................................... 22-10
Tightening torque ............................................................. 23-4
To forward and reverse clutches .................................... 32-13
To speed clutches .......................................................... 32-13
Torque Converter ............................................................. 32-2
Torque Converter and Transmission ................................ 92-3
Torque Converter Gear Pump .......................................... 32-3
Torque Converter structure .............................................. 32-2
Torque multiplication ........................................................ 32-2
Transmission .................................................................... 32-4
Transmission – Rear differential .................................... 22-10
Transmission control circuit check ................................... 63-5
Transmission cut off (Declutch) switch ........................... 62-27
Transmission Electrical Circuit ....................................... 62-27
MEMO
Maintenance Log