Kawasaki WHEEL LOADER 45ZV-2 SHOP MANUAL 93204-00080 (1)

45ZV-2

93204-00080 November 2010

SHOP MANUAL

SHOP MANUAL

- General Information - Operational Principle

WHEEL LOADER

45ZV-2 Technical Manual - General Information - Operational Principle - Diagrams

Printed in Japan (k) ( アメリカ用 )

93204-00080

©2010 KCM Corporation All rights reserved.

Powered by KUBOTA V3307-DI-T ENGINE Serial No. 00193 and up

TECHNICAL MANUAL (Operational Principle) INTRODUCTION........................................................................................................................... IN-01~02 SAFETY ............................................................................................................................................S-1~34 SECTION 1

GENERAL ...............................................................................................................4FGET-1

Group 1

Specifications ............................................................................................................. T1-1

Group 2

Component Layout..................................................................................................... T1-2

Group 3

Component Specifications ......................................................................................... T1-3

SECTION 2 SYSTEM ..................................................................................................................4FGET-2 Group 1

Control System........................................................................................................... T2-1

Group 2

Hydraulic System ....................................................................................................... T2-2

Group 3

Electrical System........................................................................................................ T2-3

SECTION 3 COMPONENT OPERATION...................................................................................4FGET-3 Group 1

Priority Valve .............................................................................................................. T3-1

Group 2

Control Valve .............................................................................................................. T3-2

Group 3

Steering Valve ............................................................................................................ T3-3

Group 4

HST Pump.................................................................................................................. T3-4

Group 5

HST Motor .................................................................................................................. T3-5

Group 6

Reduction ................................................................................................................... T3-6

Group 7

Axle ............................................................................................................................ T3-7

Group 8

Brake Master Cylinder ............................................................................................... T3-8

Group 9

Others......................................................................................................................... T3-9

ATTACHMENT DIAGRAMS Rear Harness .......................................................................................................................................

Front Harness.......................................................................................................................................

Main Harness .......................................................................................................................................

Electrical Circuit Diagram.....................................................................................................................

Hydraulic Circuit Diagram ....................................................................................................................

TECHNICAL MANUAL (Troubleshooting) (P/N 93204-00090) is separately available.

It consists of the following sections: SECTION 4 OPERATIONAL PERFORMANCE TEST Group 1 Introduction Group 2 Standard Group 3 Engine Test Group 4 Wheel Loader Test Group 5 Component Test Group 6 Adjustment

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Group 2 Component Layout Group 3 Troubleshooting A Group 4 Troubleshooting B Group 5 Troubleshooting C Group 6 Electrical System Inspection

All information, illustrations and specifications in this manual are based on the latest product information available at the time of publication. The right is reserved to make changes at any time without notice.

45ZV-2

INTRODUCTION TO THE READER • This manual is written for an experienced technician to provide technical information needed to maintain and repair this machine.

• Be sure to thoroughly read this manual for correct product information and service procedures.

ADDITIONAL REFERENCES • Please refer to the other materials (operator’s manual, parts catalog, etc.) in addition to this manual.

MANUAL COMPOSITION • This manual consists the Technical Manual and the Workshop Manual.

• Information included in the Technical Manual: technical information needed for redelivery and delivery, operation and activation of all devices and systems, operational performance tests, and troubleshooting procedures.

• Information included in the Workshop Manual: technical information needed for maintenance and repair of the machine, tools and devices needed for maintenance and repair, maintenance standards, and removal/installation and assemble/disassemble procedures.

PAGE NUMBER • Each page has a number, located on the center lower part of the page, and each number contains the following information: Example : T 1-3-5 Consecutive Page Number for Each Group Group Number Section Number T: Technical Manual

W: Workshop Manual

IN-01

INTRODUCTION SAFETY ALERT SYMBOL HEADLINE NOTATIONS

AND

In this manual, the following safety alert symbol and signal words are used to alert the reader to the potential for personal injury of machine damage.

This is the safety alert symbol. When you see this symbol, be alert to the potential for personal injury.

Never fail to follow the safety instructions prescribed along with the safety alert symbol.

The safety alert symbol is also used to draw attention to component/part weights.

To avoid injury and damage, be sure to use appropriate lifting techniques and equipment when lifting heavy parts.

•

CAUTION: Indicated potentially hazardous situation which could, if not avoided, result in personal injury or death.

• IMPORTANT: Indicates a situation which, if not conformed to the instructions, could result in damage to the machine.

•

NOTE: Indicates supplementary technical information or know-how.

UNITS USED • SI Units (International System of Units) are used in

2

Example : 24.5 MPa (250 kgf/cm , 3560 psi)

this manual.

MKSA system of units and English units are also indicated in parentheses just behind SI units.

Quantity Length Volume

Weight Force Torque

To Convert From mm mm L L 3 m kg N N N⋅m N⋅m

Into in ft US gal US qt 3 yd lb kgf lbf kgf⋅m lbf⋅ft

A table for conversion from SI units to other system units is shown below for reference purposes.

Quantity

Multiply By 0.03937 0.003281 0.2642 1.057 1.308 2.205 0.10197 0.2248 1.0197 0.7375

Pressure Power Temperature Velocity Flow rate

IN-02

To Convert From MPa MPa kW kW °C km/h -1 min L/min mL/rev

Into

Multiply By 2

kgf/cm psi PS HP °F mph rpm US gpm cc/rev

10.197 145.0 1.360 1.341 °C×1.8+32 0.6214 1.0 0.2642 1.0

SAFETY RECOGNIZE SAFETY INFORMATION • These are the SAFETY ALERT SYMBOLS. • When you see these symbols on your machine or in operator’s manual, be alert to the potential for personal injury.

• Follow recommended precautions and safe operating practices.

001-E01A-0001 SA-688

UNDERSTAND SIGNAL WORDS • On machine safety signs, signal words designating the degree or level of hazard - DANGER, WARNING, or CAUTION - are used with the safety alert symbol.

• DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

• WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

• CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

• DANGER or WARNING safety signs are located near specific hazards. General precautions are listed on CAUTION safety signs.

• Some safety signs don’t use any of the designated signal words above after the safety alert symbol has been used on this machine.

• To avoid confusing machine protection with personal safety messages, a signal word IMPORTANT indicates a situation which, if not avoided, could result in damage to the machine.

•

SA-1223

NOTE indicates an additional explanation for an element of information.

002-E01A-1223

S-1

SAFETY FOLLOW SAFETY INSTRUCTIONS • Carefully read and follow all safety signs on the machine and all safety messages in operator’s manual.

• Safety signs should be installed, maintained and replaced when necessary.

• If a safety sign or operator’s manual is damaged or missing, order a replacement from your authorized dealer in the same way you order other replacement parts (be sure to state machine model and serial number when ordering).

• Learn how to operate the machine and its controls correctly and safely.

• Allow only trained, qualified, authorized personnel to operate the machine.

• Keep your machine in proper working condition.

• Unauthorized modifications of the machine may impair its function and/or safety and affect machine life.

• Do not modify any machine parts without authorization.

Failure to do so may deteriorate the part safety, function, and/or service life. In addition, personal accident, machine trouble, and/or damage to material caused by unauthorized modifications will void Kawasaki Warranty Policy.

• Do not use attachments and/or optional parts or equipment not authorized by Kawasaki. Failure to do so may deteriorate the safety, function, and/or service life of the machine. In addition, personal accident, machine trouble, and/or damage to material caused by using unauthorized attachments and/or optional parts or equipment will void Kawasaki Warranty Policy.

• The safety messages in this SAFETY chapter are intended to illustrate basic safety procedures of machines. However it is impossible for these safety messages to cover every hazardous situation you may encounter. If you have any questions, you should first consult your supervisor and/or your authorized dealer before operating or performing maintenance work on the machine.

SA-003

003-E01B-0003

S-2

SAFETY PREPARE FOR EMERGENCIES • Be prepared if a fire starts or if an accident occurs.

• Keep a first aid kit and fire extinguisher on hand.

• Thoroughly read and understand the label attached on the fire extinguisher to use it properly.

• To ensure that a fire extinguisher can be always used when necessary, check and service the fire extinguisher at the recommended intervals as specified in the fire-extinguisher manual.

• Establish emergency procedure guidelines to cope with fires and accidents.

• Keep emergency numbers for doctors, ambulance service, hospital, and fire department posted near your telephone.

SA-437

004-E01A-0437

WEAR PROTECTIVE CLOTHING • Wear close fitting clothing and safety equipment appropriate to the job.

You may need: A hard hat Safety shoes Safety glasses, goggles, or face shield Heavy gloves Hearing protection Reflective clothing Wet weather gear Respirator or filter mask.

SA-438

Be sure to wear the correct equipment and clothing for the job. Do not take any chances.

• Avoid wearing loose clothing, jewelry, or other items that can catch on control levers or other parts of the machine.

• Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphones while operating the machine.

005-E01A-0438

S-3

SAFETY PROTECT AGAINST NOISE • Prolonged exposure to loud noise can cause impairment or loss of hearing.

• Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortably loud noises.

SA-434

006-E01A-0434

INSPECT MACHINE • Inspect your machine carefully each day or shift by walking around it before you start it to avoid personal injury.

• In the walk-around inspection be sure to cover all points described in the “INSPECT MACHINE DAILY BEFORE STARTING” section in the operator’s manual.

SA-435 007-E01A-0435

S-4

SAFETY GENERAL PRECAUTIONS FOR CAB • Before entering the cab, thoroughly remove all dirt and/or oil from the soles of your work boots. If any control such as a pedal is operated while with dirt and/or oil on the soles of the operator’s work boots the operator’s foot may slip off the pedal, possibly resulting in a personal accident.

• Do not leave parts and/or tools lying around the operator’s seat. Store them in their specified locations.

• Avoid storing transparent bottles in the cab. Do not attach any transparent type window decorations on the windowpanes as they may focus sunlight, possibly starting a fire.

• Refrain from listening to the radio, or using music headphones or mobile telephones in the cab while operating the machine.

• Keep all flammable objects and/or explosives away from the machine.

• After using the ashtray, always cover it to extinguish the match and/or tobacco.

• Do not leave cigarette lighters in the cab. When the temperature in the cab increases, the lighter may explode.

524-E01A-0000

USE HANDHOLDS AND STEPS • Falling is one of the major causes of personal injury.

• When you get on and off the machine, always face the machine and maintain a three-point contact with the steps and handrails.

• Do not use any controls as hand-holds.

• Never jump on or off the machine. Never mount or dismount a moving machine.

• Be careful of slippery conditions on platforms, steps, and handrails when leaving the machine.

SA-439 008-E01A-0439

S-5

SAFETY ADJUST THE OPERATOR'S SEAT • A poorly adjusted seat for either the operator or for the work at hand may quickly fatigue the operator leading to miss-operations.

• The seat should be adjusted whenever changing the operator for the machine.

• The operator should be able to fully depress the pedals and to correctly operate the control levers with his back against the seat back.

• If not, move the seat forward or backward, and check again.

• Adjust the rear view mirror position so that the best rear visibility is obtained from the operator’s seat. If the mirror is broken, immediately replace it with a new one.

SA-462

009-E01A-0462

ENSURE SAFETY BEFORE RISING FROM OR LEAVING OPERATOR’S SEAT • Before rising from the operator’s seat to open/close either side window or to adjust the seat position, be sure to first lower the front attachment to the ground and then move the loader control lever to the LOCK position. Failure to do so may allow the machine to unexpectedly move when a body part unintentionally comes in contact with a control lever, possibly resulting in serious personal injury or death.

• Before leaving the machine, be sure to first lower the front attachment to the ground and then move the loader control lever to the LOCK position. Turn the key switch OFF to stop the engine.

• Before leaving the machine, close all windows, doors, and access covers and lock them up.

S-6

SAFETY FASTEN YOUR SEAT BELT • If the machine should overturn, the operator may become injured and/or thrown from the cab. Additionally the operator may be crushed by the overturning machine, resulting in serious injury or death.

• Prior to operating the machine, thoroughly examine webbing, buckle and attaching hardware.

If any item is damaged or worn, replace the seat belt or component before operating the machine.

• Be sure to remain seated with the seat belt securely fastened at all times when the machine is in operation to minimize the chance of injury from an accident.

• We recommend that the seat belt be replaced every three years regardless of its apparent condition.

SA-237

010-E01A-0237

MOVE AND OPERATE MACHINE SAFELY • Bystanders can be run over.

• Take extra care not to run over bystanders. Confirm the location of bystanders before moving, or operating the machine.

• Always keep the travel alarm and horn in working condition (if equipped). It warns people when the machine starts to move.

• Use a signal person when moving, or operating the machine in congested areas. Coordinate hand signals before starting the machine.

• Use appropriate illumination. Check that all lights are operable before operating the machine. If any faulty illumination is present, immediately repair it.

SA-398

011-E01A-0398

S-7

SAFETY HANDLE STARTING AIDS SAFELY Starting fluid:

• Starting fluid is highly flammable.

• Keep all sparks and flame away when using it.

• Keep starting fluid well away from batteries and cables.

• Remove container from machine if engine does not need starting fluid.

• To prevent accidental discharge when storing a pressurized container, keep the cap on the container, and store it in a cool, well-protected location.

• Do not incinerate or puncture a starting fluid container.

SA-293

036-E01A-0293-3

OPERATE ONLY FROM OPERATOR'S SEAT • Inappropriate engine starting procedures may cause the machine to runaway, possibly resulting in serious injury or death.

• Start the engine only when seated in the operator's seat.

• NEVER start the engine while standing on the tire or on ground.

• Do not start engine by shorting across starter terminals.

• Before starting the engine, confirm that all control levers are in neutral.

• Before starting the engine, confirm the safety around the machine and sound the horn to alert bystanders.

SA-431

012-E01B-0431

S-8

SAFETY JUMP-STARTING • Battery gas can explode, resulting in serious injury.

• If the engine must be jump-started, be sure to follow the instructions shown in the “OPERATING THE ENGINE” chapter in the operator’s manual.

• The operator must be in the operator’s seat so that the machine will be under control when the engine starts.

Jump-starting is a two-person operation.

• Never use a frozen battery.

• Failure to follow correct jump-starting procedures could result in a battery explosion or a runaway machine.

SA-032

S013-E01A-0032

INVESTIGATE JOB SITE BEFOREHAND • When working at the edge of an excavation or on a road shoulder, the machine could tip over, possibly resulting in serious injury or death.

• Investigate the configuration and ground conditions of the job site beforehand to prevent the machine from falling and to prevent the ground, stockpiles, or banks from collapsing.

• Make a work plan. Use machines appropriate to the work and job site.

• Reinforce ground, edges, and road shoulders as necessary. Keep the machine well back from the edges of excavations and road shoulders.

• When working on an incline or on a road shoulder, employ a signal person as required.

• Confirm that your machine is equipped a FOPS cab before working in areas where the possibility of falling stones or debris exist.

• When the footing is weak, reinforce the ground before starting work.

• When working on frozen ground, be extremely alert. As ambient temperatures rise, footing becomes loose and slippery.

• Beware of the possibility of fire when operating the machine near flammable objects such as dry grass.

SA-447

015-E01B0447

S-9

SAFETY EQUIPMENT OF HEAD GUARD, ROPS, FOPS In case the machine is operated in areas where the possibility of falling stones or debris exist, equip a head guard, ROPS, or FOPS according to the potential hazardous conditions. (The standard cab for this machine corresponds to ROPS and FOPS.) ROPS: Roll-Over Protective Structure FOPS: Falling Object Protective Structure

SA-521

PROVIDE SIGNALS FOR JOBS INVOLVING MULTIPLE NUMBERS OF MACHINES • For jobs involving multiple numbers of machines, provide signals commonly known by all personnel involved. Also, appoint a signal person to coordinate the job site. Make sure that all personnel obey the signal person’s directions.

018-E01A-0481 SA-481

S-10

SAFETY KEEP RIDERS OFF MACHINE • Riders on machine are subject to injury such as being struck by foreign objects and being thrown off the machine.

• Only the operator should be on the machine.

Keep riders off.

• Riders also obstruct the operator’s view, resulting in the machine being operated in an unsafe manner.

SA-427

014-E01B-0427

DRIVE SAFELY • Beware of the possibility of slipping and/or turning over the machine when driving on a slope.

• When driving on level ground, hold the bucket at mark (A) 300 to 400 mm (12 to 16 in) above the ground as illustrated.

• Avoid driving over any obstacles.

• Drive the machine slowly when driving on rough terrain.

• Avoid quick direction changes. Failure to do so may cause the machine to turn over.

• If the engine stops while driving, the steering function becomes inoperative. Immediately stop the machine by applying the bake to prevent personal accident.

• • Even though the machine is equipped with the emergency steering system, if the steering function becomes inoperable during drive operation, press the emergency steering check switch on the right console to activate the emergency steering system.

Then, immediately park and stop the machine in a safe location.

• 019-E07A-0448

S-11

SA-44

SAFETY DRIVE MACHINE SAFELY (WORK SITE) • Before driving the machine, always confirm that the steering wheel/ forward/reverse lever direction corresponds to the direction you wish to drive.

• Be sure to detour around any obstructions.

• Driving on a slope may cause the machine to slip or overturn, possibly resulting in serious injury or death.

• When driving up or down a slope, keep the bucket facing the direction of travel, approximately 300 to 400 mm (approximately 12 to 16 in) (A) above the ground.

• If the machine starts to skid or becomes unstable, immediately lower the bucket to the ground and stop.

SA-449

• Driving across the face of a slope or steering on a slope may cause the machine to skid or overturn. If the direction must be changed, move the machine to level ground, then, change the direction to ensure safe operation.

SA-450

019-E05B-0515

SA-451

DRIVE SAFELY WITH BUCKET LOADED • If the machine is operated incorrectly while driving with the bucket loaded, the machine may turn over.

Be sure to follow all of the instructions indicated below.

• When driving the machine on a job site with the bucket loaded, hold the bucket as low as possible to keep the machine balanced and to have good visibility.

• Do not exceed the rated load capacity. Always operate the machine within the rated load capacity.

• Avoid fast starts, stops, and quick turns. Failure to do so may result in personal injury and/or death.

• Avoid rapid drive direction changes which could possibly cause personal injury and/or death.

S-12

SA-400

SAFETY DRIVE ON SNOW SAFELY • Beware of the possibility of slipping or turning over the machine when driving on frozen snow surfaces.

• The machine may slip more easily than expected on frozen snow surfaces even if the incline is small. Reduce speed when driving. Avoid fast starts, stops and quick turns.

• Road shoulder and/or set-up utilities covered with snow are difficult to locate. Be sure where they are before removing snow.

• Be sure to use tire chains when driving on snow.

• Avoid applying the brake for quick stops on snow.

If a quick stop is required, lower the bucket to the ground.

SA-452

052-E02A-0452

TRAVEL ON PUBLIC ROADS SAFELY • This machine is not allowed to drive on public loads with the bucket loaded.

• Be sure to empty the bucket.

• Hold the bucket at mark (A) 300 to 400 mm (12 to 16 in) above the road surface as illustrated.

• Even though the machine is equipped with the emergency steering system, if the steering function becomes inoperable during operation, press the emergency steering check switch on the right console to activate the emergency steering system.

Then, immediately park and stop the machine in a safe location.

053-E02A-0453

S-13

SA-453

SAFETY AVOID INJURY FROM ROLLAWAY ACCIDENTS • Death or serious injury may result if you attempt to mount or stop a moving machine.

To avoid rollways: • Select level ground when possible to park machine.

• Do not park the machine on a grade.

• Lower the bucket to the ground.

• Place the forward/reverse lever (switch) in neutral, and pull up the park brake switch (lever) in the ON (parking brake) position.

• Run the engine at low idle speed without load for 5 minutes to cool down the engine.

• Stop the engine and remove the key from the key switch.

• Pull the lock lever to LOCK position.

• Block both tires and lower the bucket to the ground.

• Position the machine to prevent rolling.

• Park a reasonable distance from other machines.

020-E02A-0516

S-14

SA-457

SA-458

SAFETY AVOID ACCIDENTS FROM BACKING UP AND TURNING • Make sure no one is working under or close to the machine before backing up or turning the machine to avoid personal injury and/or death by being run over or entangled in the machine.

• Keep all personnel away from the machine by sounding the horn and/or using hand signals.

Use extra care to be sure no one is in from the articulation area before turning the machine.

• Keep windows, mirrors, and lights in good condition.

• Reduce travel speed when dust, heavy rain, fog, etc., reduce the visibility.

• In case good visibility is not obtained, use a signal person to guide you.

SA-383

021-E02A-0517

SA-312

AVOID POSITIONING ANYONE

BUCKET

OVER

• Never allow the bucket to pass over co-workers and/or the dump truck operator’s cab. Falling material from the bucket or contact with bucket may cause serious personal accidents and/or damage to the machine.

• Avoid carrying the bucket over the co-workers to ensure safe operation.

023-E02A-0518

S-15

SA-518

SAFETY AVOID TIPPING DO NOT ATTEMPT TO JUMP CLEAR OF TIPPING MACHINE. MACHINE WILL TIP OVER FASTER THAN YOU CAN JUMP FREE, POSSIBLY RESULTING IN SERIOUS PERSONAL INJURY OR DEATH. IF TIPPING OVER OF THE MACHINE IS PREDICTED, SECURELY HOLD THE STEERING WHEEL TO PREVENT YOUR BODY FROM BEING THROWN OUT OF THE MACHINE. MACHINE WILL TIP OVER FASTER THAN YOU CAN JUMP FREE FASTEN YOUR SEAT BELT

• The danger of tipping is always present when operating on a grade, possibly resulting in serious injury or death.

To avoid tipping: • Be extra careful before operating on a grade.

• Prepare machine operating area flat.

• Keep the bucket low to the ground and close to the machine.

• Reduce operating speeds to avoid tipping or slipping.

• Avoid changing direction when traveling on grades.

• NEVER attempt to travel across a grade steeper than 5 degrees if crossing the grade is unavoidable.

• Reduce speed as necessary when swinging loads.

SA-463

• Be careful when working on frozen ground.

• Temperature increases will cause the ground to become soft and make ground travel unstable.

NEVER UNDERCUT A HIGH BANK • The edges could collapse or a landslide could occur causing serious injury or death.

026-E01A-0519

SA-519

S-16

SAFETY DIG WITH CAUTION • Accidental severing of underground cables or gas lines may cause an explosion and/or fire, possibly resulting in serious injury or death.

• Before digging, check the location of cables, gas lines, and water lines.

• Keep the minimum distance required by law, from cables, gas lines, and water lines.

• If a fiber optic cable should be accidentally severed, do not look into the end. Doing so may result in serious eye injury.

• Contact your local “diggers hot line” if available in your area, and/or the utility companies directly.

Have them mark all underground utilities.

SA-396

027-E01A-0396

PERFORM TRUCK LOADING SAFELY • Do not operate the machine involuntarily. Unexpected machine movement may cause personal injury and/or death.

• Do not lower the bucket with the loader control lever in the FLOAT position. The bucket may free fall, possibly causing personal injury and/or death.

• Always select a level surface for truck loading.

028-E01A-397 SA-397

AVOID POWER LINES Serious injury or death can result from contact with electric lines.

Never move any part of the machine or load closer to any electric line than 3 m (10 ft) plus twice the line insulator length.

29-E01A-0455 SA-455

S-17

SAFETY PRECAUTIONS FOR OPERATION • If the front attachment or any part of the machine comes in contact with an overhead obstacle, both the machine and the overhead obstacle may become damaged, and personal injury may result.

• Take care to avoid coming in contact with overhead obstacles with the bucket or arm during operation.

PRECAUTIONS FOR LIGHTENING • The machine is vulnerable to lighting strikes.

• In the event of an electrical storm, immediately stop operation, and lower the bucket to the ground. Evacuate to a safe place far away from the machine.

• After the electrical storm has passed, check all of the machine safety devices for any failure. If any failed safety devices are found, operate the machine only after repairing them.

SA-4EK-020

S-18

SAFETY OBJECT HANDLING • If a lifted load should fall, any person nearby may be struck by the falling load or may be crushed underneath it, resulting in serious injury or death.

• When using the machine for craning operations, be sure to comply with all local regulations.

• Do not use damaged chains or frayed cables, sables, slings, or ropes.

• Before craning, position the upper structure with the position of the bucket support located on the chassis at the front.

• Move the load slowly and carefully. Never it suddenly.

• Keep all persons well away from the load.

• Never move a load over a person’s head.

• Do not allow anyone to approach the load until it is safely and securely situated on supporting blocks or on the ground.

• Never attach a sling or chain to the bucket teeth or to the attachment. They may come off, causing the load to fall.

SA-132

032-E01A-0132

PROTECT AGAINST FLYING DEBRIS • If flying debris hit eyes or any other part of the body, serious injury may result.

• Guard against injury from flying pieces of metal or debris; wear goggles or safety glasses.

• Keep bystanders away from the working area before striking any object.

031-E01A-0432

SA-432

S-19

SAFETY PARK MACHINE SAFELY To avoid accidents: • Park machine on a firm, level surface.

• Lower bucket to the ground.

• Place the forward/reverse lever (switch) in neutral, and turn the parking brake switch (lever) in the ON (parking brake) position.

• Run engine at low idle speed without load for 3 minutes.

• Turn key switch to OFF to stop engine.

• Remove the key from the key switch.

• Lower the lock lever to the LOCK position.

• Close windows, roof vent, and cab door.

• Lock all access doors and compartments.

SA-456

033-E07B-0456

STORE ATTACHMENTS SAFELY • Stored attachments such as buckets, hydraulic hammers, and blades can fall and cause serious injury or death.

• Securely store attachments and implements to prevent falling. Keep children and bystanders away from storage areas.

504-E01A-0034

SA-034

S-20

SAFETY TRANSPORT SAFELY • Be careful because machine may turn over when loading or unloading the machine on or off of a truck or trailer.

• Observe the related regulations and rules for safe transportation.

• Select an appropriate truck or trailer for the machine to be transported.

• Be sure to use a signal person.

• Always follow the following precautions for loading or unloading: 1. Select solid and level ground.

2. Always use a ramp or deck strong enough to support the machine weight.

3. Use a low speed gear.

4. Never steer the machine while on the ramp. If the traveling direction must be changed while the ramp, unload the machine from the ramp, reposition the machine on the ground, then try loading again.

5. After loading, install the lock bar to securely hold the articulation mechanism.

6. Chock the front and rear of tires. Securely hold the machine to the truck or trailer deck with heavy chains or wire cables.

Be sure to further follow the details described in the TRANSPORTING section.

035-E07A-0454

S-21

Less than 15°

SA-454

SAFETY HANDLE FLUIDS SAFELY-AVOID FIRES • Handle fuel with care; it is highly flammable. If fuel ignites, an explosion and/or a fire may occur, possibly resulting in serious injury or death.

• Do not refuel the machine while smoking or when near open flame or sparks.

• Always stop the engine before refueling the machine.

• Fill the fuel tank outdoors.

• All fuels, most lubricants, and some coolants are flammable.

• Store flammable fluids well away from fire hazards.

• Do not incinerate or puncture pressurized containers.

• Do not store oily rags; they can ignite and burn spontaneously.

• Securely tighten the fuel and oil filler caps.

SA-018

034-E01A-0496 SA-019

S-22

SAFETY PRACTICE SAFE MAINTENANCE To avoid accidents: • Understand service procedures before starting work.

• Keep the work area clean and dry.

• Do not spray water or steam inside cab.

• Never lubricate or service the machine while it is moving.

• Keep hands, feet and clothing away from power-driven parts.

Before servicing the machine: 1. Park the machine on a level surface.

2. Lower the bucket to the ground.

3. Turn the auto-idle switch off.

4. Run the engine at slow idle speed without load for 3 minutes.

5. Turn the key switch to OFF to stop engine.

6. Relieve the pressure in the hydraulic system by moving the control levers several times.

7. Remove the key from the switch.

8. Attach a “Do Not Operate” tag on the control lever.

9. Lower the lock lever to the LOCK position.

10. Lock bar connects the front and rear frames.

11. Allow the engine to cool.

SA-028

SA-312

• If a maintenance procedure must be performed with the engine running, do not leave machine unattended.

• Never work under a machine raised by the lift arm.

• Inspect certain parts periodically and repair or replace as necessary. Refer to the section discussing that part in the “MAINTENANCE” chapter of operator’s manual.

• Keep all parts in good condition and properly installed.

• Fix damage immediately. Replace worn or broken parts. Remove any buildup of grease, oil, or debris.

• When cleaning parts, always use nonflammable detergent oil. Never use highly flammable oil such as fuel oil and gasoline to clean parts or surfaces.

• Disconnect battery ground cable (-) before making adjustments to electrical systems or before performing welding on the machine.

SA-134

500-E02C-0520 SA-527

S-23

SAFETY • Sufficiently illuminate the work site. Use a maintenance work light when working under or inside the machine.

• Always use a work light protected with a guard. In case the light bulb is broken, spilled fuel, oil, antifreeze fluid, or window washer fluid may catch fire.

SA-037

WARN OTHERS OF SERVICE WORK • Unexpected machine movement can cause serious injury.

• Before performing any work on the machine, attach a “Do Not Operate” tag on the control lever.

This tag is available from your authorized dealer.

501-E01A-0287

SS2045102

SUPPORT MACHINE PROPERLY • Never attempt to work on the machine without securing the machine first.

• Always lower the attachment to the ground before you work on the machine.

• If you must work on a lifted machine or attachment, securely support the machine or attachment. Do not support the machine on cinder blocks, hollow tires, or props that may crumble under continuous load. Do not work under a machine that is supported solely by a jack.

519-E01A-0527 SA-527

STAY CLEAR OF MOVING PARTS • Entanglement in moving parts can cause serious injury.

• To prevent accidents, care should be taken to ensure that hands, feet, clothing, jewelry and hair do not become entangled when working around rotating parts.

502-E01A-0026

S-24

SA-026

SAFETY SUPPORT MAINTENANCE PROPERLY • Explosive separation of a tire and rim parts can cause serious injury or death.

• Do not attempt to mount a tire unless you have the proper equipment and experience to perform the job. Have it done by your authorized dealer or a qualified repair service.

• Always maintain the correct tire pressure. DO NOT inflate tire above the recommended pressure.

• When inflating tires, use a chip-on chuck and extension hose long enough to allow you to stand to one side and not in front of or over the tire assembly. Use a safety cage it available.

• Inspect tires and wheels daily. Do not operate with low pressure, cuts bubbles, damaged rims, or missing lug bolts and nuts.

• Never cut or weld on an inflated tire or rim assembly. Heat from welding could cause an increase in pressure and may result in tire explosion.

SA-249

521-E02A-0249

PREVENT PARTS FROM FLYING • Travel reduction gears are under pressure.

• As pieces may fly off, be sure to keep body and face away from the axle AIR RELEASE PLUG to avoid injury.

• GEAR OIL is hot. Wait for GEAR OIL to cool, and then gradually loosen AIR RELEASE PLUG to release pressure.

503-E03A-0344

SA-344

S-25

SAFETY PREVENT BURNS Hot spraying fluids:

• After operation, engine coolant is hot and under pressure. Hot water or steam is contained in the engine, radiator and heater lines.

Skin contact with escaping hot water or steam can cause severe burns.

• To avoid possible injury from hot spraying water.

DO NOT remove the radiator cap until the engine is cool. When opening, turn the cap slowly to the stop. Allow all pressure to be released before removing the cap.

• The hydraulic oil tank is pressurized. Again, be sure to release all pressure before removing the cap.

SA-039

Hot fluids and surfaces:

• Engine oil, gear oil and hydraulic oil also become hot during operation.

The engine, hoses, lines and other parts become hot as well.

• Wait for the oil and components to cool before starting any maintenance or inspection work.

SA-225

505-E01B-0498

REPLACE RUBBER HOSES PERIODICALLY • Rubber hoses that contain flammable fluids under pressure may break due to aging, fatigue, and abrasion. It is very difficult to gauge the extent of deterioration due to aging, fatigue, and abrasion of rubber hoses by inspection alone.

• Periodically replace the rubber hoses. (See the page of “Periodic replacement of parts” in the operator’s manual.)

• Failure to periodically replace rubber hoses may cause a fire, fluid injection into skin, or the front attachment to fall on a person nearby, which may result in severe burns, gangrene, or otherwise serious injury or death.

S506-E01A-0019

S-26

SA-019

SAFETY AVOID HIGH-PRESSURE FLUIDS • Fluids such as diesel fuel or hydraulic oil under pressure can penetrate the skin or eyes causing serious injury, blindness or death.

• Avoid this hazard by relieving pressure before disconnecting hydraulic or other lines.

• Tighten all connections before applying pressure.

• Search for leaks with a piece of cardboard; take care to protect hands and body from high-pressure fluids. Wear a face shield or goggles for eye protection.

• If an accident occurs, see a doctor familiar with this type of injury immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result.

SA-031

507-E03A-0499

SA-292

SA-044

S-27

SAFETY PREVENT FIRES Check for Oil Leaks: • Fuel, hydraulic oil and lubricant leaks can lead to fires.

• Check for oil leaks due to missing or loose clamps, kinked hoses, lines or hoses that rub against each other, damage to the oil-cooler, and loose oil-cooler flange bolts.

• Tighten, repair or replace any missing, loose or damaged clamps, lines, hoses, oil-cooler and oil-cooler flange bolts.

• Do not bend or strike high-pressure lines.

• Never install bent or damaged lines, pipes, or hoses.

Check for Shorts: • Short circuits can cause fires.

• Clean and tighten all electrical connections.

• Check before each shift or after eight(8) to ten(10) hours operation for loose, kinked, hardened or frayed electrical cables and wires.

• Check before each shift or after eight (8) to ten (10) hours operation for missing or damaged terminal caps.

• DO NOT OPERATE MACHINE if cable or wires are loose, kinked, etc.

Clean up Flammables: • Spilled fuel and oil, and trash, grease, debris, accumulated coal dust, and other flammables may cause fires.

• Prevent fires by inspecting and cleaning the machine daily and by removing spilled or accumulated flammables immediately.

Check Key Switch: • If a fire breaks out, failure to stop the engine will escalate the fire, hampering fire fighting.

Always check key switch function before operating the machine every day: 1. Start the engine and run it at slow idle.

2. Turn the key switch to the OFF position to confirm that the engine stops.

• If any abnormalities are found, be sure to repair them before operating the machine.

508-E02B-0019

Check Heat Shields: • Damaged or missing heat shields may lead to fires.

• Damaged or missing heat shields must be repaired or replaced before operating the machine.

508-E02A-0393

S-28

SA-019

SAFETY EVACUATING IN CASE OF FIRE • If a fire breaks out, evacuate the machine in the following way: • Stop the engine by turning the key switch to the OFF position if there is time.

• Use a fire extinguisher if there is time.

• Exit the machine.

518-E01A-0393

SA-393

BEWARE OF EXHAUST FUMES • Prevent asphyxiation. Engine exhaust fumes can cause sickness or death.

• If you must operate in a building, be sure there is adequate ventilation. Either use an exhaust pipe extension to remove the exhaust fumes or open doors and windows to bring enough outside air into the area.

509-E01A-0016

SA-016

PRECAUTIONS GRINDING

FOR

WELDING

AND

• Welding may generate gas and/or small fires.

• Be sure to perform welding in a well ventilated and prepared area. Store flammable objects in a safe place before starting welding.

• Only qualified personnel should perform welding.

Never allow an unqualified person to perform welding.

• Grinding on the machine may create fire hazards.

Store flammable objects in a safe place before starting grinding.

• After finishing welding and grinding, recheck that there are no abnormalities such as the area surrounding the welded area still smoldering.

523-E01A-0818

S-29

SA-818

SAFETY AVOID HEATING NEAR PRESSURIZED FLUID LINES • Flammable spray can be generated by heating near pressurized fluid lines, resulting in severe burns to yourself and bystanders.

• Do not heat by welding, soldering, or using a torch near pressurized fluid lines or other flammable materials.

• Pressurized lines can be accidentally cut when heat goes beyond the immediate flame area. Install temporary fire-resistant guards to protect hoses or other materials before engaging in welding, soldering, etc.

SA-030

AVOID APPLYING HEAT TO LINES CONTAINING FLAMMABLE FLUIDS • Do not weld or flame cut pipes or tubes that contain flammable fluids.

• Clean them thoroughly with nonflammable solvent before welding or flame cutting them.

510-E01B-0030

REMOVE PAINT BEFORE WELDING OR HEATING •

Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch. If inhaled, these fumes may cause sickness.

• Avoid potentially toxic fumes and dust.

• Do all such work outside or in a well-ventilated area. Dispose of paint and solvent properly.

• Remove paint before welding or heating: 1. If you sand or grind paint, avoid breathing the dust. Wear an approved respirator.

2.

If you use solvent or paint stripper, remove stripper with soap and water before welding.

Remove solvent or paint stripper containers and other flammable material from area.

Allow fumes to disperse at least 15 minutes before welding or heating.

511-E01A-0029

S-30

SA-029

SAFETY BEWARE OF ASBESTOS DUST • Take care not to inhale dust produced in the work site. Inhalation of asbestos fibers may be the cause of lung cancer.

• Depending on the wok site conditions, the risk of inhaling asbestos fiber may exist. Spray water to prevent asbestos from becoming airborne. Do not use compressed air.

• When operating the machine in a work site where asbestos might be present, be sure to operate the machine from the upwind side and wear a mask rated to prevent the inhalation of asbestos.

• Keep bystanders out of the work site during operation.

• Asbestos might be present in imitation parts. Use only genuine Kawasaki Parts.

SA-029

PREVENT BATTERY EXPLOSIONS • Battery gas can explode.

• Keep sparks, lighted matches, and flame away from the top of battery.

• Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer.

• Do not charge a frozen battery; it may explode.

Warm the battery to 16 °C (60 °F) first.

• Do not continue to use or charge the battery when electrolyte level is lower than specified.

Explosion of the battery may result.

• Loose terminals may produce sparks. Securely tighten all terminals.

• Battery electrolyte is poisonous. If the battery should explode, battery electrolyte may be splashed into eyes, possibly resulting in blindness.

• Be sure to wear eye protection when checking electrolyte specific gravity.

512-E01B-0032

S-31

SA-032

SAFETY SERVICE AIR CONDITIONING SYSTEM SAFELY • If spilled onto skin, refrigerant may cause a cold contact burn.

• Refer to the instructions described on the container for proper use when handling the refrigerant.

• Use a recovery and recycling system to avoid leaking refrigerant into the atmosphere.

• Never touch the refrigerant.

513-E01A-0405

SA-405

HANDLE CHEMICAL PRODUCTS SAFELY • Direct exposure to hazardous chemicals can cause serious injury. Potentially hazardous chemicals used with your machine include such items as lubricants, coolants, paints, and adhesives.

• A Material Safety Data Sheet (MSDS) provides specific details on chemical products: physical and health hazards, safety procedures, and emergency response techniques.

• Check the MSDS before you start any job using a hazardous chemical. That way you will know exactly what the risks are and how to do the job safely. Then follow procedures and use recommended equipment.

• See your authorized dealer for MSDS’s (available only in English) on chemical products used with your machine.

515-E01A-0309

S-32

SA-309

SAFETY DISPOSE OF WASTE PROPERLY • Improperly disposing of waste can threaten the environment and ecology. Potentially harmful waste used with Kawasaki equipment includes such items as oil, fuel, coolant, brake fluid, filters, and batteries.

• Use leakproof containers when draining fluids.

Do not use food or beverage containers that may mislead someone into drinking from them.

• Do not pour waste onto the ground, down a drain, or into any water source.

• Air conditioning refrigerants escaping into the air can damage the Earth’s atmosphere. Government regulations require a certified air conditioning service center to recover and recycle used air conditioning refrigerants.

• Inquire on the proper way to recycle or dispose of waste from your local environmental or recycling center, or from your authorized dealer.

SA-226

516-E01A-0226

BEFORE RETURNING THE MACHINE TO THE CUSTOMER •

After maintenance or repair work is complete, confirm that: • The machine is functioning properly, especially the safety systems.

• Worn or damaged parts have been repaired or replaced.

S517-E01A-0435 SA-435

S-33

SAFETY (Blank)

S-34

SECTION 1

GENERAL ―CONTENTS― Group 1 Specifications

Group 3 Component Specifications

Specifications ...........................................T1-1-1

Engine ..................................................... T1-3-1 Engine Accessories ................................. T1-3-5 Hydraulic Component .............................. T1-3-6

Group 2 Component Layout Main Component Layout (Overview) .........T1-2-1

Electrical Component............................... T1-3-9

Main Component Layout (Body) ...............T1-2-2 Main Component Layout (Travel System) ......................................T1-2-3 Electrical System (Overview) ....................T1-2-4 Electrical System (Inside of Cab) ..............T1-2-5 Engine.................................................... T1-2-10 HST Pump / Main Pump ......................... T1-2-10 Reduction Gear / HST Motor................... T1-2-11 Control Valve.......................................... T1-2-11

4FGET-1-1

45ZV-2

(Blank)

4FGET-1-2

45ZV-2

GENERAL / Specifications SPECIFICATIONS (STANDARD)

M4FGE-12-001

Model Bucket Type Bucket Capacity: heaped Operating Weight (Canopy/Cab)

45ZV-2 Pin Type

A: Overall Length

mm (ft⋅in)

Coupler Type 0.9 (1.2) (with BOC*) 5245 / 5405 5380/5540 (11570/11920) (11860/12220) 3650 (8047) 3350 (7385) 3110 (6856) 2840 (6261) KUBOTA V3307-DI-T -1 45.6 kW/2200 min [ 62 PS/2200 rpm ] 5220 (17’2”) 5380 (17’8”)

B: Overall Width (Bucket)

mm (ft⋅in)

1990 (6’6”)

C: Overall Height

mm (ft⋅in)

2860 / 2850 (9’3”/9’4”)

D: Wheel Base

mm (ft⋅in)

2200 (7’3”)

E: Tread

mm (ft⋅in)

1470 (4’10”)

F: Ground Clearance

mm (ft⋅in)

340 (1’1”)

G: Bucket Hinge Height

mm (ft⋅in)

3160 (10’4”)

H: Dumping Clearance (45°)

mm (ft⋅in)

2500 (8’2”)

I: Dumping Reach (45°)

mm (ft⋅in)

880 (2’11”)

m3 (yd3) kg (lb)

Static Tipping Load (Straight) kgf (lbf) Static Tipping Load (Full 40 Turn) kgf (lbf) Engine

2390 (7’10”) 990 (3’3”)

R1: Minimum Turning Radius

3795 (12’5”) mm (ft⋅in)

R2: Minimum Turning Radius

4475 (14’8”)

4540 (14’11”)

mm (ft⋅in) Travel Speed Forward/Reverse km/h (mph) Transmission Speeds (F/R) Articulation Angle (Left/Right) deg Tire Size

34.0 / 34.0 (21/21) 2/2

(°)

40

-

17.5/65-20-10PR

NOTE: • * BOC (Bolt-On Cutting Edge) • These specifications are subject to change without notice.

T1-1-1

45ZV-2

GENERAL / Specifications (Blank)

T1-1-2

45ZV-2

GENERAL / Component Layout MAIN COMPONENT LAYOUT (OVERVIEW) 4

3 2

1

8

7

6

5

M4FGE-01-001

12 9 11

1 - Bucket

2 - Bell Crank 3 - Bucket Cylinder

10

M4FGE-01-002

4 - Head Light / Turn Signal / Hazard Light / Clearance Light 5 - Fuel Tank 6 - Lift Arm Cylinder

T1-2-1

7 - Lift Arm

8 - Bucket Link 9 - Hydraulic Oil Tank

10 - Rear Combination Light (Turn Signal Light / Hazard Light / Clearance Light / Brake Light) 11 - Reverse Light 12 - Backup Alarm

45ZV-2

GENERAL / Component Layout MAIN COMPONENT LAYOUT (BODY)

3

2

1

4

5

6

7

8

9 10 11

12

23

13 22 21 14

20 19 18

17

16

15

T4FG-01-02-005

123456-

Bucket Cylinder Lift Arm Cylinder Steering Valve Priority Valve Brake Master Cylinder Parking Brake Solenoid Valve

7 - Hydraulic Oil Tank 8 - Hydraulic Oil Return Filter 9 - Hydraulic Oil Suction Filter 10 - Brake Oil Tank 11 - Air Cleaner 12 - Coolant Reservoir

T1-2-2

13 - Oil Cooler 14 - Radiator 15 - Fuel Pre-Filter 16 - Fuel Filter 17 - Fuel Pump 18 - Engine

19 - HST Pump 20 - Gear Pump 21 - HST Filter 22 - Fuel Tank 23 - Control Valve

45ZV-2

GENERAL / Component Layout MAIN COMPONENT LAYOUT (TRAVEL SYSTEM)

2

1

3 4 5

6

T4FG-01-02-006

1 - Front Axle 2 - Steering Cylinder

34-

HST Motor Reduction Gear

5-

T1-2-3

Rear Axle

6-

Propeller Shaft

45ZV-2

GENERAL / Component Layout ELECTRICAL SYSTEM (OVERVIEW) 2

1

Inside of Cab Refer to T1-2-5.

3

4 5

6

17

16 7 15 8

14

9 13 12

11

10 T4FGE-01-02-007

1 - Horn 2 - Brake Light Switch 3 - Brake Pedal Angle Sensor 4 - HST Controller 5 - Air Cleaner Restriction Switch

6 - Coolant Temperature Sensor 7 - Reverse Alarm 8 - Battery 9 - Engine Speed Sensor 10 - Starter Relay 1

T1-2-4

11 - Glow Relay

16 - Speed Sensor

12 - Fusible Link (100 A) (2 Used) 13 - Brake Oil Level Sensor 14 - Starter Relay 2 15 - Fuel Level Sensor

17 - Bucket Proximity Switch

45ZV-2

GENERAL / Component Layout ELECTRICAL SYSTEM (INSIDE OF CAB) 1

2

3

Front Console Refer to T1-2-7.

Right Console Refer to T1-2-6.

Rear Console Refer to T1-2-8.

T4FG-01-02-008

1-

Radio (Optional)

2-

Rotary Beacon Switch (Optional)

T1-2-5

3-

Auxiliary

45ZV-2

GENERAL / Component Layout Right Console 1

2 3 4 5 6

7

9 8 M4FG-01-009

1 - Loader Control Lever 2 - Auxiliary Control Lever (Optional) 3 - Auxiliary Control Lever Lock (Optional)

4 - Auxiliary 5 - Ride Control Switch (Optional)

T1-2-6

6 - eco Mode Switch 7 - Heater Switch (Optional)

8 - Key Switch 9 - Loader Control Lever Lock

45ZV-2

GENERAL / Component Layout Front Console 1

2

3

4

13 5 12 6

11

7 10 8 9

T4FG-01-02-009

1 - Monitor Panel (Refer to T1-2-9.)

2 - Horn Switch 3 - Steering Wheel

5 - Front Wiper Switch (Cab)

8 - Light Switch

6 - Rear Wiper Switch (Cab)

9 - Neutral Lever Lock (Forward/Reverse Lever) 10 - Forward/Reverse Lever

7 - Turn Signal Lever / Dimmer Switch

11 - High-Low Selector Switch 12 - Work Light Switch (Cab) 13 - Hazard Light Switch

4 - Parking Brake Switch

T1-2-7

45ZV-2

GENERAL / Component Layout Rear Console 3

2

1

4 5 6 7 8 9 10

T4FG-01-02-010

11

1-

Fuse Box

4-

Parking Brake Relay [1]

7-

2-

Overrun Alarm

5-

Parking Brake Relay [2]

8-

3-

Fuse Box (Cab)

6-

Alternator Indicator Relay [3]

T1-2-8

12

HST Control Relay [4]

Emergency Parking Brake Relay [5] 9 - Flasher Unit (Turn Signal/ Hazard Light)

10 - Front Work Light Relay (Cab) 11 - Rear Work Light Relay (Cab) 12 - Front Wiper Relay (Cab)

45ZV-2

GENERAL / Component Layout Monitor Panel

1

2

3

4

5

6

8

7

9

10

11

22 12

21

20

19

18

17

16

15

14

13 M4FG-01-010

1 - Coolant Temperature Gauge 2 - Left Turn Signal Indicator

7 - Stop Indicator

13 - Not Used

19 - Overheat Indicator

8 - Service Indicator

3 - High Beam Indicator

9 - Parking Brake Indicator

14 - Discharge Warning Indicator 15 - Error Code Readout Switch

4 - Monitor Display 5 - Work Light Indicator (Optional) 6 - Right Turn Signal Indicator

10 - Clearance Light Indicator 11 - Fuel Gauge

16 - Preheat Indicator 17 - Monitor Display Selector

20 - Engine Oil Low Pressure Indicator 21 - Air Filter Restriction Indicator 22 - HST Warning Indicator

12 - Brake Oil Low Level Indicator

18 - Not Used

T1-2-9

45ZV-2

GENERAL / Component Layout ENGINE 3

5

4

6

7

8

9

2

1

T4FG-01-02-011

1 - Starter 2 - Engine Speed Sensor

45-

Engine Oil Filter Alternator

67-

Fuel Pre-Filter Fuel Filter

89-

Fuel Pump Coolant Temperature Sensor

3 - Engine Oil Pressure Switch

HST PUMP, MAIN PUMP 1

2

3

5

4

2

6

7 T4FG-01-02-012

1 - Main Pump (Loading & Steering) 2 - High-Pressure Relief Valve

3-

Forward Selection Solenoid Valve 4 - Pump Solenoid Valve

T1-2-10

5-

Low-Pressure Relief Valve

6-

Displacement Angle Control Cylinder

7-

Reverse Selection Solenoid Valve

45ZV-2

GENERAL / Component Layout REDUCTION GEAR, HST MOTOR

3

2

1

T4FG-01-02-013

1-

HST Motor

2-

EP Motor Solenoid Valve

CONTROL VALVE

3-

Reduction Gear

8 9

7

10

6

5

4 T4FGE-01-02-014

4 - Electromagnetic Detent (Bucket) 5 - Overload Relief Valve (Bucket: Rod Side)

7 - Overload Relief Valve (Auxiliary (Coupler): Rod Side) 8 - Overload Relief Valve (Auxiliary (Coupler): Bottom Side)

9 - Overload Relief Valve (Bucket: Bottom Side) 10 - Main Relief Valve

6 - Make-Up Valve (Lift Arm: Rod Side)

T1-2-11

45ZV-2

GENERAL / Component Layout (Blank)

T1-2-12

45ZV-2

GENERAL / Component Specifications ENGINE Manufacturer........................................... KUBOTA Model ...................................................... V3307-DI-T Type ........................................................ Diesel, 4-Cycle Water-Cooled, Inline, Direct Injection, Turbo Charged Cyl. No.-Bore×Stroke .............................. 4-94 mm×120 mm (3.7 in×4.7 in) 3 3 Piston Displacement ............................... 3331 cm (203 in ) -1 Rated Output........................................... 45.6 kW/2200 min (62 PS/2200 rpm) (61 HP/2200 rpm) Compression Ratio ................................. 20 to 1 Dry Weight .............................................. 268 kg (591 lb) Firing Order............................................. 1-3-4-2 Rotation Direction ................................... Clock Wise (Viewed from Crank Pulley) Dimensions Length×Width×Height ......... 655×557×738 mm (26 in×22 in×29 in) (Without Fan) COOLING SYSTEM Fan Pulley Ratio...................................... 1.18 Thermostat.............................................. Cracking Temperature at Atmospheric Pressure: 76.5°C (170°F) Full Open Temperature: 90°C (194°F) LUBRICATION SYSTEM Method .................................................... Pressure Lubrication Type Lubrication Pump Type ........................... Trochoid Type (Star Gear) Filter ........................................................ Full Flow Paper Element Cooler ..................................................... Water-Cooled

T1-3-1

45ZV-2

GENERAL / Component Specifications STARTING SYSTEM Method ..............................................................Self-Starter Type Voltage/Output ..................................................12 V/3.0 kW PREHEAT SYSTEM Method ..............................................................Glow Plug, QGS (Quick Glow System) Type (4 Used, 12V/12.6 A) ENGINE STOP SYSTEM Type ..................................................................Fuel Shut Off (Solenoid Valve) ALTERNATOR Method ..............................................................Regulator Integrated IC Type Voltage/Output ..................................................12 V/80 A SUPERCHARGING SYSTEM Type ..................................................................Exhaust Turbocharger Type, EGR (Exhaust Gas Recirculation) System Lubricating System ...........................................Pressure Lubrication/Water-Cooled Type FUEL SYSTEM Governor ...........................................................Mechanical Type Injection Pump ..................................................Bosch, K-type Minipump Injection Nozzle.................................................Bosch, P-type Hole Nozzle (2-Stage Injection-Valve Opening Pressure Nozzle)

T1-3-2

45ZV-2

GENERAL / Component Specifications IMPORTANT: The list shows the design specifications, which are not servicing standard.

Fuel Consumption Ratio ..................................250±13 g/kW⋅h (184±5% g/PS⋅h) at 2200 min-1 Maximum Output Torque..................................233±12 N⋅m (23.7±1.2 kgf⋅m, 170±9 lbf⋅ft) at 1500 min-1 No Load Speed ................................................Slow: (At Full Load: 1150±50 min-1) -1 Fast: (At Full Load: 2400±50 min )

T1-3-3

45ZV-2

GENERAL / Component Specifications Engine Performance Curve (KUBOTA V3307-DI-T) Test conditions: 1. In conformity with SAE J1349/JIS D0006-1 (Earth-moving machinery-Engines-Part 1: Test code of net power) under standard atmospheric pressure only.

2. Equipped with the air cleaner, muffler, and fan.

Torque (N⋅m)

Output (kW)

Fuel Consumption Ratio (g/kW⋅h)

-1

Engine Speed min (rpm)

T1-3-4

T4FG-01-03-001

45ZV-2

GENERAL / Component Specifications ENGINE ACCESSORIES RADIATOR ASSEMBLY Type.................................................................Radiator/Oil Cooler (Parallel Type) Radiator Oil Cooler Capacity...........................................................5.0 L (1.1 US gal) 3.3 L (0.9 US gal) Air-Tight Test Pressure.....................................100 kPa (1.0 kgf/cm2, 14.5 psi) 1500 kPa (15 kgf/cm2, 220 psi) Cap Opening Pressure ....................................49 kPa (0.5 kgf/cm2, 7.0 psi) Weight..............................................................6.3 kg (14 lb) 8.3 kg (18 lb)

BATTERY Nominal Voltage...............................................12 V Capacity...........................................................64 Ah (5-Hour Rating) Weight..............................................................Approx. 19.7 kg (43 lb)

T1-3-5

45ZV-2

GENERAL / Component Specifications HYDRAULIC COMPONENT HST PUMP Type

HST Pump: Direct Operating Proportional Solenoid Control Charge Pump: Trochoid Type Maximum Flow Rate (Theoretical) ...................HST Pump: 0 to 198 L/min (0 to 52 US gpm) Charge Pump: 43 L/min (11.4 US gpm) High-Pressure Relief Valve Set Pressure.........46.5±1.0 MPa (474±10 kgf/cm2, 6740±145 psi) Pressure Difference: 44 MPa (448 kgf/cm2, 6380 psi) Low-Pressure Relief Valve Set Pressure..........2.5±0.1 MPa (26±1 kgf/cm2, 360±14.5 psi) Cutoff Valve Set Pressure ................................43.7±1.0 MPa (445±10 kgf/cm2, 6340±145 psi) Pressure Difference: 41.2 MPa (420 kgf/cm2, 5980 psi) Weight..............................................................Approx. 60 kg (132 lb)

PUMP DEVICE (GEAR PUMP) Type.................................................................Constant Capacity Type Gear Pump Function ...........................................................Main Pump Maximum Flow Rate (Theoretical) ...................Main Pump: 80 L/min (21 US gpm) Weight..............................................................5.9 kg (13 lb) PRIORITY VALVE Relief Set Pressure ..........................................20.6 MPa (210 kgf/cm2, 2990 psi) at 100 L/min CONTROL VALVE Type.................................................................Mono-Lever Direct Operating Type (3-Spool, with Electromagnetic Detent) Main Relief Set Pressure .................................20.6 MPa (210 kgf/cm2, 2990 psi) at 80 L/min Overload Relief Set Pressure...........................23.6 MPa (230 kgf/cm2, 3220 psi) at 30 L/min (Bucket Tilt) 23.6 MPa (230 kgf/cm2, 3220 psi) at 30 L/min (Bucket Dump) Weight..............................................................8 kg (18 lb) STEERING VALVE Type.................................................................Orbitroll Type Overload Relief Set Pressure...........................23.1 MPa (235 kgf/cm2, 3350 psi) at 1 L/min Weight..............................................................6.4 kg (14 lb) SOLENOID VALVE Function ...........................................................Parking Brake BRAKE VALVE Type.................................................................Master Cylinder Size..................................................................1” 1/4 Stroke ..............................................................40 mm (1.6 in)

T1-3-6

45ZV-2

GENERAL / Component Specifications TRAVEL SYSTEM HST MOTOR Type ..................................................................Bent-Axis Type Variable Displacement Axial Plunger Motor Control System .................................................Proportional Solenoid Control Weight...............................................................Approx. 64 kg (141 lb) STANDARD AXLE (FRONT) Model ................................................................Two Stage Reduction Brake Type........................................................Wet-Type Spring Set Hydraulic Released Multi-Disc Brake Parking Brake Type...........................................Built-In Negative Type (SAHR Type) 2 Parking Brake Release Pressure......................2.5 MPa (26 kgf/cm , 363 psi) Final Reduction Ratio .......................................13.7 Weight...............................................................235 kg (518 lb) STANDARD AXLE (REAR, Reduction) Model ................................................................One-Stage Reduction Final Reduction Ratio .......................................13.7 Reduction Reduction Ratio ................................................1.77 Weight...............................................................270 kg (595 lb) STANDARD PROPELLER SHAFT Type ..................................................................Cruciform Joint Type Dimension Between Flanges ............................1509 mm (59.4 in) STEERING CYLINDER Rod Outer Diameter..........................................25 mm (1.0″) Tube Inner Diameter .........................................45 mm (1.8″) Stroke................................................................340 mm (1′ 1″) Fully Retracted Length......................................605 mm (1′ 12″) Plating Thickness..............................................30 μm (1.18 μin) Weight...............................................................8 kg (18 lb)

T1-3-7

45ZV-2

GENERAL / Component Specifications FRONT ATTACHMENT CYLINDER Lift Arm (Left/Right) Rod Outer Diameter..........................................50 mm (2.0″) Tube Inner Diameter .........................................85 mm (3.3″) Stroke................................................................552 mm (2′) Fully Retracted Length......................................898 mm (2′ 11″) Plating Thickness..............................................30 μm (1.18 μin) Weight...............................................................37 kg (82 lb)

T1-3-8

Bucket 45 mm (1.8”) 80 mm (3.1”) 457 mm (1′ 6″) 785 mm (2′ 7″) 30 μm (1.18 μin) 30 kg (66 lb)

45ZV-2

GENERAL / Component Specifications ELECTRICAL COMPONENT ENGINE OIL PRESSURE SWITCH Operating Pressure..........................................45 kPa (0.5 kgf/cm2, 6.5 psi) COOLANT TEMPERATURE SENSOR (FOR COOLANT TEMPERATURE GAUGE) Operating Temperature ....................................25 to 120°C (77 to 248°F) AIR FILTER RESTRICTION SWITCH Operating Pressure..........................................6.2±0.6 kPa (635±58 mm H2O) FUEL LEVEL SENSOR +10 0 Resistance .......................................................Empty: 90 0 Ω, Full: 10 -4 Ω ENGINE SPEED SENSOR Voltage.............................................................12 V STARTER RELAY 1 Voltage.............................................................12 V GLOW RELAY Voltage/Current ................................................12 V STARTER RELAY 2 Voltage.............................................................12 V HORN Consumption Current.......................................4 A or less at 12V Sound Pressure ...............................................111 dB (A) at 2 m Frequency........................................................(High): 440±20 Hz (Low): 370±20 Hz ILLUMINATION Work Light (Cab)..............................................12 V, 55 W Cab Light (Cab) ...............................................12 V, 10 W Head Light .......................................................12 V, 45/45 W Front Combination Light Turn Signal Light ..........................................12 V, 21 W Clearance Light ............................................12 V, 21 W Rear Combination Light Turn Signal Light ..........................................12 V, 21 W Tail Light .......................................................12 V, 5 W Brake Light ...................................................12 V, 21 W License Plate Light...........................................12 V, 10 W Reverse Light...................................................12 V, 21 W

T1-3-9

45ZV-2

GENERAL / Component Specifications (Blank)

T1-3-10

45ZV-2

SECTION 2

SYSTEM ―CONTENTS― Group 1 Control System

Group 3 Electrical System

Outline .....................................................T2-1-1

Outline..................................................... T2-3-1

HST Control .............................................T2-1-3

Main Circuit ............................................. T2-3-2

Other Controls ........................................ T2-1-11

Electric Power Circuit (Key Switch: OFF) . T2-3-3

Control by Electric and Hydraulic

Indicator Light Check Circuit

Combined Circuit .................................. T2-1-17

(Key Switch: ON) ................................... T2-3-5 Preheat Circuit (Key Switch: HEAT) ......... T2-3-6

Group 2 Hydraulic System

Starting Circuit (Key Switch: START)........ T2-3-8

Outline .....................................................T2-2-1

Charging Circuit (Key Switch: ON) ......... T2-3-14

Main Circuit ..............................................T2-2-3

Engine Stop Circuit ................................ T2-3-18

Steering Circuit.........................................T2-2-5

Lamplight Circuit.................................... T2-3-19

HST Circuit............................................. T2-2-13

Head Light Circuit .................................. T2-3-20

Brake Circuit .......................................... T2-2-20

Turn Signal Circuit ................................. T2-3-24 Brake Light Circuit ................................. T2-3-27 Hazard Light Circuit ............................... T2-3-28 Horn Circuit ........................................... T2-3-31 Reverse Light / Alarm Circuit.................. T2-3-32 Parking Brake Circuit ............................. T2-3-34 Emergency Parking Brake Circuit........... T2-3-38 Indicator Circuit ..................................... T2-3-41

4FGET-2-1

45ZV-2

(Blank)

4FGET-2-2

45ZV-2

SYSTEM / Control System OUTLINE There are two types of controllers.

• •

The HST control unit and the monitor unit are used for various operation controls of the machine.

HST Control Unit Monitor Unit

The monitor unit and the HST control unit display information on the monitors and control the machine travel function by receiving analog signals and signals from sensors and switches.

Sensors and Switches for Traveling

Each controller computes various programs by using received data, provides driving signals to the solenoid valve for traveling, and controls the HST pump and the HST motor.

Engine

HST Control Unit

HST Pump

Pump Solenoid Valve

Engine Speed Seneor

Sensors, Switches

Sensors and Switches for Monitor Monitor Unit

Reduction Gear

HST Motor

Relays

Motor Solenoid Valve Light Emitting Diode Speed Sensor

T2-1-1

T4FG-02-01-001

45ZV-2

SYSTEM / Control System The sensors and switches for HST control unit to detect the signals for various operation controls and their controls are as shown below.

Input Signal

• Forward/Reverse Lever • Engine Speed Sensor • Machine Speed Sensor • High-Low Selector Switch • Brake Angle Sensor • ECO Mode Switch

→ → → → →

HST Control Unit

T2-1-2

Operation Control HST Control →High-Low Selection Control (HST Motor) →Inching Control (HST Pump) →ECO Mode Control (HST Pump) →Overrunning control (HST Motor) →Engine protection control (HST Pump, HST Motor) Control by Electric and Hydraulic Combined Circuit →Bucket Auto Leveler Control

45ZV-2

SYSTEM / Control System HST Control The HST control consists of the following.

• High-Low Selection Control (HST Motor)

• ECO Mode Control (HST Pump)

• Inching Control (HST Pump)

• Overrunning Control (HST Motor)

• Engine Protection Control (HST Pump, HST Motor)

T2-1-3

SYSTEM / Control System High-Low Selection Control (HST Motor) Purpose: The High-Low selection control controls the HST motor displacement angle according to the selected speed.

Operation: Displacement Angle Control of HST Motor 1. When the HST control unit detects the machine speed, it computes the most suitable HST motor displacement angle.

2. The current equivalent to the computed displacement angle operation is supplied to the motor solenoid valve of the HST motor and changes the displacement angle.

3. The HST motor displacement angle is controlled by repeating step 1 to step 2.

NOTE: The speed selection is carried out by the High-Low selector switch. When the Low mode is selected, the signal of the selected speed (Low mode) is sent to the HST control unit.

A

When Low mode is selected: • The ON signal is sent to the HST control unit from the High-Low selector switch.

• The HST motor displacement angle is controlled along the A-B-C curve and the machine speed increases (or decreases, depending on the circumstance).

When High mode is selected: • The OFF signal is sent to the HST control unit from the High-Low selector switch.

• The HST motor displacement angle is controlled along the A-B-D curve and the machine speed increases (or decreases, depending on the circumstance).

B

HST Motor Displacement Angle

C

D E 0 Selected Speed Range

Low Mode

Machine Speed

High Mode

T2-1-4

T4FC-02-01-101

SYSTEM / Control System

Engine Speed Sensor

HST Control Unit

Engine

HST Pump

Reduction Gear

HST Motor

Monitor Unit

High-Low Selector Switch

Lo

Motor Solenoid Valve

Hi

Ground Speed Sensor

NOTE: The illustration shows the signal flow when the Low mode of the High-Low selector switch is selected.

T2-1-5

T4FG-02-01-002

SYSTEM / Control System ECO Mode Control (HST Motor) Purpose: When the ECO mode of the ECO mode switch is selected, the engine speed is reduced. Therefore, the fuel consumption is less than in the normal mode.

Operation: When ECO mode is selected: • When the ECO mode of the ECO mode switch is selected, the ON signal is sent to the HST control unit.

• According to the input signal the HST control unit controls the displacement angle in order to limit the HST motor maximum displacement angle.

When normal mode is selected: • When the normal mode of the ECO mode switch is selected, no signal is sent to the HST control unit. the HST motor maximum • Therefore, displacement angle is not limited.

ECO Mode Normal Mode

HST Motor Displacement Angle

HST Motor Rotation Speed (rpm)

T2-1-6

T4FG-02-01-006

SYSTEM / Control System Inching Control (HST Pump) Purpose: Inching control limits the HST pump delivery flow rate according to the brake pedal angle and applies the HST brake.

Brake Pedal

Brake Pedal Angle Sensor

Operation: 1. The brake pedal angle is transmitted to the brake pedal angle sensor through the link and converted into an input signal.

2. The signal is sent to the HST control unit from the brake pedal angle sensor. The signal varies according to the brake pedal angle.

3. The HST control unit converts into 0 to 100% for the inching angle converted value according to the input signal.

4. The HST control unit computes the inching angle value according to the signal from the brake angle sensor, and controls the displacement angle in order to limit the HST pump displacement angle.

(Refer to Hydraulic System / Inching Circuit.)

HST Control Unit T4FG-02-01-004

Brake pedal is not depressed.

Brake pedal is depressed fully.

HST Brake Applied Range Brake Pedal

T4FG-02-01-005

T2-1-7

SYSTEM / Control System Overrunning Control (HST Motor) Purpose: When the machine speed exceeds the maximum allowable speed, it decreases the machine speed within the acceptable speed range.

Operation: 1. The HST control unit computes the machine speed from the signal from the ground speed sensor.

NOTE: When it is under overrunning control, the HST warning indicator and the service indicator flash and the alarm sounds continuously.

2. When the machine speed exceeds the maximum allowable speed, the HST control unit controls the motor to increase the displacement angle.

Therefore, the machine speed decreases.

3. When the machine speed decreases to the acceptable speed range, the HST control unit releases the overrunning control and resumes the normal motor displacement angle.

Displacement Angle after Control

HST Motor Displacement Angle

Displacement Angle before Control

0 Machine Speed

T2-1-8

T4FC-02-01-101

SYSTEM / Control System Engine Protection Control (HST Pump, HST Motor) Purpose: In order to prevent overrunning of the engine caused by the HST brake, the engine protection control controls the HST motor displacement angle, and controls the engine -1 speed to 2800 min .

Operation:

4. This control releases the HST brake and prevents the engine from overrunning.

1. When releasing the accelerator while traveling at high speed, the HST brake is applied. The HST pump is turned by the pressurized oil in the HST circuit.

NOTE: This control is available when the High-Low selector switch is set to the High mode.

NOTE: This control is given priority over Overrunning Control (T2-1-8). Therefore, the machine may travel in fast speed.

2. The HST pump and the engine are connected with the shaft. Therefore, the rotation of the HST pump is transmitted to the engine as well. The engine runs at high speed.

3. The HST control unit detects the signal from the engine speed sensor. When the engine speed is -1 over 2800 min , the HST control unit controls the HST motor displacement angle, this being reduced in stages.

Maximum Displacement Angle Displacement Angle before Control HST Motor Displacement Angle

Displacement Angle after Control

Minimum Displacement Angle

Machine Speed Speed after Control Speed before Control

T2-1-9

T4FC-02-01-019

SYSTEM / Control System (Blank)

T2-1-10

SYSTEM / Control System OTHER CONTROLS Other control systems consist of the followings: • HST Warning Indicator Control • Parking Brake Operation Control (Emergency)

T2-1-11

SYSTEM / Control System HST Warning Indicator Control Purpose:

In order to protect the HST system, the HST warning indicator on the monitor unit lights when malfunction of the HST system parts occur.

Operation: When any of the parts listed below becomes faulty, the HST control unit lights the HST warning indicator on the monitor panel.

NOTE: The monitor panel lights the service indicator as well as the HST warning indicator at the same time.

• • • • • • •

Motor Solenoid Valve Engine Speed Sensor Speed Sensor Forward / Reverse Lever Brake Angle Sensor Overrun Alarm Pump Solenoid Valve

T2-1-12

SYSTEM / Control System

Brake Pedal (Inching)

Brake Angle Sensor

Forward/Reverse Selection Solenoid Valve

Engine Speed Sensor HST Control Unit Engine HST Pump 20

Pump Solenoid Valve

Monitor Unit HST Warning Indicator

Reduction Gear F

2A-11 HST Motor

N

Motor Solenoid Valve

R HST Relay Forward / Reverse Lever SpeedSensor

Fuse #13

T4FG-02-01-006

T2-1-13

SYSTEM / Control System Parking Brake Operation Control (Emergency) Purpose: The parking brake operation control lights the brake oil low level indicator on the monitor unit and applies the parking brake when the brake oil level is below the lower limit.

Operation: 1. The brake oil level sensor is turned ON when the brake oil level in the brake oil tank is below the lower limit.

2. The monitor unit lights the brake oil low level indicator and the stop indicator.

3. Emergency parking brake relay (5) is energized and the parking brake is applied when the signal from the brake oil level sensor is sent to the HST control unit.

4. The monitor unit lights the HST warning indicator and the parking brake indicator.

T2-1-14

NOTE: As for the operation circuit of the parking brake, refer to SYSTEM/Hydraulic System/ Brake Circuit.

SYSTEM / Control System

Emergency Parking Brake Relay (5)

Parking Brake Relay (1)

HST Control Unit

Brake Oil Level Sensor

Monitor Unit

Parking Brake Solenoid

Parking Brake Service Brake

ON OFF

Parking Brake Switch

Front Axle

T2-1-15

T4FG-02-01-007

SYSTEM / Control System (Blank)

T2-1-16

SYSTEM / Control System CONTROL BY ELECTRIC HYDRAULIC COMBINED CIRCUIT

AND

The electric and hydraulic combined circuit consists of the following: • Bucket Auto Leveler Control

T2-1-17

SYSTEM / Control System Bucket Auto Leveler Control Purpose: The bucket auto leveler control automatically levels the bucket at a correct digging start angle when returning the bucket to the dig position.

Operation: 1. During bucket dump operation, the bar is located in front of the bucket proximity switch.

When the bar passes near the bucket proximity switch, the bucket proximity switch is turned ON. Therefore, the electromagnet on the bucket tilting side in the control valve is also energized.

2. When the loader control lever is operated farther than the bucket roll back detent position, the loader control valve spool is held by the electromagnet on the bucket roll back end, and the bucket spool in the control valve is held.

3. Pressurized oil from the main pump flows to the bottom side of the bucket cylinder through the bucket spool in the control valve, and extends the bucket cylinder. When the bucket cylinder is extended, the bar also passes near the bucket proximity switch.

4. When the bar moves away from the bucket proximity switch, the bucket proximity switch is turned OFF. Therefore, the electromagnet on the bucket roll back side is turned OFF and the loader control lever is returned to the neutral position. As the bucket spool in the control valve are also returned to the neutral position, the bucket cylinder stops. Consequently, the bucket is set at the correct digging start angle.

T2-1-18

SYSTEM / Control System

Bar

Bucket Proximity Switch

Bucket Cylinder

Control Valve

Lift Arm

Bucket

From Fuse Box Terminal #10

Main Pump

Hydraulic Oil Tank

T2-1-19

Electromagnet on Bucket Tilting Side

T4FG-02-01-008

SYSTEM / Control System (Blank)

T2-1-20

SYSTEM / Hydraulic System OUTLINE The hydraulic system is broadly divided into the main circuit, the steering circuit, the HST circuit, and the brake circuit.

• Main Circuit Consists of the neutral circuit, the front attachment operation circuit, and the auxiliary front attachment operation circuit (optional) - composed of the main pump, the control valve, the bucket cylinder,and the lift arm cylinder.

• Steering Circuit Consists of the steering circuit and the steering stop circuit - composed of the priority valve, the steering valve, and the steering cylinder.

• HST Circuit Consists of the charging circuit, the neutral circuit, the forward travel circuit, the reverse travel circuit, and the inching circuit - composed of the HST pump and the HST motor.

• Brake Circuit Consists of the service brake circuit and the parking brake circuit - composed of the brake oil tank, the brake master cylinder, and the parking brake solenoid valve.

T2-2-1

45ZV-2

SYSTEM / Hydraulic System (Blank)

T2-2-2

45ZV-2

SYSTEM / Hydraulic System MAIN CIRCUIT Outline: • The main pump draws and delivers hydraulic oil from the hydraulic oil tank through the suction filter.

• Delivered pressurized oil flows to the control valve through the priority valve.

• Pressurized oil to the control valve flows to the cylinders in response to operation of the spool in the control valve, and the return oil flows back to the hydraulic oil tank through the control valve.

Bucket Cylinder

Lift Arm Cylinder

Control Valve Bucket Spool Lift Arm Spool

Priority Valve

Main Pump

Suction Filter

Hydraulic Oil Tank T4FG-02-02-001

T2-2-3

45ZV-2

SYSTEM / Hydraulic System Neutral Circuit

Front Attachment Circuit

• When the loader control lever is in neutral, pressurized oil from the main pump returns to the hydraulic oil tank through the neutral circuit of the control valve.

• Pressurized oil from the main pump flows to the control valve, and flows to the spools of the lift arm and bucket.

NOTE: The illustration shows oil flow without operation while the engine is running.

Auxiliary Front Attachment Operation Circuit (Optional) • Pressurized oil from the main pump flows to the control valve, and flows to the auxiliary actuator (optional) spool.

Auxiliary Actuator (Optional)

Control Valve

Auxiliary Actuator (Optional)

Lift Arm Cylinder

Lift Arm

Bucket Cylinder

Bucket

Hydraulic Oil Tank Main Pump

T4FG-02-02-002

T2-2-4

45ZV-2

SYSTEM / Hydraulic System STEERING CIRCUIT Outline: • Pressurized oil from the main pump is divided by the priority valve. One part flows to the steering valve and the other part flows to the control valve.

• Pressurized oil to the steering valve flows to the steering cylinders in response to operation of the spool in the steering valve, and the returning oil flows back to the hydraulic oil tank from the steering valve.

Steering Cylinder

Steering Valve Control Valve

Priority Valve

Main Pump

Suction Filter

Hydraulic Oil Tank

T4FG-02-02-003

T2-2-5

SYSTEM / Hydraulic System Priority Valve Circuit (When steering is in neutral) • When the engine is stopped, the priority valve spool is pushed to the right by the spring force.

• When the engine is started, pressurized oil from the main pump flows to the steering valve through the priority valve spool, and also flows to ports LS1 and LS2 through orifices 1 and 2 respectively at the same time.

• When steering is in neutral, as pressurized oil to port LS2 flows to the hydraulic oil tank through orifice 3 and the steering valve spool, port LS2 is not pressurized.

• As pressure at port LS1 is greater than the spring force, the priority valve spool moves to the left, and all pressurized oil from the main pump flows to the control valve.

• The priority valve spool is provided with a notch to send pressurized oil from the main pump to the steering valve and a notch to send pressurized oil to the control valve, which are both connected to the main pump delivery port.

• When the priority valve spool moves to the left, the notch to send pressurized oil from the main pump to the steering valve moves until the delivery port on the steering valve side in the priority valve is closed. Pressure balance is obtained and the spool stops moving.

T2-2-6

NOTE: Orifice 2 of the priority valve is installed in order to warm up the circuit by flowing pressurized oil to the hydraulic oil tank from port LS2 at neutral of the steering valve.

Although diameter of port 2 is small and temperature of the oil passing through it rises rapidly, pressure is not raised enough to influence movement of the priority valve spool.

SYSTEM / Hydraulic System Steering Cylinder

Steering Valve

P Control Valve Orifice 2 Priority Valve

Orifice 3

LS

CF

EF

Orifice 1

LS1 Spool

LS2 Spring

Main Pump

When Engine Stops T4FG-02-02-004

NOTE: The illustration shows the pressurized oil flow without operation of steering or loading circuits while the engine is running.

T2-2-7

SYSTEM / Hydraulic System Steering Circuit (When Steering is Operated) • When the steering wheel is operated, the oil passage (orifice 4) between the spool and the sleeve of the steering valve is opened in proportion to the steering wheel rotation speed. Port P is connected to the gerotor in the steering valve.

• When the steering wheel is operated quickly, orifice 4 opening increases and pressurized oil flow rate to the steering valve increases. When the steering wheel is operated slowly, orifice 4 opening decreases and pressurized oil flow rate to the steering valve decreases.

• Orifice 4 opens when the steering wheel is operated, pressurized oil between LS1 and port CF in the priority valve and orifice 4 in the steering valve flows to the gerotor.

• As pressurized oil flows to the gerotor, the oil pressure between LS1 and port CF in the priority valve and orifice 4 in the steering valve decreases, the spool in the priority valve moves to the right.

• The spool in the priority valve becomes balanced at the position where pressurized oil volume corresponding to orifice 4 open area of the priority valve flows to the steering valve.

• At this time, pressurized oil from the main pump flows to both the steering valve and the control valve.

• Pressurized oil from the main pump flows to the gerotor through the spool and sleeve in the steering valve. The gerotor delivers pressurized oil while rotating as a hydraulic motor, thus providing power steering assist. Pressurized oil from gerotor flows to the steering cylinder and the machine turns.

• When the rotation of the steering wheel is stopped, the oil passage between the spool and the sleeve in the steering valve is closed. The spool and the sleeve are returned to the neutral position by the spring force. Pressurized oil from the pump does not flow to the gerotor and the steering cylinder movement is stopped. (Refer to COMPONENT OPERATION/Steering Valve.)

T2-2-8

NOTE: Load sensing control is performed by using the combination of orifice 4 and the spool in priority valve. The spool in the priority valve corresponds to the flow rate control valve.

NOTE: As the gerotor is connected to the middle shaft of the steering valve, powered steering effect is generated. (Refer to COMPONENT OPERATION/Steering Valve.)

SYSTEM / Hydraulic System

Steering Cylinder

Steering Valve Sleeve

Gerotor

Spring

Steering Wheel

P

Spool Sleeve

Orifice 4 Control Valve Priority Valve

LS

CF

EF

LS1 Hydraulic Oil Tank

Spring

Spool Main Pump T4FG-02-02-005

NOTE: The illustration shows the pressurized oil flow when the steering wheel is turned to the right.

T2-2-9

SYSTEM / Hydraulic System Steering Stop Circuit (When steering cylinder is at stroke end) • When the steering wheel is operated, the oil passage (orifice 4) between the spool and the sleeve of the steering valve is opened in proportion to the steering wheel rotation speed.Pressure in port LS1, LS2, and CF decreases, the priority valve moves to the right.

• When the steering cylinder reaches the end of its stroke, the pressure in LS 2 in the priority valve increases due to pressurized oil from the main pump.

• When the pressure in LS 2 exceeds the specified level, the relief valve in the priority valve opens, and the pressurized oil acting on LS2 flows from the relief valve to the hydraulic oil tank.

• When the relief valve is operated, the pressurized oil in LS2 in the priority valve flows to the hydraulic oil tank. Therefore, the pressure difference between LS1 and LS2 occurs due to orifice 2.

• Therefore, the spool in the priority valve moves to the left and pressurized oil from the main pump flows to the control valve.

T2-2-10

SYSTEM / Hydraulic System Steering Cylinder

Steering Valve

Steering Wheel

Orifice 3

Orifice 2 LS

Priority Valve

Control Valve CF

EF

LS1 Hydraulic Oil Tank

LS2 Spool

Spring Relief Valve

Main Pump

NOTE: The illustration shows the pressurized oil flow when the relief valve in the priority valve is operated.

T2-2-11

T4FG-02-02-006

SYSTEM / Hydraulic System (Blank)

T2-2-12

SYSTEM / Hydraulic System HST CIRCUIT Outline: • The HST (Hydro-Static Transmission) circuit is a closed circuit, and consists of the HST pump and the HST motor.

• The HST pump has a built-in HST charging pump.

The HST charging pump is directly driven by the engine power and draws hydraulic oil from the hydraulic oil tank. The hydraulic oil is added to the low pressure side in the closed circuit in the HST pump and the HST motor through the HST filter.

• The HST pump is directly driven by the engine.

The HST motor is turned by pressurized oil from the HST pump.

• Pressurized oil from the HST charging pump also cools the HST pump and the HST motor. This pressurized oil controls the HST pump swash plate displacement angle.

• The output power of the HST motor is transmitted to the reduction gear / rear axle → the propeller shaft → the front axle → the tires in order.

NOTE: The reduction gear is connected to the rear axle.

HST Pump Engine HST Charging Pump

HST Filter

Hydraulic Oil Tank HST Motor

Reduction Gear

Rear Axle

Front Axle

T4FG-02-02-007

Propeller Shaft

T2-2-13

45ZV-2

SYSTEM / Hydraulic System Charge Circuit

Neutral Circuit

• Pressurized oil from the HST charging pump flows to the orifice in the pump solenoid valve through the HST filter.

• A pressure difference occurs between the front and the rear of the orifice by the delivery flow rate of the HST charging pump.

• The forward/reverse selection solenoid valve is located between the pump solenoid valve and the displacement angle control cylinder. When the forward/reverse lever is in neutral, the forward/reverse selection solenoid valve is kept neutral as the forward/reverse selection solenoid valve is not energized.

• The pump solenoid valve controls the HST pump displacement angle by supplying the reduced pressurized oil to the displacement angle control cylinder.

• Therefore, the pressurized oil reduced by the pump solenoid valve is not supplied to the displacement angle control cylinder. The HST pump displacement angle is kept at neutral.

• The high pressure relief valves also provide the function of make up type check valve. When the flow rate on the low pressure side in the HST close circuit is low, the make up type check valves open and pressurized oil from the HST charging pump is added.

• Therefore, pressurized oil is not delivered from HST pump. The HST motor does not rotate.

NOTE: When the forward/reverse lever is in neutral, the motor solenoid valve is energized.

NOTE: The delivery flow rate of the HST charged pump changes with the engine speed.

Therefore, the control pressure for the HST pump displacement angle changes with the engine speed.

T2-2-14

45ZV-2

SYSTEM / Hydraulic System Pump Solenoid Valve

Forward/Reverse Selection Solenoid Valve

HST Filter

HST Pump

Displacement Angle Control Cylinder

Orifice

Engine

HST Pump System Charging Pump High-Pressure Relief Valve Motor Solenoid Valve

HST Motor

T4FG-02-02-008

T2-2-15

45ZV-2

SYSTEM / Hydraulic System Forward Travel Circuit

Reverse Travel Circuit

• When setting the forward/reverse lever to the forward position, the forward selection solenoid valve of the forward/reverse selection solenoid valve is energized and the spool moves to the right.

• When setting the forward/reverse lever to the reverse position, the reverse selection solenoid valve of the forward/reverse selection solenoid valve is energized and the spool moves to the left.

• Therefore, the circuit between the pump solenoid valve and the displacement angle cylinder is connected, and pressurized oil from the HST charging pump is supplied to the displacement angle control cylinder.

• As pressurized oil from the HST charging pump is supplied to the right side of displacement angle cylinder, the HST pump displacement angle direction is opposite to the forward circuit flow.

• As pressurized oil from the HST charging pump is supplied to the left side of displacement angle control cylinder, the piston of the displacement angle cylinder moves to the right.

• Therefore, the HST motor rotates to the reverse direction.

• Therefore, the HST pump displacement angle is changed from the neutral position and the HST pump delivers pressurized oil.

• Pressurized oil from the HST pump is supplied to the HST motor.

• Therefore, the HST motor rotates in the forward direction.

T2-2-16

SYSTEM / Hydraulic System Pump Solenoid Valve

Forward/Reverse Selection Control Valve

HST Pump

Displacement Angle Control Cylinder

HST Motor

T4FG-02-02-009

NOTE: The illustration shows the forward travel circuit.

T2-2-17

SYSTEM / Hydraulic System Inching Circuit • The signal from the HST control unit energizes the pump solenoid valve and moves the spool. The circuit between the pump solenoid valve and the forward/reverse selection solenoid valve is connected to the hydraulic oil tank. (Refer to Control System / HST Brake (Inching) Control.)

• Therefore, as the control pressure in the HST pump displacement angle decreases, the displacement angle control cylinder moves to return to the neutral position.

• Consequently, the HST pump displacement angle goes to neutral and the HST pump delivery flow rate is reduced.

• As the HST pump delivery flow rate is reduced, the rotation speed of the HST motor decreases and the machine slows down.

• The control pressure in the HST pump displacement angle varies according to the brake pedal angle. When depressing the brake pedal fully, the HST pump displacement angle goes to neutral.

T2-2-18

SYSTEM / Hydraulic System

Brake Pedal

Brake Pedal Angle Sensor

Pump Solenoid Valve

HST Control Unit

Forward/Reverse Selection Solenoid Valve

Displacement Angle Control Cylinder

HST Pump T4FG-02-02-010

NOTE: The illustration shows the pressurized oil from when the brake pedal is depressed.

T2-2-19

SYSTEM / Hydraulic System BRAKE CIRCUIT Service Brake Circuit (Refer to COMPONENT OPERATION / Brake Master Cylinder.)

• The brake pedal is connected to the master cylinder via the link.

• The brake master cylinder is filled with brake oil from the brake oil tank.

• Pressurized oil from the brake master cylinder is routed to the front axle brake and the service brake is applied when the brake pedal is depressed.

Parking Brake Circuit • Pressurized oil from the HST charging pump is routed to the parking brake solenoid valve.

• When the parking brake switch is turned OFF, the parking brake solenoid valve is energized and pressurized oil flows to the parking brake cylinder so that the parking brake is released.

• When the parking brake switch is turned ON, the parking brake solenoid valve is not energized and pressurized oil stops being supplied to the parking brake so that the parking brake is applied.

NOTE: The service brake circuit is held due to the brake master cylinder with the engine stopped.

T2-2-20

SYSTEM / Hydraulic System

HST Charging Pump

Parking Brake Solenoid Valve Signal for Parking Brake Release Brake Oil Hydraulic Oil Tank Tank Brake Pedal

Brake Master Cylinder

Parking Brake

Service Brake

Front Axle T4FGE-02-02-011

NOTE: The illustration shows the pressurized oil flow when the parking brake solenoid valve is energized and the parking brake is released, and the pressurized oil flow of the service brake circuit when the brake pedal is depressed.

T2-2-21

SYSTEM / Hydraulic System (Blank)

T2-2-22

SYSTEM / Electrical System OUTLINE The electrical circuit is broadly divided into the main circuit, the lamplight circuit, and the control circuit

• Main Circuit Circuit for engine start/stop, circuit for battery charging

• Lamplight Circuit Circuit for traveling (composed of headlights, turn signals, brake lights, and horn)

• Control Circuit (Refer to SYSTEM/Control System.)

Control circuit for engine, HST pump, HST motor, and valves [composed of actuator as solenoid valve, HST control unit, monitor unit, switch, sensor, and pressure switch] Functions and compositions of the main circuit and the lamplight circuit are explained in this group.

T2-3-1

45ZV-2

SYSTEM / Electrical System MAIN CIRCUIT • Electric power circuit: It provides electric power source for the electrical system.

• Indicator light check circuit: It checks the bulbs for monitor warning lamp and indicators.

• Preheat circuit: It assists the engine in starting in cold weather.

• Starting circuit: It starts the engine.

• Charging circuit: It supplies electricity to the battery and charges the battery.

• Engine stop circuit: It stops the engine.

T2-3-2

45ZV-2

SYSTEM / Electrical System ELECTRIC POWER SWITCH: OFF)

CIRCUIT

(KEY

The battery ground terminal is connected to the chassis. Current from the battery positive terminal flows as shown below when the key switch is in the OFF position.

Battery ↓ Fusible Link

Although the key switch is in the OFF position, a very small amount of current is supplied to the memory circuits. Disconnect the battery ground terminal when the machine is stopped for long periods.

→Fuse Box

→ Fuse #13 → Fuse #14 → Fuse #19 → Fuse #20

HST Controller Relay [4] Montir Unit (Backup Power) (Option Power) Hazard Switch, Turn Signal Lever

→Fuse Box (Cab)

→ Fuse # 6 → Fuse # 7 → Fuse # 8 → Fuse # 9 → Fuse # 10

(Option Power) (Option Power) Cab Light, Radio (Optional), (Backup Power) Work Light (Front) Work Light (Rear)

→Key Switch

Fuse Box

Fuse Box (Cab)

Monitor Unit

6 7 8 9 10

1A-1

Key Switch

13 14

19 20

Starter Motor Fusible Link (100A)

Engine

(Power)

Battery (12 VDC) T4FG-02-03-001

T2-3-3

45ZV-2

SYSTEM / Electrical System (Blank)

T2-3-4

45ZV-2

SYSTEM / Electrical System INDICATOR LIGHT CHECK CIRCUIT (KEY SWITCH: ON) • When the key switch is turned to the ON position,

• The monitor unit starts the liquid crystal display as

terminal B is connected to terminal ACC in the key switch.

well as checks the indicator bulbs by illuminating the warning lamp and indicators.

• Current from terminal ACC in the key switch flows to terminal 1A-2 in the monitor unit through fuse #11 in fuse box.

Fuse Box Monitor Unit 1A-2

11 Key Switch

Starter Motor Fusible Link (100A)

Engine

(Power ) Battery T4FG-02-03-002

T2-3-5

45ZV-2

SYSTEM / Electrical System PREHEAT CIRCUIT (KEY SWITCH: HEAT) • When the key switch is turned to the HEAT position, terminal B is connected to terminal R1 in the key switch.

• Current from terminal R1 energizes the glow plug relay. Battery power is supplied to the glow plug from the glow plug relay through the fusible link (100A).

• While the glow plug relay is energized, the pre-heating is carried out as the power is supplied to the glow plug from the glow plug relay.

• While pre-heating is operating, the glow plug relay is ON so that current is supplied to the monitor unit and lights the preheat indicator.

• Even if the pre-heating is not operating, the preheat indicator lights for 2 seconds to check the indicator bulbs.

T2-3-6

45ZV-2

SYSTEM / Electrical System

Key Switch Preheat Indicator

Monitor Unit

2A-1

Glow Plug Relay

Glow Plug Engine

Starter Motor

Fusible Link (100A)

(Power) Battery T4FG-02-03-003

NOTE: The illustration shows the current flow when preheating is operating and with the glow plug relay energized and power supplied to the glow plugs.

T2-3-7

45ZV-2

SYSTEM / Electrical System STARTING START)

CIRCUIT

(KEY

SWITCH:

Forward/Reverse Lever in Neutral

• When the key switch is turned to the START position, terminal B is connected to terminals ACC and C in the key switch.

• Current from terminal ACC is supplied to terminal R in the starter relay 2 through fuse #9 in fuse box.

• Current from terminal C in the key switch is supplied to the starter relay 1 coil through the neutral circuit in the forward/reverse lever, and to terminal S in the starter relay 2.

• Therefore, starter relay 1 is energized and battery power is supplied to terminal S of the starter motor from starter relay 1.

• Consequently, the starter motor relay is turned ON so that the starter motor rotates.

• When the engine has started, the current from terminal L of the alternator stops.

• Current from terminal BR in the key switch is supplied to the fuel pump through fuse #8 in fuse box so that it operates. Another current is supplied to the engine stop solenoid holding side so that the plunger is held.

T2-3-8

45ZV-2

SYSTEM / Electrical System Fuse Box

Key Switch B

R1 R2 BR ACC C

HEAT OFF ON START

8 9

Forward/Reverse Lever Starter Relay 1 F N

Starter Relay 2 R

R L S P

Starter Motor

Engine Stop Solenoid

Engine Alternator

E B

P

S

R L B

Fuel Pump

Fusible Link (100A)

(Starting/ Charging)

＋

－

(Power) Battery

T4FG-02-03-005

NOTE: The illustration shows the current flow when the forward/reverse lever is in the neutral position and the engine speed is -1 1150 min (rpm) or less.

T2-3-9

45ZV-2

SYSTEM / Electrical System (Blank)

T2-3-10

45ZV-2

SYSTEM / Electrical System Starter Relay 2 Operation

• When the key switch is turned to the START position, continuity between terminals B and ACC in the key switch is established. Current is supplied to the base in transistor Tr3 through coil R in the starter relay 2. Transistor Tr3 is turned ON and current is supplied to coil R in starter relay 1.

Consequently, battery power is supplied to terminal S in the starter motor from starter relay 1 so that the starter is operated.

• When this frequency reaches 170 Hz (alternator rotation speed is 1700 r/min), transistor Tr3 is turned OFF as no current is supplied to the base in transistor Tr3.

Current to coil R in starter relay 1 is stopped at this time so that the starter is turned OFF. This keeps the starter from over-spinning or being driven by the engine flywheel and being damaged.

• When the engine is started, the alternator begins charging and a pulse wave pattern of current, in a frequency in proportion to the engine speed is sent from terminal P in the alternator.

Alternator

Starter Switch B R R Starter Relay 2 L

L

R R

P

P

Starter Relay 1

S

Tr3 E

Battery

To Starter Motor Terminal S

T4FG-02-03-004

T2-3-11

45ZV-2

SYSTEM / Electrical System Forward/Reverse Lever at Operated Position

• Starting Circuit • When the key switch is turned to the START position, terminal B is connected to terminals ACC and C in the key switch.

• Battery power is supplied to starter relay 1 through terminal B in the starter motor and the fusible link (100A).

• When either the forward/reverse lever is in the forward or the reverse position, starter relay 1 will not energize as current from terminal C in the key switch is not supplied to the neutral circuit in the forward/reverse lever.

Therefore, battery power is stopped at starter relay 1.

• When either the forward/reverse lever is in the forward or the reverse position, the starter motor will not operate even when the key switch is turned to the START position

T2-3-12

45ZV-2

SYSTEM / Electrical System Fuse Box

Key Switch B

R1 R2 BR ACC C

HEAT OFF ON START

9

Forward/Reverse Lever

Starter Relay 1 F N

Starter Relay 2 R

R L S P

Starter Motor

Engine Stop Solenoid

Engine Alternator

E B

P

S

R L B

Fuel Pump (Starting/ Charging) Fusible Link (100A) ＋

−

(Power) Battery T4FG-02-03-006

NOTE: The illustration shows the current flow when the forward/reverse lever is in the reverse position.

T2-3-13

45ZV-2

SYSTEM / Electrical System CHARGING CIRCUIT (KEY SWITCH: ON) • After the engine starts and the key switch is released, the key switch returns to the ON position.

• Terminal B is connected to terminal ACC in the key switch with the key switch ON.

• Current from terminal ACC in the key switch energizes the charge lamp relay [3] through fuse #9 in the fuse box.

• The alternator starts generating electricity with the engine running. Current from terminal B in the alternator is supplied to the battery through the slow blow fuse (starting/charging), starter motor terminal B, and charges the battery.

• When current from terminal "a" in charge lamp relay [3] is supplied to terminal 1A-14 in the monitor unit as the generating electricity start signal of alternator terminal L, the alternator indicator lights. When no current is supplied to terminal 1A-14, the alternator indicator goes off.

T2-3-14

45ZV-2

SYSTEM / Electrical System

Fuse Box

Alternator Indicator Monitor Unit

Key Switch B

R1 R2 BR ACC C

1A-14

HEAT OFF ON START

9

Charge Lamp Relay ［3］

a

Fusible Link

Starter Motor

(Starting/ Charging)

Alternator Engine

B

P R L

＋

－

B

Battery

(Power)

T4FG-02-03-007

T2-3-15

45ZV-2

SYSTEM / Electrical System Alternator Operation

Regulator Operation

• The alternator consists of field coil FC, stator coil

• The regulator is an IC chip, which maintains

SC and diode D.

generated voltage at a constant level.

• At the beginning, no current is flowing through

• When generating voltage exceeds the set voltage,

field coil FC. When the rotor starts rotating, alternate current is generated in stator coil SC by the rotor remanent magnetism.

the regulator reduces current through field coil FC. This reduces generating voltage of stator coil SC.

• When current flows through field coil FC, the rotor is further magnetized so that the generating voltage increases. Current flowing through field coil FC increases. Therefore, generating voltage increases and the batteries start charging.

• When generating voltage becomes lower than the set voltage, the regulator increases current through field coil FC. This increases generating voltage of stator coil SC.

• The above operation is repeated so that the alternator generating voltage is kept constant.

T2-3-16

45ZV-2

SYSTEM / Electrical System

Alternator

Starter Switch IC Regulator

B R

SC D

Starter Relay 2 Starter Relay1

L Ds

R R

D P

Tr3

Battery

FC Tr1

Tr2 To Starter Motor Terminal S

E T4FG-02-03-004

T2-3-17

45ZV-2

SYSTEM / Electrical System ENGINE STOP CIRCUIT • Current from terminal BR is supplied to the engine

• When the key switch is changed ON into OFF,

stop solenoid holding side through fuse #8 in fuse box with the key switch ON so that the plunger of the engine stop solenoid is held.

current from terminal BR is not supplied and the plunger of the engine stop solenoid is not held so that the control rack is pushed by the spring force and the engine is stopped.

• In addition, current is not supplied to the fuel pump and it is stopped.

Fuse Box

Key Switch B

R1 R2 BR ACC C

HEAT OFF ON START

8

Engine Battery Power

Engine Stop Solenoid

Fuel Pump

Holding Side

T4FG-02-03-009

NOTE: The illustration shows the current flow when the key switch is in the ON position.

T2-3-18

45ZV-2

SYSTEM / Electrical System LAMPLIGHT CIRCUIT • Headlight circuit: It turns on or off the headlight, the clearance light and the license-plate light (optional).

• Turn signal circuit: It operates the turn signal.

• Brake light circuit: It turns on and off the brake light.

• Hazard light circuit: It operates the hazard light.

• Horn circuit: It operates the horn.

• Reverse light/alarm circuit: It operates the reverse light and the reverse alarm.

• Parking brake circuit: It applies and releases the parking brake.

T2-3-19

45ZV-2

SYSTEM / Electrical System HEADLIGHT CIRCUIT Clearance Light Lighting Circuit

• When the key switch is turned to the ON position, terminal B is connected to terminal ACC in the key switch.

• Current from terminal ACC is supplied to the headlight switch through fuse #12 in fuse box.

• When the headlight switch is positioned to turn on the Clearance Light, power from terminal (1) in the headlight switch is supplied to terminal 1B-21 in the monitor unit and the clearance light indicator lights.

• Electrical power to the fuse box is divided and supplied to fuse #4 and fuse #5. Power from fuse #4 lights the left front clearance lights, right rear clearance lights, and license-plate light.

Power from fuse #5 lights the right front clearance lights and left rear clearance lights.

T2-3-20

45ZV-2

SYSTEM / Electrical System Key Switch B

Monitor Unit

R1 R2 BR ACC C

HEAT OFF ON START

Clearance Light Indicator

1B-21

Fuse Box

4 5

12 Headlight Switch

Clearance Light (Front Right Side)

Tail Light (Right Side) License-Plate Light Tail Light (Left Side)

Clearance Light (Front Left Side)

Fusible Link

Starter Motor Engine

Battery T4FG-02-03-010

T2-3-21

45ZV-2

SYSTEM / Electrical System Headlight Lighting Circuit

• When the key switch is turned to the ON position, terminal B is connected to terminal ACC in the key switch.

• Current from terminal ACC is supplied to the headlight switch through fuse #12 in fuse box.

• When the headlight switch is positioned to turn on the headlights, power lights each clearance light.

(Refer to Clearance Light Lighting Circuit.) Power from terminal #2 in the headlight switch is supplied to the dimmer switch.

• When the dimmer switch is set to Low (low beam), power is divided and supplied to fuse #1 and fuse #2 in fuse box.

• Power from fuse #1 in the fuse box lights the low beam of right headlight.

• Power from fuse #2 in the fuse box lights the low beam of left headlight.

• When the dimmer switch is set to High (high beam), power lights the high beam of head lights through fuse #3 in fuse box.

• Power is supplied to terminal 1B-22 in the monitor unit and lights the high beam indicator.

T2-3-22

45ZV-2

SYSTEM / Electrical System Key Switch B

Monitor Unit

R1 R2 BR ACC C

HEAT OFF ON START

High Beam Indicator

1B-22

Fuse Box 1 2 3

12 Headlight Switch

Dimmer Switch

High Beam Headlight (Right Side) Low Beam High Beam Headlight (Left Side) Low Beam

Fusible Link

Starter Motor Engine

Battery T4FG-02-03-011

T2-3-23

45ZV-2

SYSTEM / Electrical System TURN SIGNAL CIRCUIT • Battery power is supplied to the flasher unit through fuse #20 in fuse box with the key switch OFF.

• Battery power is supplied to the turn signal switch through terminal L in the flasher unit.

• When the turn signal switch is turned to left (L), power from the turn signal switch is supplied to the left turn signal light and terminal 1-19 in the monitor unit.

• Consequently, the left front and rear turn signal lights and the left turn signal indicator on the monitor unit flash.

T2-3-24

45ZV-2

SYSTEM / Electrical System Key Switch Turn Signal Indicator (Left Side)

Monitor Unit

B

R1 R2 BR ACC C

HEAT OFF ON START

1A-19

Turn Signal Indicator (Right Side)

1A-20

Fuse Box

Hazard Light Switch

Flasher Unit

20

Turn Signal Light (Front Right Side)

Turn Signal Light (Rear Right Side)

Turn Signal Light (Front Left Side)

Fusible Link

Starter Motor

Turn Signal Light (Rear Left Side)

Engine

Battery T4FG-02-03-012

NOTE: The illustration shows the current flow when the turn signal switch is set to turn left (L).

T2-3-25

45ZV-2

SYSTEM / Electrical System (Blank)

T2-3-26

45ZV-2

SYSTEM / Electrical System BRAKE LIGHT CIRCUIT • When the key switch is turned to the ON position, current from terminal ACC in the key switch is supplied to the brake light switch through fuse #7 in the fuse box.

• When the brake pedal is depressed, the brake light is grounded.

• Therefore, battery power lights the brake light.

Key Switch B

R1 R2 BR ACC C

HEAT OFF ON START

Brake Pedal Fuse Box Brake Light Switch

7

Starter Motor Brake Light (Right Side)

Fusible Link Engine

Battery Brake Light (Left Side) T4FG-02-03-013

T2-3-27

45ZV-2

SYSTEM / Electrical System HAZARD LIGHT CIRCUIT • Battery power is supplied to the flasher relay through fuse #20 in the fuse box with the key switch OFF.

• Battery power is supplied to the hazard light switch through terminal L in the flasher unit.

• When the hazard light switch is turned to the ON position, battery power is supplied to all of the turn signal lights and terminal 1A-19 and terminal 1A-20 in the monitor unit.

• Consequently, all of turn signal lights and left/right turn signal indicator on the monitor unit blink.

T2-3-28

45ZV-2

SYSTEM / Electrical System Key Switch Turn Signal Indicator (Left Side)

Monitir Unit

B

R1 R2 BR ACC C

HEAT OFF ON START

1A-19

Turn Signal Indicator (Right Side)

1A-20

Fuse Box

Hazard Light Switch

Flasher Unit

20 Turn Signal Light (Front Right Side) Turn Signal Light (Rear Right Side)

Turn Signal Light (Front Left Side)

Fusible Link

Stater Motor Engine

Turn Signal Light (Rear Left Side)

Battery T4FG-02-03-014

T2-3-29

45ZV-2

SYSTEM / Electrical System (Blank)

T2-3-30

45ZV-2

SYSTEM / Electrical System HORN CIRCUIT • When the key switch is turned to the ON position,

• When the horn switch is pushed, it is grounded.

power from terminal ACC is supplied to the horn relay through fuse #7 in the fuse box.

• Therefore, battery power is supplied to the horn and it sounds.

Key Switch B

R1 R2 BR ACC C

HEAT OFF ON START

Horn Switch

Fuse Box

Low 7

Horn

High

Fusible Link

Starter Motor Engine

Battery

T4FG-02-03-015

T2-3-31

45ZV-2

SYSTEM / Electrical System REVERSE LIGHT / ALARM CIRCUIT When Forward/Reverse lever is operated

• When the key switch is turned to the ON position, power from terminal ACC is supplied to parking brake relay [2] through fuse #7 in the fuse box.

• Current through parking brake relay [2] is supplied to the forward/reverse lever through parking brake relay [1].

• When the forward/reverse lever is set to the reverse position, battery power is divided and one circuit is supplied to the reverse light and the reverse alarm.

• Another circuit is supplied to the reverse side of forward/reverse selection solenoid valve in the HST pump so that the signal is sent to the HST control unit and [R] on the forward/reverse and shift position indicator on the monitor LCD is displayed.

T2-3-32

45ZV-2

SYSTEM / Electrical System

Forward/Reverse Lever FN Key Switch R

Parking Brake Relay [1]

B

Parking Brake Relay [2]

R1 R2 BR ACC C

HEAT OFF ON START

Fuse Box

6

Reverse Light

Fusible Link

Starter Motor Engine

Reverse Alarm

Battery

T4FG-02-03-016

T2-3-33

45ZV-2

SYSTEM / Electrical System PARKING BRAKE CIRCUIT Parking brake switch is changed into OFF from ON after engine starts

• When the key switch is turned ON, current from terminal ACC is supplied to the parking brake switch through fuse #9 in the fuse box and charge lamp relay [3].

• In addition, current through fuse #6 in the fuse box is supplied to parking brake relay [1] from parking brake relay [2].

• Power through terminal #b in parking brake relay [2] is supplied to terminal #b in parking brake relay [1] and terminal #4 in the parking brake switch through terminal #a in parking brake relay [2].

• The parking brake switch consists of the three circuits (ON-Neutral-OFF). If turning ON, the switch is kept ON. If turning OFF, the switch returns to neutral position when releasing the switch.

• When the parking brake switch is turned OFF, power through terminal #4 in the parking brake switch is not supplied to terminal #2 in it so that parking brake relay [1] is not energized.

• Power through terminal #b in parking brake relay [1] is supplied to the parking brake solenoid valve through terminal #e in parking brake relay [1].

IMPORTANT: The parking brake cannot be released unless the engine is running.

• Consequently, the parking brake is released as the parking brake solenoid valve is activated.

T2-3-34

45ZV-2

SYSTEM / Electrical System

OFF Neutral ON

Key Switch Parking Brake Switch

B Parking Brake Relay [1]

Parking Brake Relay [2]

Charge Lamp Relay [3]

R1 R2 BR ACC C

HEAT OFF ON START

Monitor Unit

Parking Brake Indicator

Fuse Box

1A-17

6 9

Starter Motor

Alternator Engine

Parking Brake Solenoid Valve Fusible Link

Battery

T4FG-02-03-017

NOTE: The illustration shows the current flow when the parking brake switch is turned to the OFF position and the parking brake switch is not released while running the engine.

T2-3-35

45ZV-2

SYSTEM / Electrical System Parking brake switch is turned ON after engine starts

• When the parking brake switch is turned to the ON, power through terminal #4 in the parking brake switch is supplied to terminal #c in parking brake relay [1] through terminal #2 in the parking brake switch.

• As parking brake relay [1] is energized, power to the parking brake solenoid valve through terminal #e in the parking brake relay [1] is stopped.

• Power from terminal #a in parking brake relay [1] lights the parking brake indicator on the monitor unit.

• Consequently, as the parking brake solenoid valve is not energized, the parking brake is applied.

T2-3-36

45ZV-2

SYSTEM / Electrical System OFF Neutral ON

Key Switch Parking Brake Switch

B Parking Brake Relay [1]

Parking Brake Relay [2]

Charge Lamp Relay [3]

R1 R2 BR ACC C

HEAT OFF ON START

Monitor Unit Parking Brake Indicator

Fuse Box

1A-17

6 9

Starter Motor

Alternator Engine

Parking Brake Solenoid Valve Fusible Link

Battery

T4FG-02-03-018

T2-3-37

45ZV-2

SYSTEM / Electrical System EMERGENCY PARKING BRAKE CIRCUIT • When the service brake system malfunctions and the brake pedal strokes too far, the HST control unit energizes the emergency parking brake relay.

• Consequently, as the parking brake solenoid valve is not energized, the parking brake applies.

T2-3-38

45ZV-2

SYSTEM / Electrical System

OFF Neutral

Parking Brake Switch

ON

Parking Brake Relay [1]

Charge Lamp Relay [3] Emergency Parking Brake Prking Brake Relay [2] Relay

B

Key Switch R1 R2 BR ACC C

HEAT OFF ON START

Monitor Unit Parking Brake Indicator

Fuse Box

1A-17

6 9

29

HST Control Unit

Starter Motor

Alternator Engine

Brake Pedal Angle Sensor Parking Brake Solenoid Valve Fusible Link

Battery

T4FG-02-03-024

T2-3-39

45ZV-2

SYSTEM / Electrical System (Blank)

T2-3-40

45ZV-2

SYSTEM / Electrical System INDICATOR CIRCUIT The indicator circuit consists of the following:

• Overheat Indicator • Engine Oil Low Pressure Indicator • Brake Oil Low Level Indicator • Air Filter Restriction Indicator

T2-3-41

45ZV-2

SYSTEM / Electrical System Overheat Indicator Purpose: It illuminates the overheat indicator on the monitor panel to alert the operator of high engine coolant temperature.

NOTE: The monitor panel illuminates the stop indicator as well as the overheat indicator at the same time.

Operation:

• The overheat indicator illuminates when the coolant temperature needle of the monitor panel reaches the red zone.

• The overheat indicator goes off when the coolant temperature needle of the monitor panel is below the red zone.

Monitor Unit

Engine

Water Temperature Unit

Overheat Indicator 2A-9

Stop Indicator

T4FG-02-03-019

T2-3-42

45ZV-2

SYSTEM / Electrical System Engine Oil Low Pressure Indicator Purpose: It illuminates the engine oil low pressure indicator on the monitor panel to alert the operator of low engine lubricant oil pressure.

3. When the engine lubricant oil pressure returns to the normal range, the engine oil pressure switch is disconnected from ground.

Operation:

4. When the engine oil pressure switch is disconnected from ground, the monitor panel turns off the low engine oil pressure indicator.

1. When the engine lubricant oil pressure becomes lower than the normal range, the engine oil pressure switch is grounded.

2. When the engine oil pressure switch is grounded, the monitor panel illuminates the engine oil low pressure indicator.

Monitor Unit

NOTE: The monitor panel illuminates the stop indicator as well as the low engine oil pressure indicator at the same time.

Engine Engine Oil Pressure Switch

Engine Oil Low Pressure Indicator

1A-8

Stop Indicator

T4FG-02-03-020

T2-3-43

45ZV-2

SYSTEM / Electrical System Brake Oil Low Level Indicator Purpose: It illuminates the brake oil low level indicator on the monitor panel to alert the operator of low brake oil level.

3. When the brake oil level returns to normal, the brake oil level switch is disconnected from the ground.

Operation:

4. When the brake oil level switch is disconnected from ground, the monitor panel turns off the brake oil low level indicator.

1. When the brake oil level becomes lower than the normal, the brake oil level switch is grounded.

2. When the brake oil level switch is grounded, the monitor panel illuminates the brake oil low level indicator.

NOTE: The monitor panel illuminates the stop indicator as well as the brake oil low level indicator at the same time.

Brake Oil Level Switch

Monitor Unit

Brake Oil Low Level Indicator 1A-13

Stop Indicator

21

T4FG-02-03-021

T2-3-44

45ZV-2

SYSTEM / Electrical System Air Filter Restriction Indicator Purpose: It illuminates the air filter restriction indicator on the monitor panel to alert the operator of the clogged air filter.

3. When the clogged air filter is serviced, the air cleaner restriction switch is disconnected from ground.

Operation:

4. When the air cleaner restriction switch is disconnected from ground, the monitor panel turns off the air filter restriction indicator.

1. When the air filter is clogged, the air cleaner restriction switch is grounded.

2. When the air cleaner restriction switch is grounded, the monitor panel illuminates the air filter restriction indicator.

NOTE: The monitor panel illuminates the service indicator as well as the air filter restriction indicator at the same time.

Air Cleaner Restriction Switch

Monitor Unit

Engine

Air Filter Restriction Indicator 1A-9

Service Indicator

T4FG-02-03-022

T2-3-45

45ZV-2

SYSTEM / Electrical System (Blank)

T2-3-46

45ZV-2

SECTION 3

COMPONENT OPERATION ―CONTENTS― Group 1 Priority Valve

Group 5 HST Motor

Outline .....................................................T3-1-1

Outline..................................................... T3-5-1

Structure ..................................................T3-1-2

Operation ................................................ T3-5-4

Operation .................................................T3-1-3

Regulator................................................. T3-5-6 Motor Solenoid Valve ............................... T3-5-6

Group 2 Control Valve Outline .....................................................T3-2-1

Group 6 Reduction

Hydraulic Circuit .......................................T3-2-4

Outline..................................................... T3-6-1

Operation .................................................T3-2-6

Construction ............................................ T3-6-2

Main Relief Valve.................................... T3-2-15 Overload Relief Valve ............................. T3-2-17 Make-Up Valve ....................................... T3-2-19

Group 3 Steering Valve

Group 7 Axle Outline..................................................... T3-7-1 Differential ............................................... T3-7-2 Limited Slip Differential (LSD)

Outline .....................................................T3-3-1

(Optional)............................................... T3-7-6

Structure ..................................................T3-3-2

Service Brake .......................................... T3-7-8

Operation .................................................T3-3-3

Parking Brake ........................................ T3-7-10

Overload Relief Valve ...............................T3-3-6

Final Drive / Axle Shaft .......................... T3-7-12

Make-Up Valve .........................................T3-3-6

Group 8 Brake Master Cylinder Group 4 HST Pump

Outline..................................................... T3-8-1

Outline .....................................................T3-4-1

Structure.................................................. T3-8-2

Forward / Reverse Selection

Operation ................................................ T3-8-3

Solenoid Valve........................................T3-4-7 Pump Solenoid Valve................................T3-4-8

Group 9 Others

Cutoff Valve............................................ T3-4-10

Gear Pump .............................................. T3-9-1

High Pressure Relief Valve ..................... T3-4-11

Propeller Shaft......................................... T3-9-2

Low Pressure Relief Valve ...................... T3-4-11

Parking Brake Solenoid Valve .................. T3-9-3

HST Charging Pump............................... T3-4-12

4FGET-3-1

45ZV-2

(Blank)

4FGET-3-2

45ZV-2

COMPONENT OPERATION / Priority Valve OUTLINE The priority valve delivers pressurized oil from the main pump to the steering valve and the loading control valve in proportion to the steering valve operation. (Refer to SYSTEM / Hydraulic System.)

A relief valve is provided in the priority valve. When the steering cylinder is at its limit, the relief valve prevents the circuit pressure between the priority valve and steering valve from increasing more than the set pressure.

Relief Valve Port P (From Main Pump)

Port T (To Hydraulic Oil Tank)

Port LS (To Steering Valve)

Port EF (To Control Valve)

T3-1-1

Port CF (To Steering Valve)

W4FC-03-11-003

45ZV-2

COMPONENT OPERATION / Priority Valve STRUCTURE The priority valve consists of the relief valve, the spool, the spring, orifice A, orifice B, and orifice C. The illustration shows the spool position when the engine stops. The spool is pushed to the right by the spring.

Port P is connected to the main pump. Port CF is connected to the steering valve. Port EF is connected to the control valve.

Relief Valve Spring

Spool Port P

Port T

Port LS

Port EF Orifice C

Orifice B

Port CF Orifice A

T3-1-2

W4FC-03-11-003

45ZV-2

COMPONENT OPERATION / Priority Valve OPERATION When steering is in neutral: 1. Pressurized oil from the main pump flows to port P and is divided into three directions in the inner passage of the spool.

2. When the steering valve is in neutral (the steering wheel is not operated), pressurized oil from port CF to the steering valve is blocked by the steering valve so that pressure in port CF increases.

3. As the pressure in port CF increases, pressurized oil from the main pump flows to chamber A and chamber B respectively through orifice A and orifice B.

4. As pressurized oil in chamber B flows to the hydraulic oil tank through port LS and the steering valve, pressure in chamber B becomes lower than that in chamber A due to orifice B. 5. When the pressure difference overcomes the spring force, the spool moves to the left.

6. Therefore, pressurized oil from the main pump flows to the loading control valve through port EF.

Steering Valve

Port P (From Main Pump) Chamber B

Spring

Spool Priority Valve Chamber A

Port LS (To Steering Valve)

Orifice A Orifice C

Orifice B

Port EF (To Control Valve) Port CF (To Steering Valve)

T487-03-01-007

Port P (From Main Pump)

Port EF (To Control Valve)

T3-1-3

T487-03-01-003

45ZV-2

COMPONENT OPERATION / Priority Valve When steering is operated: NOTE: Orifice D in the steering valve is a variable orifice so that the open area increases in proportion to the steering wheel rotation angle.

1. The spool in the steering valve moves at the moment when the steering wheel is rotated, so that orifice D opens.

2. Pressurized oil in the circuit between orifice D in the steering valve and chamber A and port CF in the priority valve flows to the gerotor.

3. As pressurized oil flows to the gerotor, pressure in the circuit between chamber A and port CF in the priority valve and orifice D in the steering valve decreases so that the spool in the priority valve moves to the right.

4. The spool in the priority valve becomes stable at the position where pressurized oil flows to the steering valve in proportion to the orifice D open area.

5. At this time, pressurized oil from the main pump flows to the steering valve and the control valve respectively through the spool.

6. Pressurized oil from the main pump flows to the gerotor through the spool and the sleeve in the steering valve.

7. The gerotor delivers pressurized oil while rotating as a hydraulic motor. Pressurized oil from gerotor flows to the steering cylinder and the machine turns.

T3-1-4

45ZV-2

COMPONENT OPERATION / Priority Valve

Steering Cylinder

Steering Valve Gerotor

Sleeve Orifice D

Steering Wheel Spool Sleeve Port P (From Main Pump) Priority Valve

Spool

Chamber A

Port EF (To Loading Control Valve)

T3-1-5

Port CF (To Steering Valve)

T487-03-01-004

45ZV-2

COMPONENT OPERATION / Priority Valve When steering cylinder is fully stroked: 1. Pressurized oil to port P in the steering valve is divided inside the spool. One circuit flows to the gerotor. The other flows to port LS in the priority valve and acts on chamber B through orifice C. 2. As pressure in port P increases when the steering cylinder reaches the end of its stroke, pressure in chamber B in the priority valve also increases through port LS. 3. When pressure in chamber B increases more than the set pressure, the relief valve in the priority valve opens and pressurized oil acting on chamber B flows to the hydraulic oil tank through the relief valve.

4. As pressurized oil in chamber B flows to the hydraulic oil tank when the relief valve opens, the pressure difference between chamber A and chamber B occurs due to orifice B. 5. When the pressure difference overcomes the spring force, the spool in the priority valve moves to the left.

6. Pressurized oil from the main pump flows to the control valve through port EF and the spool in the priority valve.

7. Therefore, when the steering cylinder is at the end of its stroke, pressurized oil flows to the control valve. At this time, pressure acting on the steering cylinder is as much as the set pressure of the relief valve.

T3-1-6

45ZV-2

COMPONENT OPERATION / Priority Valve

Steering Cylinder

Steering Valve

Gerotor

Spool Port P (From Main Pump) Priority Valve Relief Valve

Chamber A

Port LS (From Steering Valve)

Orifice C Chamber B OrificeB

Port EF (To Loading Control Valve) Spring

T487-03-01-005

T3-1-7

45ZV-2

COMPONENT OPERATION / Priority Valve (Blank)

T3-1-8

45ZV-2

COMPONENT OPERATION / Control Valve OUTLINE The loading control valve controls the pressure, flow rate, and flow direction in the hydraulic circuit.

The major parts of the control valve are the main relief valve, the overload relief valves, load check valves, and the spool. The spool is manually operated by the control lever and cable assembly.

Make-Up Valve (Lift Arm: Rod Side)

Overload Relief Valve (Auxiliary (Coupler): Rod Side)

Overload Relief Valve (Auxiliary (Coupler): Bottom Side) Lift Arm

Machine Front

Overload Relief Valve (Bucket: Rod Side)

Main Relief Valve Overload Relief Valve (Bucket: Bottom Side)

T3-2-1

Bucket

T4FGE-03-02-001

45ZV-2

COMPONENT OPERATION / Control Valve Component Layout 1

2

9

3

5

8

4

7

6 T4FGE-03-02-002

1 - Overload Relief Valve (Coupler: Rod Side) 2 - Overload Relief Valve (Coupler: Bottom side) 3 - Make-Up Valve (Lift Arm: Rod Side)

4 - Overload Relief Valve (Bucket: Rod Side) 5 - Overload Relief Valve (Bucket: Bottom Side)

T3-2-2

6 - Main Relief Valve 7 - Load Check Valve (Bucket Circuit)

8 - Load Check Valve (Lift Arm Circuit) 9 - Load Check Valve (Coupler Circuit)

45ZV-2

COMPONENT OPERATION / Control Valve

A

A

B

B

C

C

T4FGE-03-02-003

1

Section B-B

Section A-A 3

2

5

4

6

T4FG-03-02-004 T4L1-03-02-005

Section C-C 7

8

9

T4FG-03-02-005

1 - Main Relief Valve 2 - Overload Relief Valve (Coupler: Rod Side) 3 - Load Check Valve (Coupler Circuit)

4 - Overload Relief Valve (Coupler: Bottom side) 5 - Make-Up Valve (Lift Arm: Rod Side)

T3-2-3

6 - Load Check Valve (Lift Arm Tandem Circuit) 7 - Overload Relief Valve (Bucket: Rod Side)

8 - Load Check Valve (Bucket Tandem Circuit) 9 - Overload Relief Valve (Bucket: Bottom Side)

45ZV-2

E

COMPONENT OPERATION / Control Valve HYDRAULIC CIRCUIT Main Circuit The main circuit contains a parallel circuit, which enables combined operations.

The main circuit (between the pump and the cylinder) is provided with the main relief valve. The main relief valve prevents the pressure in main circuit from increasing over the set pressure when the spool is in operation (or when the control lever is in operation).

The overload relief valves are provided in the bucket circuit and the auxiliary (coupler) circuit (between the control valve and the cylinder). The overload relief valve prevents excessive circuit pressure caused by external forces in the front attachment circuit from increasing over the set pressure when the spool is in neutral (when the control lever is at neutral).

The make-up valve is provided in the lift arm lower circuit (between the control valve and the cylinder).

When pressure in the lift arm lower circuit decreases, the make-up valve draws oil from the hydraulic oil tank and prevents cavitation.

T3-2-4

45ZV-2

COMPONENT OPERATION / Control Valve Overload Relief Valve

Coupler Cylinder

Auxiliary (Coupler)

Lift Arm Cylinder

Make-Up Valve

Lift Arm Parallel Circuit

Bucket Cylinder

Bucket

Overload Relief Valve

Main Relief Valve Main Pump

T3-2-5

Hydraulic Oil Tank

T4FGE-03-02-002

45ZV-2

COMPONENT OPERATION / Control Valve OPERATION When bucket is in neutral position • Bucket spool (1) blocks cylinder port A1 (rod side) and port B1 (bottom side) when the loader control lever is in neutral (N) position.

Pressurized oil from main circuit (2) is routed to drain circuit (4) and to the hydraulic oil tank through neutral circuit (3). Consequently, the bucket cylinder rod is kept at this position.

Bucket

Bucket Cylinder Ａ1

Ｂ1

2 1

4

Hydraulic Oil Tank

T3-2-6

3 T4L1-03-02-006

45ZV-2

COMPONENT OPERATION / Control Valve When bucket tilts Operation: 1. Bucket spool (1) moves to the right (illustrated below) when the loader control lever is in the ROLL BACK position.

2. Pressurized oil from main circuit (2) is routed to the bucket cylinder bottom side from port B1 through load check valve (5) as neutral circuit (3) is blocked.

3. Therefore, pressurized oil in the bucket cylinder rod side is routed to drain circuit (4) and the hydraulic oil tank through port A1.

4. Consequently, the bucket cylinder rod is extended so that the bucket rolls back.

Bucket

Bucket Cylinder

Ａ1

Ｂ1

1

5

4

3 Hydraulic Oil Tank

T3-2-7

2 T4L1-03-02-007

45ZV-2

COMPONENT OPERATION / Control Valve When bucket dumps Operation: 1. Bucket spool (1) moves to the left (illustrated below) when the loader control lever is in the DUMP position.

2. Pressurized oil from main circuit (2) is routed to the bucket cylinder rod side from port A1 through load check valve (5) as neutral circuit (3) is blocked.

3. Therefore, pressurized oil in the bucket cylinder bottom side is routed to drain circuit (4) and the hydraulic oil tank through port B1.

4. Consequently, the bucket cylinder rod is retracted so that the bucket dumps.

Bucket

Bucket Cylinder

Ａ1

Ｂ1

1

5

4

Hydraulic Oil Tank

T3-2-8

3

2 T4L1-03-02-008

45ZV-2

COMPONENT OPERATION / Control Valve When lift arm is in neutral • Lift arm spool (1) blocks cylinder port A2 (rod side) and port B2 (bottom side) when the loader control lever is in the neutral (N) position.

Pressurized oil from main circuit (2) is routed to drain circuit (4) and the hydraulic oil tank through neutral circuit (3). Consequently, the lift arm cylinder is held in that position.

Lift Arm

Lift Arm Cylinder

Ａ2

Ｂ2

1

2

Hydraulic Oil Tank

4

3 T4FG-03-02-00

T3-2-9

45ZV-2

COMPONENT OPERATION / Control Valve When lift arm raises Operation: 1. Lift arm spool (1) moves to the right (illustrated below) when the loader control lever is in the RAISE position.

2. Pressurized oil from main circuit (2) is routed to the lift arm cylinder bottom side from port B2 through load check valve (5) as neutral circuit (3) is blocked.

3. Therefore, pressurized oil in the lift arm cylinder rod side is routed to drain circuit (4) and the hydraulic oil tank through port A2.

4. Consequently, the lift arm cylinder rod is extended so that the lift arm rises.

Lift Arm

Lift Arm Cylinder Ａ2

Ｂ2

1

5 4

Hydraulic Oil Tank

T3-2-10

2 T4FG-03-02-010

3

45ZV-2

COMPONENT OPERATION / Control Valve When lift arm lowers Operation: 1. Lift arm spool (1) moves to the left (illustrated below) when the loader control lever is in the LOWER position.

2. Pressurized oil from main circuit (2) is routed to the lift arm cylinder rod side from port A2 through load check valve (5) as neutral circuit (3) is blocked.

3. Therefore, pressurized oil in the lift arm cylinder bottom side is routed to drain circuit (4) and the hydraulic oil tank through port B2.

4. Consequently, the lift arm cylinder rod is retracted so that the lift arm lowers.

Lift Arm

Lift Arm Cylinder

Ａ2

Ｂ2

1

Hydraulic Oil Tank

5 4

T3-2-11

2 3

T4FG-03-02-01

45ZV-2

COMPONENT OPERATION / Control Valve When lift arm floats Operation: • Lift arm spool (1) moves to the left (illustrated below) when the loader control lever is in the FLOAT position.

• Pressurized oil from main circuit (2) is routed to drain circuit (4) and the hydraulic oil tank through neutral circuit (3). In addition, port A2 and port A1 are connected to drain circuit (4) so that pressurized oil is also routed to the lift arm cylinder bottom and rod sides.

• Therefore, pressurized oil in the lift arm cylinder bottom and rod sides are routed to drain circuit (4) and the hydraulic oil tank through port A2 and port A1.

• Consequently, the lift arm cylinder rod is extend or retracted freely by external forces.

T4FG-03-02-012

2

1 3

4

T3-2-12

45ZV-2

COMPONENT OPERATION / Control Valve When coupler pin is locked Operation: 1. Bucket spool (1) moves to the right (illustrated below) when the auxiliary control lever is in the INSTALLATION position.

2. Pressurized oil from main circuit (2) is routed to the coupler cylinder bottom side through port B3 and load check valve (5) as neutral circuit (3) is blocked.

3. Therefore, pressurized oil in the coupler cylinder rod side is routed to drain circuit (4) and the hydraulic oil tank through port A3.

4. Consequently, the coupler cylinder rod is extended so that the coupler pin is inserted into the pin hole of the bucket.

Bucket

Coupler Cylinder

Ｂ3

1

5

Ａ3

4

Hydraulic Oil Tank

3

2 T4FGE-03-02-009

T3-2-13

45ZV-2

COMPONENT OPERATION / Control Valve When coupler pin is unlocked Operation: 1. Auxiliary spool (1) moves to the left (illustrated below) when the auxiliary control lever is in the REMOVAL position.

2. Pressurized oil from main circuit (2) is routed to the coupler cylinder rod side through port A3 and load check valve (5) as neutral circuit (3) is blocked.

3. Therefore, pressurized oil in the coupler cylinder bottom side is routed to drain circuit (4) and the hydraulic oil tank through port B3.

4. Consequently, the coupler cylinder rod is retracted so that the coupler pin comes out from the pin hole of the bucket.

Bucket

Coupler Cylinder

Ａ3

Ｂ3

1

5

4

Hydraulic Oil Tank

3

2 T4FGE-03-02-010

T3-2-14

45ZV-2

COMPONENT OPERATION / Control Valve MAIN RELIEF VALVE The main relief valve prevents pressure inside the main circuit from increasing over the relief valve set pressure when operating loading circuit cylinders.

This function prevents oil leakage from the hoses and piping fittings as well as cylinder breakage.

Relief Operation 1. Pressure in port HP (main circuit) acts on the pilot poppet through orifice A in the main poppet and orifice B in the seat.

2. When pressure in port HP reaches the set force of spring B, the pilot poppet is opened, pressurized oil from passage A flows to port LP (hydraulic oil return to tank) through the outer circumference of the sleeve.

3. At this time, a pressure difference occurs between port HP and the spring chamber due to orifice A. 4. When this pressure difference reaches the set force of spring A, the main poppet moves to the right and is opened. Pressurized oil from port HP flows to port LP. 5. Consequently, pressure in Port HP (main circuit) decreases.

6. When pressure in Port HP (main circuit) decreases to the relief valve specified level, the main poppet is closed by the force of spring A.

T3-2-15

45ZV-2

COMPONENT OPERATION / Control Valve During Normal Operation:

Orifice A

Main Poppet

Seat

Orifice B

Passage A

Spring B

HP

LP Sleeve

Spring A

Spring Chamber

Pilot Poppet

T4FG-03-02-013

During Relief Operation: Main Poppet

Orifice A Seat

Orifice B

Passage A

Spring B

HP

LP Sleeve

T4FG-03-02-014

Spring A

Spring Chamber

T3-2-16

Pilot Poppet

45ZV-2

COMPONENT OPERATION / Control Valve OVERLOAD RELIEF VALVE (WITH MAKE-UP FUNCTION) The overload relief valves are provided with the circuits in the bottom and the rod sides of the bucket and in the bottom and the rod sides of the coupler (auxiliary). The overload relief valve controls pressure in each of these circuits that is caused by an external force as when driving against and pushing the bucket.

It also makes up or replenishes oil by drawing oil from the hydraulic oil tank port in to prevent cavitation or a void when pressure in the front attachment circuit decreases.

Make-Up Operation 1. When pressure in port HP (front attachment circuit) decreases lower than pressure in port LP (hydraulic oil tank), the sleeve moves to the right.

2. Hydraulic oil in port LP flows to port HP and cavitation or a void is prevented.

3. When pressure in port HP increases more than the specified level, the sleeve is closed by the force of spring C.

Bottom Side and Rod Side Circuits of Bucket Relief Operation 1. Pressure in port HP (front attachment circuit) acts on the pilot poppet through the orifice in the piston.

2. When pressure in port HP reaches the set force of spring B, the pilot poppet is opened, pressurized oil from passage A flows to port LP (hydraulic oil return to tank) through the outer circumference of the sleeve.

3. At this time, a pressure difference occurs between port HP and the spring chamber due to the orifice.

4. When this pressure difference reaches the set force of spring A, the main poppet is opened and pressurized oil from port HP flows to port LP. 5. Consequently, the pressure in Port HP (front attachment circuit) decreases.

6. When pressure in Port HP (front attachment circuit) decreases to the relief valve specified level, the piston and the main poppet are closed by the force of spring A. The circuit in the bottom and the rod sides of the coupler (auxiliary) are also relieved in the same way.

T3-2-17

45ZV-2

COMPONENT OPERATION / Control Valve During Normal Operation: Main Poppet

Sleeve

Spring A

Passage A

Spring B

HP

LP (To Tank) Orifice

Piston

T4GB-03-02-030

Spring Chamber

During Relief Operation: Main Poppet

Sleeve

Pilot Poppet

Spring A

Spring C

Passage A Spring B

HP

Orifice

Piston

LP (To Tank)

T4GB-03-02-031

Spring Chamber

Pilot Poppet

During Make-Up Operation: Sleeve

HP

LP (To Tank)

T4GB-03-02-032

Spring C

T3-2-18

45ZV-2

COMPONENT OPERATION / Control Valve MAKE-UP VALVE The make-up valve prevents cavitation or a void from forming in the lift arm rod side circuit.

As for other cylinder circuits, cavitation is prevented by the make-up function of each overload relief valve.

In Neutral 1

2

3

4

Operation: 1. Pressurized oil in port HP (actuator circuit) acts on spring chamber (4) through passage (2) in poppet (1). Therefore, pressure in port HP is equal to that in spring chamber (4).

2. As pressure in port HP is high and the force to close poppet (1) (pressure in spring chamber (4) × pressure area S2) is greater than the force to open poppet (1) (pressure at cylinder side × pressure area S1), poppet (1) is forced to close.

S2

S1

HP

LP (To Tank) T4FG-03-02-015

In Operation 1

3. When pressure in port HP is lower than that in port LP, the force to close poppet (1) is equal to the spring (3) force.

4. When the force to open poppet (1) (pressure in port T × (pressure area S2 - S1) is greater than the force to close poppet (1) (spring (3) force), poppet (1) is opened and hydraulic oil is supplied to port HP.

2

3 4

S2

S1

HP

5. Therefore, cavitation in port HP is prevented.

LP (To Tank) T4FC-03-02-016

1 - Poppet 2 - Passage

T3-2-19

34-

Spring Spring Chamber

45ZV-2

COMPONENT OPERATION / Control Valve (Blank)

T3-2-20

45ZV-2

COMPONENT OPERATION / Steering Valve OUTLINE The steering valve is located between the priority valve and the steering cylinder.

The overload relief valve and the make-up valve are provided in the steering valve.

The steering valve supplies pressurized oil from the main pump to the steering cylinders through the priority valve in response to the movement of the steering wheel. (Refer to SYSTEM / Hydraulic System / Steering Circuit.)

The overload relief valve is operated when the circuit pressure between the steering cylinder and the steering valve is beyond the relief valve set pressure.

Port L (for Left Steering)

Port LS

The make-up valve is operated when the circuit pressure between the steering cylinder and the steering valve is lower than the pressure in the hydraulic oil tank.

Port R (for Right Steering)

Steering Wheel

T4FC-03-04-001

Port T (to Hydraulic Oil Tank)

Port P (from Priority Valve)

T3-3-1

45ZV-2

COMPONENT OPERATION / Steering Valve STRUCTURE 11

12

10

The steering valve consists of gerotor (8), drive (7), sleeve (3), spool (4), pin (5), housing (1), and centering springs (2).

When the steering wheel is rotated, spool (4) rotates and an oil passage is provided between spool (4) and sleeve (3). Pressurized oil from the main pump is controlled by spool (4) and sleeve (3), and flows to the steering cylinder.

9

Centering springs (2) are installed to both spool (4) and sleeve (3). When the steering wheel is released, centering spring (2) returns sleeve (3) to the neutral position.

1

2

5

4

3

7

6

8

T4FG-03-03-004

4

2 3 1

Port R

Port L

5 Port P Port T

10 9

8

7

6 T4FC-03-04-002

1 - Housing 2 - Centering Spring 3 - Sleeve

456-

Spool Pin Plate

789-

T3-3-2

Drive Gerotor Spacer

10 - Cap 11 - Check Valve 12 - Check Valve

45ZV-2

COMPONENT OPERATION / Steering Valve OPERATION Sleeve (3), spool (4), and drive (7) are mutually connected by pin (5). When the steering wheel (spool (4)) is rotated, a relative displacement angle arises between sleeve (3) and spool (4) due to the long hole of spool (4).

Port L

Port R

7

The movement of the steering wheel is transmitted only to spool (4), and port P (from the main pump) is connected to port R (to the main valve) or port L through sleeve (3) and spool (4).

4

3

Steering Wheel

Port T Port P

T4FG-03-03-006

Steering Wheel

T4FG-03-03-005

5

4

3

T3-3-3

7

45ZV-2

COMPONENT OPERATION / Steering Valve Left Steering 1. When the steering wheel is rotated to the left, spool (4) rotates. Pressurized oil from the main pump flows in the order of port P - sleeve (3) spool (4) - sleeve (3) - housing (1) - gerotor (8).

4. When pressurized oil from the main pump flows to gerotor (8), gerotor (8) rotates to the left. Rotation of gerotor (8) is transmitted to sleeve (3) through drive (7), and sleeve (3) rotates to the left.

2. Pressurized oil from gerotor (8) flows in the following order; housing (1) - sleeve (3) - spool (4) - sleeve (3) - port L – the steering cylinders. The steering cylinders direct the machine to the left.

5. When sleeve (3) rotates at the same rate as spool (4), the passage between sleeve (3) and spool (4) is closed and the operation of the steering cylinders is stopped.

3. Returning oil from the steering cylinders flows to port R, flows in the following order; housing (1) sleeve (3) - spool (4) - sleeve (3) - port T, and returns to the hydraulic oil tank.

6. Gerotor (8) rotates in response to rotation of the steering wheel, and the steering cylinders are operated in response to the amount of turns of the steering wheel.

Steering Cylinders

T

L

R

P

Steering Pump

1 8 7

T4FG-03-03-001

4

2

3

Steering Valve

T3-3-4

45ZV-2

COMPONENT OPERATION / Steering Valve Right Steering

Neutral

When the steering wheel is rotated to the right, pressurized oil from the main pump flows in the following order; port P - port R – the steering cylinders. The steering cylinders direct the machine to the right.

Returning oil from the steering cylinders flows in the following order; port L - port T and returns to the hydraulic oil tank.

When the steering wheel is not rotated, pressurized oil from the main pump acts on port P in the steering valve.

However, pressurized oil does not flow to the steering cylinders as they are blocked by spool (4). Therefore, the steering cylinders do not operate.

Right Steering: T

R

L

P

T4FG-03-03-002

In Neutral: T

P

4

T4FG-03-03-003

T3-3-5

45ZV-2

COMPONENT OPERATION / Steering Valve OVERLOAD RELIEF VALVE Make-Up Valve

The overload relief valves are located in the steering valve and prevent the circuit pressure between the steering cylinder and the steering valve from increasing beyond the relief valve set pressure.

When an external force is applied to the left and right steering directions, oil pressure is developed in the circuit. When the circuit pressure exceeds the set spring force of the overload relief valve, the poppet in the overload relief valve moves to the right and the oil passage is opened so that pressurized oil flows to the hydraulic oil tank.

Overload Relief Valve

Overload Relief Valve

Port T

When the circuit pressure decreases, the poppet moves to the left due to the spring force so that the oil passage is closed again.

T4FG-03-03-006

MAKE-UP VALVE The make-up valves are located in the steering valve.

When the circuit pressure between the steering cylinder and the steering valve is lower than the pressure in hydraulic oil tank, the make-up valve draws the hydraulic oil from port T in order to prevent cavitation or a void in the circuit.

When the circuit pressure between the steering cylinder and the steering valve is lower than the pressure in the hydraulic oil tank, the ball of the make-up valve moves to the right and the oil passage is opened. Therefore, hydraulic oil from port T is drawn and delivered to the circuit with low oil pressure between the steering cylinder and the steering valve.

When the circuit pressure between the steering cylinder and the steering valve increases, the ball is moved to the left by pressurized oil and the oil passage is closed again.

T3-3-6

45ZV-2

COMPONENT OPERATION / Steering Valve B

Poppet

Spring

Overload Relief Valve

A A

Section A-A

A

T4FC-03-04-011

A B T4FC-03-04-009

C

Section B-B

T4FG-03-03-004

Ball

Make-Up Valve

D D

Section D-D

T4FC-03-04-012

D

D View C

T4FC-03-04-010

T3-3-7

45ZV-2

COMPONENT OPERATION / Steering Valve (Blank)

T3-3-8

45ZV-2

COMPONENT OPERATION / HST Pump OUTLINE The HST pump is a two-direction displacement angle swash plate type variable displacement plunger pump.

The forward/reverse selection solenoid valve (3), the pump solenoid valve (2), the cutoff valve (4), the high pressure relief valves (5,10), the low pressure relief valve (8), and the HST charging pump (7) are provided in the HST pump.

The HST pump (6) consists of the shaft, the plunger, the cylinder block, the displacement angle control cylinder, and the swash plate.

Engine power is transmitted to the shaft of the HST pump directly. The shaft rotation of the HST pump is also transmitted to the main pump unit through the coupling.

3

A

2

4 5

View A

15 1

16

6 7

17

8 9

14

13

12

10

11

T4FG-03-04-001

1 - Displacement Angle Control Cylinder 2 - Pump Solenoid Valve

6 - Port MB

11 - Port S

16 - Port Fa

7 - HST Charging Pump

12 - Port G

17 - Port B (Port A at Opposite Side)

3 - Forward/Reverse Selection Solenoid Valve 4 - Cutoff Valve 5 - High-Pressure Relief Valve

8 - Low-Pressure Relief Valve

13 - Port T2

9 - Port MA 10 - High-Pressure Relief Valve

14 - Port PS (T1) 15 - Port Fe

T3-4-1

45ZV-2

COMPONENT OPERATION / HST Pump 2

3

Port T2

Port Fa

Port Fe

Port T1

(Port MB) Port B

1 4

Port A

7

Port G

6

Port S

5

(Port MA) T4FG-03-04-002

1 - Displacement Angle Control Cylinder 2 - Forward/Reverse Selection Solenoid Valve 3 - Pump Solenoid Valve 4 - HST Charging Pump

5 - Cutoff Valve

9 - Swash Plate

12 - Pin

6 - Low-Pressure Relief Valve

10 - Plunger

13 - Displacement Angle Piston

7 - High-Pressure Relief Valve 8 - Shaft

11 - Cylinder Block

14 - Spring

1

3

2

5

7

4 8 6 7 T4FG-03-04-003

T3-4-2

45ZV-2

COMPONENT OPERATION / HST Pump Rotary Group Part:

12

8

9

10

11 T4FG-03-04-004

Displacement Angle Control Cylinder Part: 3

2 1 1

13

14

12

13

12

9 T4FG-03-04-005

T3-4-3

45ZV-2

COMPONENT OPERATION / HST Pump Operation The shaft is splined to the cylinder block. The plungers are installed in the cylinder block.

Engine power is transmitted to the shaft of the HST pump directly. As the shaft is rotated, the plungers rotate with the cylinder block together.

The plungers slide on the swash plate so that the plungers reciprocate in the cylinder block as the swash plate is positioned at an angle toward the plungers. By this reciprocation, hydraulic oil is drawn in and delivered. Either port A or port B is selected as a delivery port by the displacement angle control of the swash plate.

Delivery Flow Rate Increasing and Decreasing Operation HST pump delivery flow rate is varied by changing the displacement angle of the swash plate and changing the stroke of the plunger.

As the swash plate is connected to the displacement angle piston of the displacement angle cylinder through the pin, the swash plate operates according to the movement of the displacement angle piston.

The displacement angle piston has a built-in spring, which acts on the direction of the displacement angle piston to return to neutral. The displacement angle piston position is moved by the displacement angle control pressure applied to the displacement angle cylinder. Therefore, the displacement angle of the swash plate is changes as required.

T3-4-4

45ZV-2

COMPONENT OPERATION / HST Pump Rotary Group Part:

Inlet Pin A

Shaft

B Plunger Swash Plate

Cylinder Block

Outlet

T4FG-03-04-004

Displacement Angle Control Cylinder Part:

Displacement Angle Piston

Spring

Pin

Displacement Angle Piston

T3-4-5

Pin

Swash Plate

T4FG-03-04-005

45ZV-2

COMPONENT OPERATION / HST Pump Recovery Moment Function 1. α (alpha) and β (beta) are the ranges of pressurized oil applied to the plunger through the valve plate. The comparison between α and β is shown below. α<β 2. When the HST motor is loaded, the pressure in the circuit from the HST pump to the HST motor increases. Increased pressure acts on the plunger of the HST pump.

3. As there is a rage difference between α (alpha) and β (beta) on the high-pressure port of the valve plate, the pressurized oil force acting on the plunger through β (beta) is greater than that through α (alpha).

The range difference of (β - α) × Circuit pressure force pushes the bottom of the swash plate as it pivots around the displacement angle center.

Then, the swash plate moves to neutral.

(Recovery moment.)

Swash Plate

Plunger

Valve Plate

T4FG-03-04-007

Low-Pressure Port

High-Pressure Port

Range α

4. The range of motion (angle) of the swash plate is in proportion to the HST circuit pressure (between HST pump and HST motor).

When pressure is low, the motion angle is smaller.

When pressure is high, the motion angle is greater.

Displacement Angle Center

Range β

Valve Plate T487-03-04-068

T3-4-6

45ZV-2

COMPONENT OPERATION / HST Pump FORWARD / REVERSE SELECTION SOLENOID VALVE The forward/reverse selection solenoid valve controls the pump displacement angle direction and changes the delivery direction (port A or port B) of pressurized oil.

Pressurized oil from the pump solenoid valve to control the displacement angle control cylinder acts on the forward/reverse selection solenoid valve.

The forward or the reverse selection solenoid valve is energized and the spool is operated according to the signal from the FNR lever.

Then, the hydraulic circuit to the corresponding displacement angle control cylinder is connected.

Therefore, the pump displacement angle is controlled and the delivery direction of pressurized oil is changed.

Displacement Angle Control Cylinder

A

Reverse Selection Solenoid Valve

Spool

Forward Selection Solenoid Valve

To Port B (Reverse) From Charging Pump

HST Pump

To Port A (Forward) T4FC-03-08-005

Displacement Angle Control Cylinder

Forward/Reverse Selection Solenoid Valve Reverse Selection Solenoid Valve View A

Port B (Port A at Opposite Side)

Forward Selection Solenoid Valve

T4FG-03-04-001

T3-4-7

45ZV-2

COMPONENT OPERATION / HST Pump PUMP SOLENOID VALVE The pump solenoid valve is a proportional solenoid valve and controlled by the command signal from the HST control unit.

The command signal is a current value. The pump displacement angle is the maximum at the maximum current value and is the minimum at the minimum current value.

The spool position is changed by changing the current value so that the servo piston operation is controlled.

Max. Displacement Angle Motor Displacement Angle

Min. Displacement Angle Max. Current Min. Current Value Value Command Signal Current

T4FG-03-04-009

Pump Solenoid Valve

P2

P1 T4FG-03-04-010

Pump Solenoid Valve

P1

P1 Q

Forward/Reverse Selection Solenoid Valve (Forward Side)

P2

T3-4-8

P2

Forward/Reverse Selection Solenoid Valve (Reverse Side)

T4FG-03-04-008

45ZV-2

COMPONENT OPERATION / HST Pump Constant Torque Control The command signal current from the HST controller that controls swash plate movement prevents engine overload stop by controlling the pump's displacement.

When the engine is loaded and the engine speed decreases, the HST controller reduces the command signal current to the pump solenoid valve.

The displacement of the HST pump and the inlet torque of the pump are both reduced.

Pump displacement is balanced with the engine torque.

When the load is increased, the engine speed is slightly decreased, and the HST controller compensates for the load and against the HST pump displacement angle to use the available engine torque without stopping the engine.

T3-4-9

Torque T

P Engine Torque

Overloading State

P’

Stable State

Pump Torque

N N’ N

Engine Speed T81S-03-01-011

45ZV-2

COMPONENT OPERATION / HST Pump CUTOFF VALVE The cutoff valve regulates the maximum circuit pressure and protects the circuit on the high pressure side.

Control Pressure of Displacement Angle Control Cylinder

When the high-pressure side in the travel circuit reaches the specified circuit pressure, the control pressure acting on the swash plate displacement angle control cylinder through the forward/reverse selection solenoid valve is reduced.

B

A

When the control pressure of the displacement angle control cylinder is reduced, the pump displacement angle is balanced in order to deliver only the pressurized oil flow rate corresponding to the specified pressure.

T81S-03-01-019

Heat generation is lessened as the circuit pressure on the high-pressure side is regulated by the pump flow rate control.

The cutoff valve regulates circuit pressure on the high-pressure side.

Therefore, the cutoff valve pressure is usually set at 2 2 to 3 MPa (20 to 31 kgf/cm , 290 to 435 psi) lower than that of the high pressure relief valve.

Hexagon Nut

Spring

To Forward/Reverse Selection Solenoid Valve

To Hydraulic Oil Tank

To HST Close Circuit A

To HST Close Circuit B

T81S-03-01-022

Screw with Hexagon Hole

Guide

Spool

Piston

T3-4-10

Barrel

Spool

Valve Seat

45ZV-2

COMPONENT OPERATION / HST Pump HIGH-PRESSURE RELIEF VALVE The high-pressure relief valve regulates the maximum pressure of the travel circuit and protects the circuit on the high-pressure side. The high-pressure relief valve has a check valve function for HST charge.

When the pressurized oil flow rate to the inlet circuit is low, the HST charge pressurized oil is routed to the inlet circuit.

LOW-PRESSURE RELIEF VALVE The low-pressure relief valve regulates the HST charge pressure.

The low-pressure relief valve always operates during machine operation. The relieved oil returns to the hydraulic oil tank through the pump housing for lubrication and cooling.

Hexagon Nut

T81S-03-01-020

Spring

Spring Seat

Piston

Adjusting Screw

Plug

NOTE: The illustration shows the low-pressure relief valve.

T3-4-11

45ZV-2

COMPONENT OPERATION / HST Pump HST CHARGING PUMP The HST charging pump is coaxially connected to the shaft of the HST pump. Therefore, when the engine runs, the HST charging pump rotates with the HST pump.

The HST charging pump is a trochoid type pump.

The inner rotor and the outer rotor rotates together by engaging so that hydraulic oil is drawn to chamber A and delivered from chamber B.

Inner Rotor

Chamber B Outer Rotor

Chamber A T4FC-03-08-100

T3-4-12

45ZV-2

COMPONENT OPERATION / HST Motor OUTLINE HST motor is a bent-axis type variable displacement axial plunger motor and consists of the regulator, the shaft, the plunger, the rotor, and the valve plate.

The motor solenoid valve is provided in the regulator of the HST motor.

HST Motor: Port T1

View X

Regulator

Port A

Port B

X

Port T2

EP Motor Solenoid Valve

T4FG-03-05-001

1

2

Port T1

Port B

Port A

Port T2 T4FG-03-05-002

1 - Regulator

2 - EP Motor Solenoid Valve

T3-5-1

45ZV-2

COMPONENT OPERATION / HST Motor HST Motor: View X

1

X

2 T4FG-03-05-001

Rotary Group Part:

4

5

3

6 10 7

9 8

T4FC-03-09-006

1 - Regulator 2 - EP Motor Solenoid Valve 3 - Shaft

4 - Plunger 5 - Rotor 6 - Valve Plate

7 - Control Rod 8 - Spring

T3-5-2

9 - Center Pin 10 - Bearing

45ZV-2

COMPONENT OPERATION / HST Motor (Blank)

T3-5-3

45ZV-2

COMPONENT OPERATION / HST Motor OPERATION The output shaft of the rotary group is supported to the motor casing by two bearings. The center pin connects the output shaft to the rotor and is located in the rotor center hole. The valve plate is provided in the rotor end.

The spring applies the appropriate force to the rotor and brings the rotor into contact with the valve plate.

There are seven plungers in the rotor.

Rotation direction of the HST motor is determined by entering pressurized oil into either port A or port B. When traveling forward, pressurized oil from the pump flows to the rotor through port B of the valve plate.

When the plunger is pushed by pressurized oil, component force (FV) of pushing force (F) rotates the output shaft.

As the output shaft rotates the rotor, the plungers reach port A in sequence.

When a plunger reaches port A, pressurized oil in the rotor is pushed by the plunger.

Therefore, pressurized oil is returned to the HST circuit.

The valve plate is connected to the regulator through the control rod. The valve plate position is changed by the operation of the regulator.

Thus, the HST motor speed is changed.

T3-5-4

45ZV-2

COMPONENT OPERATION / HST Motor

Output Shaft

Rotor

Spring Valve Plate

Bearing

Center Pin

Plunger

T202-03-06-003

FV

F

FR Plunger

Port B

Output Shaft

Valve Plate

Rotor

Port A

T487-03-05-006

T3-5-5

45ZV-2

COMPONENT OPERATION / HST Motor REGULATOR The regulator consists of the servo piston, the control rod, the balance spring, the spring, and the spool.

Valve Plate

The motor solenoid valve is provided in the regulator of HST motor.

Servo Piston

The servo piston of the regulator is connected to the motor valve plate via the control rod. When operating the servo piston, the valve plate position is changed.

Therefore, the motor displacement angle is changed and the motor speed is controlled.

Control Rod

Balance Spring

The servo piston operation is controlled by the motor solenoid valve.

Spring

Spool

Motor Solenoid Valve

T4FC-03-09-003

MOTOR SOLENOID VALVE The motor solenoid valve is a proportional solenoid valve and controlled by the command signal from the HST control unit.

The command signal is a current value.

The motor displacement angle is the maximum at the maximum current value and is the minimum at the minimum current value.

The spool position is changed by changing the current value so that the servo piston operation is controlled.

Maximum Displacement

Motor Displacement Angle

Minimum Displacement

Minimum Current Value

Maximum Current Value

Command Current

T3-5-6

45ZV-2

COMPONENT OPERATION / HST Motor Displacement Displacement Angle)

Angle Control (From Large Angle to Small Displacement

3. Therefore, the servo piston moves downward and the motor displacement angle decreases.

1. Pressurized oil from port B (or port A) flows to the plunger through the valve plate.

The other pressurized oil opens the check valve, and flows to the spool and the small chamber of the servo piston.

2. The motor solenoid valve receives the signal from the HST control unit. When the spool moves upward, pressurized oil in the large chamber of the servo piston flows to the hydraulic oil tank through the spool.

Spool

4. Consequently, the motor rotates at fast speed.

From HST Control Unit

EP Motor Solenoid Valve

Check Valve

B

Motor Circuit Pressure

A

Servo Piston

T4FG-03-05-003

NOTE: The illustration shows the circuit when traveling forward.

T3-5-7

45ZV-2

COMPONENT OPERATION / HST Motor Displacement Displacement Angle)

Angle Control (From Small Angle to Large Displacement

1. Pressurized oil from port B (or port A) flows to the plunger through the valve plate.

The other pressurized oil opens the check valve, and flows to the spool and the small chamber of the servo piston.

3. As for the pressure receiving area in the servo piston, as the area in the large chamber is larger than that in the small chamber, the servo piston moves upward to the position where the servo piston balances with the balance spring so that the motor displacement angle increases.

2. The motor solenoid valve receives the signal from the HST control unit.

When the spool moves downward, pressurized oil from port B (or port A) flows to the large chamber side of the servo piston through the spool.

Spool

4. Consequently, the motor rotates at slow speed.

Motor Solenoid Valve

From HST Control Unit

Balance Spring

Check Valve

B Motor Circuit Pressure

A

Servo Piston

T4FG-03-05-004

NOTE: The illustration shows the circuit when traveling forward.

T3-5-8

45ZV-2

COMPONENT OPERATION / Reduction OUTLINE The reduction box consists of the HST motor input shaft, input gear, output shaft, and output gear.

The reduction box transmits the output power from the HST motor to the output shaft.

The front of the output shaft is connected to the propeller shaft and the back is connected to the pinion shaft of the rear axle respectively.

Air Breather

Rear Axle HST Motor Mounting Port

Filler (Level) Plug

Drain Plug

Filler (Level) Plug

T4FG-03-06-001

T3-6-1

45ZV-2

COMPONENT OPERATION / Reduction CONSTRUCTION 2

1

3

4

5

HST Motor Mounting Port Pinion Shaft (Rear Axle)

Rear Axle

12 Rear Axle Support

11

10

8

9

7

6 T4FG-03-06-002

1 - HST Motor Input Shaft 2 - Roller Bearing 3 - Housing

456-

Input Gear Roller Bearing Oil Seal

789-

T3-6-2

Roller Bearing Output Gear Roller Bearing

10 - Oil Seal 11 - Output Shaft 12 - Output Flange

45ZV-2

COMPONENT OPERATION / Axle OUTLINE The axle consists of the differential, final drive, axle shaft, and brake.

(The brake is equipped with only the front axle.)

Final Drive

Axle Shaft

Power from the reduction box is transmitted to the front axle and the rear axle via the propeller shaft. Inside the axle, power is transmitted to the differential, divided into left and right, and drives the final drive and the wheels through the axle shaft.

Differential

Brake

A

View A

T4FG-03-07-001

T3-7-1

45ZV-2

COMPONENT OPERATION / Axle DIFFERENTIAL When the machine is steered or traveling on bumpy roads, the differential enables the left and the right drive wheels to rotate at different rotating speeds.

1

2

3

4

5

6

7

8

9

10 11 12

16

13 15

14 Speed Sensor Mounting Part

T4FG-03-07-002

12345-

Roller Bearing Side Gear A Ring Gear Differential Gear Body Pinion Gear

6789-

Spider Differential Gear Case Side Gear B Roller Bearing

10 - Pinion Shaft 11 - Roller Bearing 12 - Spacer 13 - Roller Bearing

T3-7-2

14 - Output Flange 15 - Oil Seal 16 - Ring Nut

45ZV-2

COMPONENT OPERATION / Axle Function

• Purpose of Differential When the machine is steered, as the inner wheel turns with a smaller radius, the outer wheel needs to rotate faster for smooth steering.

Suppose the rear wheel drives by directly installing the gear to the propeller shaft with a shaft having no differential. Suppose the rear wheel, with installing gear to propeller shaft directly is driven by the shaft having no differential.

In this case, the outer wheel and the inner wheel always rotate at the same amount. So when the machine is steered, the outer wheel cannot rotate more than the inner wheel, and skidding sideways or tire wear takes place. As the axle shaft is subjected to torsional stress, transmission of drive force becomes unstable.

When a differential is installed, as the inner and the outer wheels can rotate at different rotating speeds, the problem mentioned above is eliminated.

Extension Line of Rear Wheel Centers

In Turning of Machine

In Traveling of Machine on Rough Roads T202-03-05-005

T3-7-3

45ZV-2

COMPONENT OPERATION / Axle • Principle of Differential W

W

Operational principle of the differential is explained comparing it to the racks and the pinion gear in the drawing.

When load W is equally applied to racks A and B, if C is moved upward by the distance of H, racks A and B move by the same distance of H in unison with the pinion together.

W C

C H

H

H

If moved by removing the load to rack B, the pinion rotates on rack A (with load applied) and moves rack B upward. At this time, the distance where rack B moves is longer than the distance where the pinion moves while rotating.

2H

Rack (A)

Distance where rack B moves can be calculated by using the equation of H+H=2H. This principle is applied to the differential.

Rack (B)

Rack (A)

Pinion

Rack (B)

Pinion T202-03-05-006

• Operation of Differential 10

9

- In Traveling Straight 1

In case resistances applied to axle shafts (7, 8) connected by splines to differential side gears (2, 3) are the same, or in case the machine is traveling straight on plane roads, differential pinion gears (1, 4) do not rotate.

Differential pinion gears (1, 4) and side gears (2, 3) remain fixed by being mutually geared, and rotate with housing (6) connected with ring gear (9).

In case all parts are rotating solidly like this, differential function of the differential does not work, and gears (1, 2, 3, 4) play only the role of joints to connect axle shafts (7, 8).

T3-7-4

8

2

3

4

7

6

T487-03-06-014

45ZV-2

COMPONENT OPERATION / Axle - When Steering When the machine is turned, uneven resistances are applied to the drive wheels.

Therefore, due to the difference of the resistances applied to the inner and outer wheels, differential pinion gears (1, 4) start revolving on side gears (2, 3), while rotating round the pinion shaft.

Consequently, in case the resistance force applied to shaft (7) is great, pinion gears (1, 4) rotate in the same direction as the rotational direction on side gear (2) of shaft (7).

The speed of shaft (7) is lowered, the same amount of the speed reduction is applied to speed up shaft (8) and the differential rotation action takes place.

Suppose ring gear (9) is driven by drive pinion (10) at the speed of 100. In the condition of the machine traveling straight, the drive wheels on the both sides rotate at the same speed.

10

9

1

8

2

3

4

7

6

T487-03-06-014

However, in case the machine is turned and the speed of the right drive wheel is lowered to 90, the left wheel turns at the speed of 100+(100−90)=110 as the speed of 10(100−90=10) is added to the speed of the left wheel.

If ring gear (9) rotates at the speed of 100, the summation of the speeds of the left and right wheels becomes always 200 regardless of movement of the respective wheels.

T3-7-5

45ZV-2

COMPONENT OPERATION / Axle LIMITED SLIP DIFFERENTIAL (LSD) (OPTIONAL)

Operational Principle

The wheel loader is often operated on slippery ground as when used in sand and muddy soil application. In places like these, the tires will slip due to tractive conditions.

LSD is designed so that the clutch discs are inserted between the side gear and the differential gear case, which restricts the movement of the two axle shafts and helps keep tire speeds close to the same.

As tractive force may be transmitted to the slipping tire and not to the tire firmly contacting the work site surface, not only is the operation of the wheel loader made less efficient but tire life is also shortened.

As one shaft begins to turn faster due to tire slippage on a slick surface, that clutch disc set engages due to the opposing spider gear bias ratio forcing the small amount of slack toward the side that is slipping.

To help avoid this, the Limited Slip Differential (LSD) is provided with a differential clutch device to keep the movement of the left and right wheels at close to the same pace so that traction is better.

This creates better tractive effort to move the machine.

Ring Gear

Pinion Gear Side Gear

Spider

Differential Gear Case

Disc Friction Washer

T3-7-6

Clutch Disc

T4FG-03-07-011

45ZV-2

COMPONENT OPERATION / Axle Traveling Straight with the Same Road Resistances to Left and Right Tires As the differential pinion gear and the left and right pinion gears rotate at close to the same rate, the tractive forces of the left and right tires are similar.

Pinion Gear Side Gear Differential Gear Case

Traveling on Ground with Less Traction (Different Road Resistances to Left and Right Tires) Tractive force is transmitted to the differential gear case, pinion gear and side gear from the ring gear.

P

When this happens, thrust force (P) occurs due to rotation of the pinion gear so that the side gear is pushed by the rounded surface of the pinion gears.

The clutch disc is geared with the differential gear case through the friction washer. The side gears are fixed to the clutch discs by splines, normally the left and right gears rotate at the same speed.

T4FG-03-07-012

Friction Washer

Clutch Disc

Disc

When tractive force sent to a slipping tire is greater than the work surface resistance, part of the torque of the slipping tire is sent to the opposite tire and the tire contacting the work surface with traction is provided with more torque.

Until the clutch disc begins to slip, the left and right gears solidly rotate at a constant speed.

T3-7-7

45ZV-2

COMPONENT OPERATION / Axle SERVICE BRAKE The brake is a wet-type spring set hydraulic released multi-disc brake and is assembled in the axle case.

The disc brake is installed to the front wheels of the machine.

• When brake is applied Oil pressure from the brake valve acts on the back of brake piston (5) and moves brake piston (5).

Brake disc (2) and brake plate (3) are fitted tightly via end plate (4).

The inner surface of brake disc (2) is fitted to differential gear case B (8). The outer surface of brake plate (3) is fixed to axle case (1).

The rotation of brake disc (2) stops and differential gear case B (8) stops.

In addition, brake piston (5) pushes return spring (6) via end plate (4). When piston (11) is pushed further, clutch plate (9) and clutch disc (10) are firmly pressed together.

The inner surface of clutch disc (10) is fitted to shaft (7). The outer surface of clutch disc plate (9) is fixed to differential gear case B (8).

• When brake is released When oil pressure from the brake valve is decreased, brake piston (5) is returned by return spring (6).

Brake disc (2) is freed and the machine can travel.

T3-7-8

45ZV-2

COMPONENT OPERATION / Axle

2

1

10

9

11

3

8

4

Brake Oil Pressure

5

6

7

T4FG-03-07-003

1 - Axle Case 2 - Brake Disc 3 - Brake Plate

4 - End Plate 5 - Brake Piston 6 - Return Spring

7 - Axle Shaft 8 - Differential Gear Case B 9 - Clutch Disc Plate

• When bake is applied 2

3

2

10 - Clutch Disc 11 - Piston

• When brake is released 2

4

3

2

4

From Brake Valve

10

9

11

6

To Brake Valve

10

5 T4FG-03-07-004

T3-7-9

9

11

6

5 T4FG-03-07-005

45ZV-2

COMPONENT OPERATION / Axle PARKING BRAKE The parking brake is a wet-type spring apply hydraulic released multi-disc brake. The brake is released when the parking brake release pressure acts on the oil chamber in the parking brake piston.

The parking brake is used in combination with the service brake and is installed in the front axle.

• When brake is applied When the parking brake switch is set to the ON position, the brake release pressure from the parking brake solenoid valve does not act on the oil chamber in parking brake piston (5). Spring (6) moves parking brake piston (5) to the left so that piston pin (7) is moved to the left.

Brake disc (2) and brake plate (3) are firmly pressed together.

The inner surface of brake disc (2) is splined to shaft (8) through differential gear case (10). The outer surface of brake plate (3) is fixed to axle case (1).

Therefore, the rotation of brake disc (2) stops so that the parking brake is applied.

• When brake is released When the parking brake switch is set to the OFF position, the brake release pressure from the parking brake solenoid valve acts on the oil chamber in parking brake piston (5).

Parking brake piston (5) moves to the right so that piston pin (7) is moved to the right by return spring (9).

Then, brake disc (2) is freed so that the parking brake is released.

T3-7-10

45ZV-2

COMPONENT OPERATION / Axle 1

3

2

Parking Brake Release Pressure

4

Oil Chamber

5 6

10

9

8

7 T4FG-03-07-003

1 - Axle Case 2 - Brake Disc 3 - Brake Plate

4 - End Plate 5 - Parking Brake Piston 6 - Spring

7 - Piston Pin 8 - Shaft

• When brake is applied 2

3

2

9 - Return Spring 10 - Differential Gear Case B

• When brake is released 4 To Parking Brake Solenoid Valve

5

6

2

3

2

4

9

7 T4FG-03-07-006

T3-7-11

From Parking Brake Solenoid Valve

5

6

7 T4FG-03-07-007

45ZV-2

COMPONENT OPERATION / Axle FINAL DRIVE / AXLE SHAFT The final drive is the planet torque multiplying device to reduce the speed in the power transmission system.

As for power transmission, power from the differential is transmitted from the shaft, rotates three planetary gears in the ring gear, and transmits rotation of the planetary gear to the planetary carrier.

Final Drive Axle Shaft

Ring Gear

Planetary Gear

Planetary Carrier

Shaft

Housing

T4FG-03-07-010

T4GD-03-10-002

T3-7-12

45ZV-2

COMPONENT OPERATION / Brake Master Cylinder OUTLINE The brake master cylinder supplies pressurized oil in proportion to brake pedal stroke and operates the front wheel service brake.

The brake master cylinder is connected to the brake pedal via the link.

When the brake pedal is depressed, the HST controller receives the signal from the brake angle sensor and acts on the pump control valve in the HST pump so that delivery flow rate from the HST pump is reduced.

(Refer to SYSTEM / Hydraulic System.)

Brake Pedal

Brake Light Switch

Brake Pedal

Brake Angle Sensor

Brake Valve T4FG-03-08-001

T3-8-1

45ZV-2

COMPONENT OPERATION / Brake Master Cylinder STRUCTURE The brake master cylinder consists of the pressure chamber and reservoir chamber.

Then, they are connected via the relief port.

The brake master cylinder has a push rod, piston, return spring, the P (primary) cup which seals and pressure chamber, and the S (secondary) cup which seals the reservoir.

From Brake Oil Tank

Push Rod

S (Secondary) Cup

Reservoir Chamber

Relief Port Piston

To Front Axle Brake Pedal

T4FG-03-08-002

P (Primary) Pressure Cup Chamber

T3-8-2

Return Spring

45ZV-2

COMPONENT OPERATION / Brake Master Cylinder OPERATION • When brake pedal is operated 1. When the brake pedal is not depressed, piston (3) is pushed to the left by return spring (4).

2. Consequently, when the brake pedal is in neutral, the pressure chamber and the reservoir chamber are connected via the relief port, and are connected to brake oil tank.

3. When the brake pedal is depressed, push rod (1) pushes piston (3) to the right and compresses return spring (4).

4. Therefore, the pressure chamber and the reservoir chamber are blocked and brake oil in the pressure chamber is routed to the brake front axle side.

Brake Oil Tank

3

2

Reservoir Chamber

1

Relief Port

To Front Axle Brake Pedal

5

Pressure Chamber

4

T4FG-03-08-003

1 - Push Rod 2 - S (Secondary) Cup

3-

Piston

4-

T3-8-3

Return Spring

5-

P (Primary) Cup

45ZV-2

COMPONENT OPERATION / Brake Master Cylinder (Blank)

T3-8-4

45ZV-2

COMPONENT OPERATION / Others GEAR PUMP The gear pump (main pump) is connected to the HST pump in tandem. Engine output power is transmitted to the HST pump shaft directly. The rotation of the HST pump shaft is transmitted to the gear pump.

Drive Gear

The gear pump (main pump) supplies pressurized oil to the main and steering circuit.

When the shaft rotates, the drive gear rotates, so that the driven gear is rotated. Pressurized oil drawn to the pump fills the spaces between the gear teeth and housing, and is delivered to the outlet port along the inside of the housing.

Outlet Port

Inlet Port

Housing

Driven Gear T487-03-01-006

Drive Gear

HST Pump

Driven Gear

T3-9-1

T4FG-03-09-001

45ZV-2

COMPONENT OPERATION / Others PROPELLER SHAFT The propeller shaft is installed between the gear reduction box and the front axle.

The propeller shaft transmits the power from the gear reduction box to the front axle. The universal joint provides flexibility to the shaft.

Between Front Axle and Reduction

Universal Joint

Universal Joint

T4GD-03-12-001

T3-9-2

45ZV-2

COMPONENT OPERATION / Others PARKING BRAKE SOLENOID VALVE Pressurized oil from the HST charging pump is accumulated in the HST pump and its pressure always acts on the inlet of the parking brake solenoid valve.

From HST Pump

When the parking brake solenoid valve is activated, pressurized oil in the HST charging pump flows to the parking brake through the spool and releases the parking brake.

1

To Hydraulic Oil Tank

2

3

4

5

6

7

T4FC-03-06-004

1 - Parking Brake Piston Chamber (Front Axle) 2 - Plug

3 - Body

5 - Spool

4 - Spring

6 - O-Ring

T3-9-3

7 - Solenoid

45ZV-2

COMPONENT OPERATION / Others (Blank)

T3-9-4

45ZV-2