KCM WHEEL LOADER 30ZV-2 40ZV-2A 42ZV-2 SHOP MANUAL 93202-00032 (1)

30ZV-2 40ZV-2A 42ZV-2

93202-00032 June 2017

SHOP MANUAL

SHOP MANUAL

WHEEL LOADER

- General Information - Operational Principle

30ZV-2 40ZV-2A 42ZV-2 Technical Manual -General Information -Operational Principle

Printed in Japan (K) （アメリカ用）

93202-00032

©2017 KCM Corporation All rights reserved.

Powered by KUBOTA D1803-M-D1-E3B Engine (30ZV-2) KUBOTA V2403-M-DI-E3B Engine (40ZV-2A, 42ZV-2) Serial No. 30ZV-2A 30K1-5001 and up 40ZV-2A 40K1-5001 and up 42ZV-2A 01037-01793, 05001 and up

93202-00032

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

GENERAL ......................................................................................................................T-1

Group 1

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

Group 2

Component Specifications ....................................................................................... T1-2

Group 3

Component Layout .................................................................................................. T1-3

SECTION 2

SYSTEM .........................................................................................................................T-2

Group 1

Fuel System............................................................................................................. T2-1

Group 2

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

Group 3

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

SECTION 3

COMPONENT OPERATION ...........................................................................................T-3

Group 1

HST Pump ............................................................................................................... T3-1

Group 2

HST Motor ............................................................................................................... T3-2

Group 3

Axle ......................................................................................................................... T3-3

Group 4

Brake ....................................................................................................................... T3-4

Group 5

Orbitrol ..................................................................................................................... T3-5

Group 6

Control Valve ........................................................................................................... T3-6

Group 7

Main Pump .............................................................................................................. T3-7

TECHNICAL MANUAL (Troubleshooting) (P/N 93202-00042) 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

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Group 2 Failure List Group 3 Engine Group 4 Vehicle Performance

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.

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 2

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

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-2644

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 per-

sonal 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 KCM Warranty Policy.

• Do not use attachments and/or optional parts or equipment not authorized by KCM. 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 KCM 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 at-

tached 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 atten-

tion 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.

NEVER RIDE ATTACHMENT • Never allow anyone to ride attachment or the load.

This is an extremely dangerous practice.

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. Con-

firm 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-448

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 op-

erating 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. Unex-

pected 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 take the following actions.

• If you are around the machine, evacuate to a safe place far away from the machine.

• If you are in the cab, stay in the cab until lightning has passed and safety is secured. Close the cab doors and windows. Lower the bucket to the ground, and stop the engine. Put your hands on your lap to avoid contact with any metal surfaces.

Never go out of the cab.

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

S-18

SA-4EK-020

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.

• 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.

500-E02C-0520

S-23

SA-028

SA-312

SA-134

SA-527

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

SS2045102-4

SUPPORT MACHINE PROPERLY • Never attempt to work on the machine without se-

curing 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 KCM/Hitachi 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 Safety Data Sheet (SDS) provides specific details on chemical products: physical and health hazards, safety procedures, and emergency response techniques.

• Check the SDS 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 SDS’s (available only in English) on chemical products used with your machine.

515-E01A-0309

S-32

SA-2579

SAFETY DISPOSE OF WASTE PROPERLY • Improperly disposing of waste can threaten the en-

vironment and ecology. Potentially harmful waste used with KCM/Hitachi 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 ̿CONTENTS̿ Group 1 Specification Specifications ...........................................T1-1-2

Group 2 Component Specification Engine......................................................T1-2-1 HST Pump ...............................................T1-2-3 Gear Pump...............................................T1-2-4 Orbitrol .....................................................T1-2-5

Group 3 Component Layout Main Component (Overview) ....................T1-3-1 Main Component (Power Line) .................T1-3-3 Hydraulic System (Overview)....................T1-3-4 Electrical System (Overview) ....................T1-3-5 Electrical System (Meter Panel)................T1-3-7 Engine......................................................T1-3-8 HST Pump ...............................................T1-3-9 Reduction...............................................T1-3-10 Control Valve.......................................... T1-3-11

T-1-1

30_42ZV-2

(Blank)

T-1-2

30_42ZV-2

GENERAL / Specification (Blank)

T1-1-1

30_42ZV-2

GENERAL / Specification SPECIFICATIONS

42ZV2-01-01-01

Model

Unit

Standard Bucket Capacity (BOC)

3

30ZV-2

40ZV-2A

42ZV-2

m (yd )

0.4 (0.52)

0.5 (0.65)

0.6 (0.78)

Canopy spec.

kg (lb)

3085 (6800)

3810 (8390)

4030 (8890)

Cab spec.

kg (lb)

3245 (7150)

3970 (8750)

4195 (9250)

kg (lb)

700 (1540)

860 (1890)

980 (2170)

-

KUBOTA D1803-M-DI

A: Overall Length

mm (in)

4410 (173.6)

B: Overall Width (Bucket)

mm (in)

1570 (61.8)

1690 (66.5)

Canopy spec.

mm (in)

2485 (97.8)

2565 (101.0)

Cab spec.

mm (in)

2480 (97.6)

2560 (100.7)

D: Wheel Base

mm (in)

1780 (70.1)

1850 (72.8)

E: Tread

mm (in)

1180 (46.5)

1260 (49.6)

F:

mm (in)

255 (10.0)

295 (11.6)

G: Dumping Clearance

mm (in)

2025 (79.7)

2325 (91.5)

2380 (93.7)

H: Dumping Reach

mm (in)

880 (34.7)

930 (36.6)

995 (39.2)

R1: Minimum Rotation Center of Outside Radius Tire

mm (in)

3005 (118.3)

R2: Minimum Rotation Bucket Outside Radius Edge

mm (in)

3610 (142.2)

Operating Weight Rated Machine Weight Engine

C: Overall Height

Minimum Ground Clearance

3

Travel Speed

Forward/Reverse km/h (mph)

Transmission Speeds

Forward/Reverse

Articulation Angle (Left/Right) Tire Size

KUBOTA V2403-MDI 4620 (182.0)

3125 (123.0) 3820 (150.4)

15/15 (9.3/9.3)

3870 (152.4)

17/17 (10.5/10.5)

2/2

deg.

4925 (193.9)

1/1 41

12.5/70-16 8PR (L2)

T1-1-2

15.5/60-18-8PR (L2)

30_42ZV-2

GENERAL / Component Specification ENGINE (30ZV-2) Item

Unit

Specification

Engine Model

KUBOTA D1803-M-DI-E3B

Engine Type

Four-Cycle Diesel Engine, Water-cooled

Cylinder No.-Bore x Stroke

mm (in)

3-87u102.4 (3.43u4.03)

Piston Displacement

L (US gal)

1.826 (0.5)

Combustion Chamber Type

Reentrant Type (Direct Injection)

Rated Output

kW (PS)/rpm

22.2r5%/2200 (30r5%/2200)

Gross Output/Torque

kW (PS)/ N m (lbf ft)

22.8 (31.0) r5%/113.6 (83.8)

No Load Maximum Idle Speed/Idle Speed

rpm

2470

Maximum Output Torque/Engine Speed

N m (lbf ft)/rpm

Injection Order

0

+25 -70 /1075 -25

113.6 (83.8) r5%/1400 1-2-3

Direction of Rotation

CCW (Viewed from Flywheel End Side)

Injection Nozzle

Bocch P Type Hose Nozzle

Injection Pump

Bocch K Type Mini Pump

Injection Pressure

2

MPa (kgf/cm , psi)

Injection Timing

TC-4.75p to -6.25p

Compression Ratio

20.2

Fuel Fuel Consumption Ratio

First: 18.6 (190, 2700) Second: 22.6 (230, 3280)

Diesel Fuel g/kW h (g/ps h)

245 (180)

Cooling System

Pressurized Radiator (Forced Circulation with Cooling Pump)

Lubrication System

Forced Lubrication with Trochoid Pump

Lubricant Oil

CD class and above 10W-30

Lubricant Oil Capacities

L (US gal)

5.6 (1.5)

Lubricant Oil Effective Dose

L (US gal)

1.3 (0.3)

Coolant Capacities

L (US gal)

1.7 (0.4) (Engine Only)

Air Cleaner

Cyclone Separator Type Filter

Regulator

IC Type (Built-in Alternator)

Dimension: LengthuWidthuHeight

mm (in)

550.8u516.9u647.8 (22u20u26) (without Fun)

Weight (Dry)

kg (lb)

170 (380)

Starting Method

Starter (with Glow Plug)

Starter Motor

V-kW

12-2.0

Alternator

V-kW

12-720 (60A)

Battery Capacity

V-Ah

12-52 Ah (Genial Climate) 12-64 Ah (Cold Climate)

T1-2-1

30_42ZV-2

GENERAL / Component Specification ENGINE (40ZV-2A/42ZV-2) Item

Unit

Specification

Engine Model

KUBOTA V2403-M-DI-E3B

Engine Type

Four-Cycle Diesel Engine, Water-cooled

Cylinder No.-Bore x Stroke

mm (in)

4-87u102.4 (3.43u4.03)

Piston Displacement

L (US gal)

2.434 (0.6)

Combustion Chamber Type

Reentrant Type (Direct Injection)

Rated Output

kW (PS)/rpm

33.6(45.7)r5%/2400

Gross Output/Torque

kW (PS)/ N m (lbf ft)

34.1(46.4) r5%/155.9 (115)

No Load Maximum Idle Speed/Idle Speed

rpm

2670

Maximum Output Torque/Engine Speed

N m (lbf ft)/rpm

Injection Order

0

+25 -70 /1075 -25

155.9 (115) r5%/1400 1-3-4-2

Direction of Rotation

CCW (Viewed from Flywheel End Side)

Injection Nozzle

Bocch P Type Hose Nozzle

Injection Pump

Bocch K Type Mini Pump

Injection Pressure

2

MPa (kgf/cm , psi)

Injection Timing

TC-4.75p to -6.25p

Compression Ratio

20.2

Fuel Fuel Consumption Ratio

First: 18.6 (190, 2700) Second: 22.6 (230, 3280)

Diesel Fuel g/kW h (g/ps h)

238 (175)

Cooling System

Pressurized Radiator (Forced Circulation with Cooling Pump)

Lubrication System

Forced Lubrication with Trochoid Pump

Lubricant Oil

CD class and above 10W-30

Lubricant Oil Capacities

L (US gal)

7.6 (2)

Lubricant Oil Effective Dose

L (US gal)

1.8 (0.5)

Coolant Capacities

L (US gal)

3.7 (1) (Engine Only)

Air Cleaner

Cyclone Separator Type Filter

Regulator

IC Type (Built-in Alternator)

Dimension: LengthuWidthuHeight

mm (in)

645.8u516.9u630.8 (25u20u25)

Weight (Dry)

kg (lb)

199 (440)

Starting Method

Starter (with Glow Plug)

Starter Motor

V-kW

12-2.0

Alternator

V-kW

12-720 (60A)

Battery Capacity

V-Ah

12-52 Ah (Genial Climate) 12-64 Ah (Cold Climate)

T1-2-2

30_42ZV-2

GENERAL / Component Specification HST PUMP (30ZV-2) Part Name Type

Variable Piston Pump A4VG28DA

Driving Method Delivery Flow Rate

Engine-Crankshaft Direct Coupling 0 to 28 CC rev 2

High Pressure Relief Valve Set Pressure

35 MPa (357 kgf/cm , 5076 psi)

Low Pressure Relief Valve Set Pressure

2.5 MPa (25.5 kgf/cm , 363 psi)

2

Control System

DA Control

Weight

36 kg (79 lb)

HST Charging Pump

Gear Type

HST PUMP (40ZV-2A/42ZV-2) Part Name Type Driving Method Delivery Flow Rate

Variable Piston Pump A4VG28DA Engine-Crankshaft Direct Coupling 0 to 28 CC rev 2

High Pressure Relief Valve Set Pressure

38.5 MPa (393 kgf/cm , 5584 psi)

Low Pressure Relief Valve Set Pressure

2.5 MPa (25.5 kgf/cm , 363 psi)

2

Control System

DA Control

Weight

36 kg (79 lb)

HST Charging Pump

Gear Type

T1-2-3

30_42ZV-2

GENERAL / Component Specification GEAR PUMP (30ZV-2) Part Name Type

2-Unit Gear Pump DDG1A166F9H9-R421

Driving Method

Gear Type 1st Pump: 16.2 cm

Displacement

2nd Pump: 6.5 cm

Weight

3

3

6.9 kg (15 lb) 1st Pump: For Steering/Implement

Function

2nd Pump: For HST Charging

GEAR PUMP (40ZV-2A) Part Name Type

2-Unit Gear Pump DDG1A186F9H9-R423

Driving Method

Gear Type 1st Pump: 19.3 cm

Displacement

2nd Pump: 6.5 cm

Weight

3

3

7 kg (15 lb) 1st Pump: For Steering/Implement

Function

2nd Pump: For HST Charging

GEAR PUMP (42ZV-2) Part Name Type

2-Unit Gear Pump DDG1A226F9H9-R424

Driving Method Displacement Weight Function

Gear Type 1st Pump: 22.4 cm 2nd Pump: 6.5 cm

3

3

7 kg (15 lb) 1st Pump: For Steering/Implement 2nd Pump: For HST Charging

T1-2-4

30_42ZV-2

GENERAL / Component Specification ORBITROL (30ZV-2) Part Name

Orbitrol

Type

PGD1R175XA3E Load Sensing/with Non Load Reaction Priority Valve (Dynamic Signal Type)

Valve System Relief Valve Set Pressure

2

17.2 MPa (175 kgf/cm ) (2495 psi) 3

Displacement

3

120 cm /rev (7.3 in /rev) 2

Maximum Pressure (Priority Valve)

20.6 MPa (210 kgf/cm ) (2990 psi)

System Control Pressure (Priority Valve)

0.35 MPa (3.6 kgf/cm ) (51 psi)

Rated Flow Rate (Priority Valve)

2

80.0 L/min (21 US gal/min)

ORBITROL (40ZV-2A/42ZV-2) Part Name

Orbitrol

Type Valve System

LJGUD1E Load Sensing/with Non Load Reaction Priority Valve (Dynamic Signal Type) 2

Relief Valve Set Pressure

17.2 MPa (175 kgf/cm ) (2495 psi)

Overload Relief Valve Set Pressure

22.6 MPa (230 kgf/cm ) (3280 psi)

Displacement Maximum Pressure (Priority Valve)

2

3

3

148 cm /rev (9 in /rev) 2

20.6 MPa (210 kgf/cm ) (2990 psi) 2

System Control Pressure (Priority Valve)

0.2 MPa (1.8 kgf/cm ) (29 psi)

Rated Flow Rate (Priority Valve)

40 L/min (10.6 US gal/min)

T1-2-5

30_42ZV-2

GENERAL / Component Specification (Blank)

T1-2-6

30_42ZV-2

GENERAL / Component Layout MAIN COMPONENT (OVERVIEW) 8

7 6 5 4

3

2

9 10 1

11

ME804-01-03-01KC

1 - Bucket 2 - Bucket Link 3 - Bell Crank

4 - Bucket Cylinder 5 - Combination Lamp (Turn Signal Light and Clearance Light) 6 - Head Lamp

T1-3-1

7 - Back Mirror 8 - Canopy

10 - Lift Cylinder 11 - Lift Arm

9 - Fuel Feed Port

30_42ZV-2

GENERAL / Component Layout

1

2

3

4

5 9 6

7

8

ME804-01-03-02KC

1 - Operator Seat 2 - Engine Hood

4 - Counterweight 5 - Backlight

6 - Towing Pin 7 - Combination Lamp (Turn Signal, Tail Light, and Stop Light)

8 - Reflector 9 - Hydraulic Oil Tank

3 - Radiator/Oil Cooler

T1-3-2

30_42ZV-2

GENERAL / Component Layout MAIN COMPONENT (POWER LINE) 9

10

8

7

1

2

3 4

5

6

T4EK-01-03-003

1 - Front Axle 2 - Propeller Shaft (Front) 3 - HST Motor

4 - Reduction 5 - Propeller Shaft (Rear) 6 - Rear Axle

7 - Engine 8 - HST Pump

T1-3-3

9 - Main Pump 10 - Charging Pump

30_42ZV-2

GENERAL / Component Layout HYDRAULIC SYSTEM (OVERVIEW) 2

1

3

4

9

8

7 6

5 T4EK-01-03-004

1 - Bucket Cylinder 2 - Inching Valve 3 - Hydraulic Oil Tank

4 - Hydraulic Oil Return Filter 5 - Oil Cooler

6 - HST Oil Filter 7 - Steering Cylinder

T1-3-4

8 - Control Valve 9 - Lift Cylinder

30_42ZV-2

GENERAL / Component Layout ELECTRICAL SYSTEM (OVERVIEW) 2

1

3

4

5

6

7

8

9

17 10

16 15 14

12

13

11

T4EK-01-03-005

12345-

Bucket Proximity Switch Horn Head Light Front Combination Lamp Meter Panel

6789-

Combination Lamp Switch Starter Switch Fuse Box Battery

10 - Combination Lamp 11 - Back Lamp 12 - Backup Alarm 13 - Solenoid Valve

T1-3-5

14 - Fuel Pump 15 - Fuel Gauge Sending Unit 16 - Brake Lamp Switch 17 - Shift Lever

30_42ZV-2

GENERAL / Component Layout

2

1

4

5

7

6

8

3

9

12

14

10 11

13

T4EK-01-03-006

1 - Meter Panel 2 - Parking Brake Switch 3 - Fuse Box 4 - Glow Relay

5 - Relay 4 (For Parking Brake) 6 - Relay 3 (For Parking Brake) 7 - Relay 1 (For Monitor Lamp Check) 8 - Relay 2 (For Monitor Lamp Check)

9 - Slow Blow Fuse

12 - Glow Lamp Timer

10 - Starter Relay

13 - Solenoid (Forward)

11 - Flasher Unit

14 - Solenoid (Reverse)

T1-3-6

30_42ZV-2

GENERAL / Component Layout ELECTRICAL SYSTEM (METER PANEL) 1

2

3

4

5

6

4

2

7

10

9

8

T4EK-01-03-007

1 - Brake Oil Low Level Indicator 2 - Left Turn Signal Indicator 3 - Charging Lamp

4 - FNR Indicator 5 - Engine Oil Pressure Indicator 6 - Glow Signal

T1-3-7

7 - Parking Brake Indicator 8 - Hour Meter

9 - Fuel Gauge 10 - Temperature Gauge

30_42ZV-2

GENERAL / Component Layout ENGINE 1 2

3

6

7

4 5

8

10

9 T4EK-01-03-008

1 - Glow Plug 2 - Temperature Gauge Sender Unit 3 - Engine Oil Level Gauge

4 - Engine Stop Solenoid 5 - Engine Oil Filter 6 - Engine Oil Pressure Switch

T1-3-8

7 - Starter Motor 8 - Alternator

9 - Water Drain Plug 10 - Drive Belt

30_42ZV-2

GENERAL / Component Layout HST PUMP

1

4

2

5 6

3

7

14

8

13 12

11

9

10 T4EK-01-03-009

1234-

Gear Pump Solenoid Valve A (Forward) Solenoid Valve B (Reverse) High Pressure Relief Valve

5678-

Gauge Port Suction Port Low Pressure Relief Valve DA Valve

9 - Gauge Port 10 - High Pressure Relief Valve 11 - Supply Port

T1-3-9

12 - Supply Port 13 - Delivery (Main Port) 14 - Delivery (Charging Port)

30_42ZV-2

GENERAL / Component Layout REDUCTION 1

2

8

3

7 4 5

6

9

T4EK-01-03-010

1 - Reduction Gear Case 2 - Plug (Oil Feed Port)

4 - Cover 5 - Plug (Oil Drain)

6 - Plug (Oil Level) 7 - Plug

8 - Bleeder 9 - Bolt (For Parking Brake Forcibly Release)

3 - Flange

T1-3-10

30_42ZV-2

GENERAL / Component Layout CONTROL VALVE

1 5

2 3

4

6 5

7

8

T4EK-01-03-011

1 - Outlet Section 2 - Lift Section

3 - Tilt Section 4 - Main Relief Valve

5 - Overload Relief Valve 6 - Antivoid Valve

T1-3-11

7 - Inlet Section 8 - Electromagnetic Detent

30_42ZV-2

GENERAL / Component Layout (Blank)

T1-3-12

30_42ZV-2

SECTION 2

SYSTEM

—CONTENTS— Group 1 Fuel System Outline .....................................................T2-1-1

Group 2 Hydraulic System Outline .....................................................T2-2-1 HST Circuit...............................................T2-2-4 HST Oil Filter ...........................................T2-2-6 Brake Circuit ............................................T2-2-7 Parking Brake Circuit ...............................T2-2-8 Steering Circuit.........................................T2-2-9 Main Hydraulic Circuit.............................T2-2-12

Group 3 Electrical System Outline .....................................................T2-3-1 Electrical Circuit (Front Side)....................T2-3-2 Electrical Circuit (Rear Side) ....................T2-3-3 Electrical Circuit (Coupler Position) ..........T2-3-4 Fuse Valve and Circuit Name ...................T2-3-5 Electric Power Circuit ...............................T2-3-7 Preheat Circuit (Key Switch: HEAT) ..........T2-3-8 Preheat Circuit (Key Switch: START TO ON) ..................T2-3-9 Charging Circuit .....................................T2-3-10 Starting Circuit........................................ T2-3-11 Engine Stop Circuit.................................T2-3-12 Monitor Indicator Circuit .........................T2-3-13 Gauge Circuit .........................................T2-3-14 Travel Circuit ..........................................T2-3-15 Travel Circuit (Forward)..........................T2-3-16 Travel Circuit (Backward) .......................T2-3-17 Parking Brake Circuit .............................T2-3-18 Light Circuit ............................................T2-3-25 Horn Circuit ............................................T2-3-26 Auto Leveler Circuit ................................T2-3-26

T-2-1

30_42ZV-2

(Blank)

T-2-2

30_42ZV-2

SYSTEM / Fuel System OUTLINE Fuel system consists of the fuel tank, the fuel filter and the piping.

Fuel Tank

Fuel Piping

The fuel tank is installed to the rear frame left side with the bolts. The fuel hose (Feed, Return) is connected to the engine.

In addition, the fuel sensor is installed in the fuel tank.

The remaining amount of fuel is indicated on the fuel gauge.

Fuel (diesel oil) is suctioned from fuel tank (1) by fuel pump (2) and filtrated by water separator (6) and fuel filter (3) The filtered fuel is supplied to injection pump (4) Fuel is compressed and delivered to injection nozzle (5) by using injection pump (4) corresponding to the injection timing of each cylinder in the engine, and injected to the combustion chamber.

In case of the trapping air, turn the starter switch to the ON position, and the air bleeding can be performed through the returning circuit.

(Automatic air bleeding mechanism)

6

5

2

3

4

1

TE804-02-01-001

1 - Fuel Tank 2 - Fuel Pump

3 - Fuel Filter 4 - Injection Pump

5 - Injection Nozzle

T2-1-1

6 - Water separator

30_42ZV-2

SYSTEM / Fuel System Fuel Filter The fuel filter has the drain function to separate foreign particle contained in fuel and precipitated water.

Float (5) is built in filter cartridge (7).

When water accumulates, float (5) is floated.

T4EK-02-01-002

1 2

8

3

7

4 5

6

T4EK-02-01-003

1 - Filter Head 2 - O-Ring

3 - Element 4 - Spring

5 - Float 6 - Retaining Ring

T2-1-2

7 - Filter Cartridge 8 - O-Ring

30_42ZV-2

SYSTEM / Fuel System Water separator The water separator has the drain function to separate foreign particle contained in fuel and precipitated water.

Float (5) is built in filter cup (6).

When water accumulates, float (5) is floated.

ME804-07-003

M4FG-07-065

1

2

3

4 5

6

7

M4FG-07-066

12-

Filter Head O-Ring

3 - Screen 4 - Spring

5 - Float 6 - Filter Cup

T2-1-3

7-

Retaining Ring

30_42ZV-2

SYSTEM / Fuel System (Blank)

T2-1-4

30_42ZV-2

SYSTEM / Hydraulic System OUTLINE

Steering Cylinder 55u30u228 mm (2.4u1.2u9.0 in)

Parking Solenoid

Oil Cooler

Power Steering Assy

Return Filter

10˩

The hydraulic system consists of HST circuit, the brake circuit, the steering circuit and the main hydraulic circuit. < Hydraulic Circuit Diagram: 30ZV-2 >

Service Brake

Inching Valve

38.5MPa

Main Relief

Valves

10˩

Main Pump

Control Valve

HST Filter

Charging Pump

Bucket Cylinder 65u40u364 mm (2.6u1.6u14.3 in)

Lift Cylinder 2 - 65u40u450 mm (2.6u1.6u17.7 in)

HST Pump

T4EK-02-02-001

T2-2-1

30_42ZV-2

Bucket Cylinder 70u45u431 mm (2.8u1.8u17 in)

Lift Cylinder 2 - 65u40u539 mm (2.6u1.6u21.2 in)

T2-2-2 Inching Valve

38.5MPa

10˩

HST Filter

Parking Solenoid

Steering Cylinder 60u30u228 mm (2.4u1.2u9.0 in)

Oil Cooler

Power Steering Assy

Return Filter

10˩

< Hydraulic Circuit Diagram: 40ZV-2A >

Valves

Main Relief

Control Valve

SYSTEM / Hydraulic System

Service Brake

Charging Pump

Main Pump

HST Pump

40ZV2-02-02-01

30_42ZV-2

Bucket Cylinder 70u45u450 mm (2.8u1.8u17.7 in)

Lift Cylinder 2 - 70u45u531 mm (2.8u1.8u20.9 in)

T2-2-3 Inching Valve

38.5MPa

10˩

HST Filter

Parking Solenoid

Steering Cylinder 60u30u228 mm (2.4u1.2u9.0 in)

Oil Cooler

Power Steering Assy

Return Filter

10˩

< Hydraulic Circuit Diagram: 42ZV-2 >

Valves

Main Relief

Control Valve

SYSTEM / Hydraulic System

Service Brake

Charging Pump

Main Pump

HST Pump

42ZV2-02-02-01

30_42ZV-2

SYSTEM / Hydraulic System HST CIRCUIT The HST (Hydro-Static Transmission) circuit consists of main hydraulic suction circuit (A), charging pump circuit (B), HST close circuit (C) and lubrication and cooling (drain) circuit (D).

Pressurized oil by charging pump (2) is discharged and filled up in both casing of HST pump (1) and HST motor (4). Pressurized oil cools each part and flows to oil cooler (6).

Hydraulic oil is cooled by oil cooler (6) and retuned to hydraulic tank (5).

2

7

5

1

B

3

C

4

A

D

6 T4EK-02-02-004

1 - HST Pump 2 - Gear Pump (Charging)

3 - HST Oil Filter 4 - HST Motor

5 - Hydraulic Oil Tank 6 - Radiator (Oil Cooler)

T2-2-4

7 - Inching Valve

30_42ZV-2

SYSTEM / Hydraulic System HST Circuit Diagram Line Filter

Direction Selector Valve

DA Valve

Charging Pump

High-Pressure Relief Valve

Low-Pressure Relief Valve T4EK-02-02-005

Item 1. High Relief Pressure 2. Low Relief Pressure 3. Main Pump Flow Rate 4. Charging Pump Flow Rate

30ZV-2 35 MPa 2 (357 kgf/cm , 5088 psi) 2.5 MPa 2 (26 kgf/cm , 360 psi) 3 16.2 cc/rev (0.99 in /rev) 3

6.5 cc/rev (0.4 in /rev)

T2-2-5

40ZV-2A 38.5 MPa 2 (392 kgf/cm , 5597 psi) 2.5 MPa 2 (26 kgf/cm , 360 psi) 3 19.3 cc/rev (1.2 in /rev) 3

6.5 cc/rev (0.4 in /rev)

42ZV-2 38.5 MPa 2 (392 kgf/cm , 5597 psi) 2.5 MPa 2 (26 kgf/cm , 360 psi) 3 22.4 cc/rev (1.4 in /rev) 3

6.5 cc/rev (0.4 in /rev)

30_42ZV-2

SYSTEM / Hydraulic System HST OIL FILTER Pressurized oil from the charging pump assembly flows into cartridge assembly (1) through the inlet port and is filtered in element (2).

Pressurized oil from the outlet port is sent to the inching valve assembly.

In case the element clogs, when inlet port pressure increases and outlet port pressure difference is 0.34 MPa (49.3 psi) or more, bypass valve (3) is opened and pressurized oil does not flow through element (2), but to the outlet port directly.

IN

OUT

3

1

2

T4EK-02-02-006

1 - Cartridge Assembly

2 - Element

3 - Bypass Valve

T2-2-6

30_42ZV-2

SYSTEM / Hydraulic System BRAKE CIRCUIT Service Brake

Inching Mechanism

Service brake uses the wet type disc brake installed to the input shaft in the reduction gear.

Brake pedal (1) and the inching valve lever are connected with the link.

Service brake is the hydraulic type and consists of brake pedal (1), brake oil tank (2), master cylinder (3) and the piping.

When depressing brake pedal (1) (either right or left), the HST pump inching function (HST brake function) operates and the wet type disc brake puts brake on the machine.

This master cylinder (3) is single type and the brake hydraulic line is one system.

4

1 6

8

3

2 5

7

9

T4EK-02-02-007

1 - Brake Pedal 2 - Brake Oil Tank 3 - Master Cylinder

4 - Brake Lump Switch 5 - Brake Oil Level Switch

6 - Brake Oil Level Indicator 7 - Bleeder (Air Bleeding)

T2-2-7

8 - Inching Valve 9 - Reduction Gear Assembly

30_42ZV-2

SYSTEM / Hydraulic System PARKING BRAKE CIRCUIT The parking brake uses the wet type disc brake in common with the service brake.

The parking brake consists of the HST charge hydraulic circuit as the hydraulic source, and the electrical circuit such as the parking brake switch and the parking brake solenoid valves.

1

2

6

3

5

4

T4EK-02-02-008

1 - Inching Valve 2 - Hydraulic Oil Tank

3 - HST Pump 4 - Reduction Gear

5 - Solenoid Valve

T2-2-8

6 - Return Filter

30_42ZV-2

SYSTEM / Hydraulic System STEERING CIRCUIT The steering system mainly consists of the steering ® wheel, the power steering (orbitrol ), the steering cylinder and the piping.

When operating (rotating by hand) the steering wheel, ® the orbitrol (power steering) directly installed to the steering shaft of the steering column assembly operates.

Pressurized oil is sent to the steering cylinder and the machine direction is changed.

1

2

3

5

6

4

T4EK-02-02-009

1 - Steering Wheel 2 - Steering Column Assembly

3 - Power Steering (Orbitrol®) 4 - Return Filter

5 - Check Valve

T2-2-9

6 - Steering Cylinder

30_42ZV-2

SYSTEM / Hydraulic System Steering Circuit Diagram ®

As for the power steering (orbitrol ), hydraulic oil is delivered to the steering cylinder and the machine direction is changed according to the steering wheel operation.

Hydraulic oil delivered from the steering cylinder ® flows back to the power steering (orbitrol ).

Hydraulic oil is filtrated in the return filter and returns to the hydraulic tank.

Hydraulic oil suctioned from the hydraulic tank by using the main pump is delivered to the power ® steering (orbitrol ). Hydraulic oil is divided into the main hydraulic circuit and the steering hydraulic circuit.

As the steering hydraulic circuit is adopted the load sensing system, the steering hydraulic circuit sends hydraulic oil required for changing the machine di® rection to the power steering (orbitrol ) preferentially.

The steering hydraulic circuit returns redundant hydraulic oil to the main circuit. < 30ZV-2 >

V

148 cc/rev

Steering Cylinder

L R

17.2 MPa

Pressure Port

T

Power Steering (Orbitrol® )

P

EF

0.15 MPa To Control Valve P Port

10 P

Main Pump

0.05 MPa

Return Filter Hydraulic Oil Tank

T4EK-02-02-010

T2-2-10

30_42ZV-2

SYSTEM / Hydraulic System < 40ZV-2A/42ZV-2 >

V 148 cc/rev

Steering Cylinder

L R

17.2 MPa

Pressure Port

T

Power Steering (Orbitrol® )

P

EF

0.15 MPa To Control Valve P Port

Main Pump

10 P 0.05 MPa Return Filter Hydraulic Oil Tank

42ZV2-02-02-02

T2-2-11

30_42ZV-2

SYSTEM / Hydraulic System MAIN HYDRAULIC CIRCUIT The main hydraulic device consists of the main pump, the control valve, the hydraulic tank, the return filter, the lift arm cylinder, the bucket cylinder and the hydraulic piping.

When the main pump (connected to the charging pump) is used as the power source by operating the shovel control lever, change the pressurized oil flow by the control valve and load the work device.

1

2

3 4

5

8

6

7

T4EK-02-02-011

1 - Tilt Arm Cylinder 2 - Bucket Cylinder (Right)

3 - Orbitrol® 4 - Hydraulic Oil Tank

5 - Return Filter 6 - HST Pump (Main Pump)

T2-2-12

7 - Control Valve 8 - Lift Arm Cylinder (Left)

30_42ZV-2

SYSTEM / Hydraulic System Main Hydraulic Circuit Diagram Hydraulic oil aspirated from the hydraulic tank by using the main pump is delivered to the priority valve ® (PV) in the orbitrol . Hydraulic oil is divided into the main hydraulic circuit and the steering hydraulic circuit.

Pressurized oil in the main hydraulic circuit is delivered to the control valve.

When the control valve is in neutral, pressurized oil flows in the valve and returns to the hydraulic tank through the return filter.

When the spool in the control valve moves by operating the control valve, the hydraulic oil flows the selected oil passage in the valve to the lift arm cylinder and the bucket cylinder. Each cylinder is activated.

Hydraulic oil delivered from the cylinder flows back to the control valve.

Hydraulic oil returns to the hydraulic tank through the return filter.

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42ZV2-02-02-03

T2-2-13

30_42ZV-2

SYSTEM / Hydraulic System (Blank)

T2-2-14

30_42ZV-2

SYSTEM / Electrical System OUTLINE The electrical system consists of the main circuit, the monitor circuit and the travel circuit.

x Main circuit 1. Electric power circuit: It is an electrical power source for all electrical systems on the machine.

2. Preheating circuit: It assists the engine in starting in cold weather.

3. Charging circuit: It charges the batteries and complements power consumption.

4. Starting/Stop circuit: It starts and stops the engine by the engine stop solenoid.

x Monitor circuit 1. Monitor indicator circuit: It indicates the machine operation status in the meter panel.

2. Gauge circuit: It indicates the engine coolant temperature and the remaining amount of fuel in the meter panel.

x Travel system circuit 1. Travel system circuit: It changes forward/reverse selector by the shift lever and controls the parking brake by the parking brake switch.

x Other circuits 1. Light circuit: It turns each light (head light, turn signal light, rear combination light, reverse light) ON and OFF. 2. Horn circuit: It sounds the horn (alarming horn).

3. Auto leveler circuit: It turns the proximity switch of the auto leveler device (bucket horizontal mechanism) ON and OFF.

T2-3-1

30_42ZV-2

SYSTEM / Electrical System ELECTRICAL CIRCUIT (FRONT SIDE) 04

03

05 Parking Brake Switch

Hour Meter Fuel Gauge

Coolant Temperature Gauge

01

Illumination Light

Steering Column

Dimmer Switch

Hazard Switch

Meter Panel

Horn. Switch

Combination Light Switch

07 Stop Light Switch

Shift Lever Clearance Light (5W)

Turn Signal Light R.H (21W)

08

Head Light (55W) Horn Hazard Switch

06

09

Auto Leveler Proximity Switch

02

Diode

C/V Tilt Detent

Head Light (55W)

33

10

Color Code and Color (Standard Color) Color code Color BW of the color codes indicates that the B Black initial color stands for base color (black) W White and the next color stands for marking R Red color (white).

G Green L Y Br O P

Clearance Light (5W)

Blue Yellow Brown Orange Pink

TE804-02-03-001

T2-3-2

30_42ZV-2

Relay [3] (For Parking Brake).

Relay [1] (For Monitor Lamp Check and Parking Brake).

01

02

T2-3-3 (R) Solenoid

15 28

12 HST Pump

17

Fuel Pump

18 Battery

Stop Solenoid

Coolant Temperature Gauge Sending Unit

Glow Plug Relay Alternator

Slow Brow Fuse

Engine Oil Pressure Switch Starter Motor

Slow Brow Fuse

22

Brake Fluid Level Switch

Fuel Gauge Sending Unit

13 (F) Solenoid

19 20

Glow Plug

21

Diode

Tail Light (5W) Stop Light (21W)

Tail Light (5W) Stop Light (21W)

(21W)

Tune Signal Light L.H

Backup Alarm

Back Light (21W)

License Light (Optional)

(21W)

Turn Signal Light R.H

23

Parking Brake Solenoid Valve

Parking Brake Solenoid

14

Key Switch

16

Key Switch Connection Table

SYSTEM / Electrical System

ELECTRICAL CIRCUIT (REAR SIDE) 25

24

26

Starter Relay

Flasher Unit

Preheat Indicator Timer

Flasher Unit

27

Relay [4] (For Parking Brake)

11 Relay [2] (For Monitor Lamp Check).

29

31

30

T4EK-02-03-002

30_42ZV-2

SYSTEM / Electrical System

18

26

09

32

08

33

06

10

07

04

31

29

27

03

30

05

24

10

25

28

02

02

01

01

16

22

15

19

23

14

13

11

17

20

21

12

ELECTRICAL CIRCUIT (COUPLER POSITION)

T4EK-02-03-003

T2-3-4

30_42ZV-2

SYSTEM / Electrical System FUSE VALUE AND CIRCUIT NAME No.

Fuse Value

1

15 A

2

15 A

3

10 A

4 5 6 7 8 9 10

10 A 20 A 20 A 10 A 5A 5A 10 A

Circuit HST Pump (F, R) Solenoid Parking Brake Solenoid Relay (3), Relay (4), Back Light, Backup Alarm Stop Light, Horn Coolant Temperature Gauge, Fuel Gauge, Hour Meter, Relay (1), (2), (4) Monitor Indicator Auto Leveler Proximity Switch, Control Valve Tilt Detent Head Light, Clearance Light, Tail Light Optional Flasher Unit, Turn Signal Light Clearance Light Right, Tail Light Left Clearance Light Left, Tail Light Right Fuel Pump, Engine Stop Solenoid

T2-3-5

30_42ZV-2

SYSTEM / Electrical System (Blank)

T2-3-6

30_42ZV-2

SYSTEM / Electrical System ELECTRICAL POWER CIRCUIT The battery negative terminal is grounded to the chassis.

Current from the battery plus terminal flows as illustrated below when the key switch is in the OFF position.

Key Switch Connection

Cab Harness

Slow Blow Fuse

Battery Starter Motor

T4EK-02-03-004

T2-3-7

30_42ZV-2

SYSTEM / Electrical System PREHEAT CIRCUIT (KEY SWITCH: HEAT) 1. When the key switch is turned to the HEAT position, current energizes the glow plug relay and flows to the glow plug.

3. The preheat indicator timer turns OFF the preheat indicator for 5 seconds to notify the completion of the pre-heating.

2. The other current flows through the preheat indicator timer and lights the preheat indicator.

Key Switch Connection

Meter Panel

19 Glow Plug Relay

Preheat Indicator Timer

Slow Blow Fuse

Slow Blow Fuse

Diode

16 L

21

BY

20 01 03

L

L BY

BY Battery Starter Motor

Alternator

Glow Plug

T4EK-02-03-005

T2-3-8

30_42ZV-2

SYSTEM / Electrical System PREHEAT CIRCUIT (KEY SWITCH: START TO ON) 4. When the key switch is turned to the START position, current flows from key switch terminal C to the preheat indicator timer through the shift lever and lights the preheat indicator.

6. When the key switch is returned to the ON position after the engine starts, current exciting the glow plug relay is blocked, and current to the glow plug is blocked.

5. The other current flows through the preheat indicator timer and lights the preheat indicator.

Key Switch Connection

Meter Panel

19 Glow Plug Relay

Preheat Indicator Timer

Slow Blow Fuse

Slow Blow Fuse

Diode

16 L

21

BY

20 01 03

L

L BY

BY Battery Starter Motor

Alternator

Glow Plug

T4EK-02-03-006

T2-3-9

30_42ZV-2

SYSTEM / Electrical System CHARGING CIRCUIT 1. After the engine starts and the key switch is released, the switch turns to the ON position.

When the key switch is in the ON position, terminal B is connected to terminal B, terminal Acc and terminal R2 in the starter switch.

2. When the engine starts, the alternator starts rotating and generating electricity.

3. Current from alternator terminal B flows to the batteries through the slow blow fuse (75 A) and charges the batteries.

At the same time, current flows through the fuse box and powers the head light and others. In addition, current from terminal N of the alternator flows to relay [1].

When the battery charge is normal, the alternator indicator goes off.

Key Switch Connection

Meter Panel Alternator Indicator

Relay [1]

Fuse Box

Slow Blow Fuse

Slow Blow Fuse

11

21

03

20

01 B

WR B

B

Starter Motor WR

Alternator

WR Battery

T4EK-02-03-007

T2-3-10

30_42ZV-2

SYSTEM / Electrical System STARTING CIRCUIT 1. Key switch ON o START operation:

2. Key switch ON o START operation on the engine operating condition:

The starter relay coil is energized from key switch terminal C through the neutral switch of the shift lever. The relay is closed.

Therefore, positive current from the battery relay flows through the starter relay to the starter motor and the starter motor is operated.

Key Switch Connection

Fuse Box

Current does not flow to the starter relay coil as terminal L in the alternator is not grounded (the monitor lamp goes off) in the engine operating condition.

The relay is opened and the starter motor is not operated.

Diode Starter Relay

Slow Blow Slow Blow Fuse Fuse

21 18 20

17

01

01

Battery

31

Fuel Pump

22

Shift Lever Alternator Starter Motor Stop Solenoid

26

Engine

08

T4EK-02-03-008

T2-3-11

30_42ZV-2

SYSTEM / Electrical System ENGINE STOP CIRCUIT 1. Starter switch is ON: Positive current from the fuse box energizes the stop solenoid coil and is operated.

2. Starter switch is OFF: The engine stops since current does not flow to stop solenoid coil.

Key Switch Connection

Diode Starter Relay

Fuse Box

Slow Blow Slow Blow Fuse Fuse

21 18 20

17

01

01

Battery

31

Fuel Pump

22

Shift Lever Alternator Starter Motor Stop Solenoid

08

26

Engine

T4EK-02-03-009

T2-3-12

30_42ZV-2

SYSTEM / Electrical System MONITOR INDICATOR CIRCUIT

Relay [1] (For Monitor Indicator Check and Parking )

Fuse Box

Monitor Panel

Relay [2] (For Monitor Indicator Check)

11

12

03

01

01

02

02 Brake Fluid Level Switch

Alternator Engine Oil Pressure Switch Engine

03 T4EK-02-03-010

T2-3-13

30_42ZV-2

SYSTEM / Electrical System GAUGE CIRCUIT Coolant Temperature Gauge

Monitor Panel Fuel Gauge

Fuse Box Hour Meter

04

03

01

01

Fuel Sensor

Engine Coolant Temperature Sensor

02

02

T4EK-02-03-011

T2-3-14

30_42ZV-2

SYSTEM / Electrical System TRAVEL CIRCUIT Relay [1] (For Monitor Indicator Check and Parking Brake)

Relay [3] (For Parking Brake)

Relay [4] (For Parking Brake)

Fuse Box

11

13

14

Parking Brake Switch

05

Meter Panel

01 02 04 Shift Lever

08

[F] Solenoid

[R] Solenoid

HST Pump Parking Brake Solenoid

Parking Brake Solenoid Valve

T4EK-02-03-012

T2-3-15

30_42ZV-2

SYSTEM / Electrical System TRAVEL CIRCUIT (FORWARD) Shift lever “N” o “F”: In case parking brake is released, relay [4] is closed (refer to Parking Brake Circuit) and current from the fuse flows to the parking brake solenoid and the shift lever.

Current flows to solenoid F of HST pump by operating the shift lever “N” o “F”.

Relay [3] (For Parking Brake)

Relay [4] (For Parking Brake)

Relay [1] (For Monitor Indicator Check and Parking Brake)

Fuse Box

11

13

14

Parking Brake Switch

05

Monitor Panel

01 02 04 Shift Lever

08

[F] Solenoid

[R] Solenoid

HST Pump Parking Brake Solenoid

Parking Brake Solenoid Valve

T4EK-02-03-013

T2-3-16

30_42ZV-2

SYSTEM / Electrical System TRAVEL CIRCUIT (BACKWARD) Shift lever: In case “N” o “R” parking brake is released, relay [4] is closed (refer to Parking Brake Circuit) and current from the fuse flows to the parking brake solenoid and the shift lever.

Current flows to solenoid R of HST pump by operating the shift lever “N” o “R”.

Relay [3] (For Parking Brake)

Relay [1] (For Monitor Indicator Check and Parking Brake)

Relay [4] (For Parking Brake)

Fuse Box

11

13

14

Parking Brake Switch

05

Monitor Panel

01

02 04 Shit Lever

To Back Lamp

08

[F] Solenoid

[R] Solenoid

HST Pump Parking Brake Solenoid

Parking Brake Solenoid Valve T4EK-02-03-014

T2-3-17

30_42ZV-2

SYSTEM / Electrical System PARKING BRAKE CIRCUIT Then, current does not flow to the parking brake switch and the parking brake is locked.

Current from other fuse flows through relay [4] and lights the parking brake monitor indicator.

Before Starting the Engine (Key Switch is ON): Current from the fuse to relay [1] energizes the relay coil and the relay is opened.

Relay (3) Relay (4)

Relay (1)

Parking Brake Switch

Alternator

Fuse

Shift Lever

Parking Brake Solenoid Valve Parking Brake Solenoid

[F] Solenoid

[R] Solenoid HST Pump

T4EK-02-03-015

T2-3-18

30_42ZV-2

SYSTEM / Electrical System After Starting the Engine: As relay [4] is not operated, current keeps the parking brake lock conditions and lighting the monitor indicator.

5. Current from the fuse to relay [1] flows to terminal [6] of the parking brake switch as the relay is closed.

Relay (1)

Relay (3)

Relay (4)

Parking Brake Switch

Alternator

Fuse

Shift Lever

Parking Brake Solenoid Valve Parking Brake Solenoid

[F] Solenoid

[R] Solenoid HST Pump

T4EK-02-03-016

T2-3-19

30_42ZV-2

SYSTEM / Electrical System 2. Parking brake switch is OFF As relay [4] is not operated, current keeps the parking brake lock conditions and lighting the monitor indicator.

(Rapid starting prevention circuit)

Current from the fuse to relay [1] flows to terminal [6] of the parking brake switch as the relay is closed.

Relay (1)

Relay (3)

Relay (4)

Parking Brake Switch

Alternator

Fuse

Shift Lever

Parking Brake Solenoid Valve Parking Brake Solenoid

[F]Solenoid

[R]Solenoid HST Pump

T4EK-02-03-017

T2-3-20

30_42ZV-2

SYSTEM / Electrical System 3. Parking Brake Switch is Operated ON2 (Auto Restoration) Current from the fuse to relay [1] flows to terminal [6] of the parking brake switch and flows from terminal [1-3] and terminal [4-6] to relay [3] and relay [4].

On the other hand, current to relay [4] energizes the relay [4] coil and the contact is opened.

The circuit to the monitor indicator is blocked and the monitor indicator goes off.

Current to relay [3] flows to the parking brake solenoid and the parking brake is unlocked.

Relay (3) Relay (4)

Relay (1)

Parking Brake Switch

Alternator

Fuse

Shift Lever Parking Brake Solenoid Valve Parking Brake Solenoid

[F] Solenoid

[R] Solenoid (HST Pump)

T4EK-02-03-018

T2-3-21

30_42ZV-2

SYSTEM / Electrical System After Operating the Parking Brake Switch to OFF (Auto Restoration): 1. Once the parking brake switch is ON2 (Auto Restoration), relay [4] is kept opened.

2. When the parking brake switch is turned ON1, terminal [1-2] and terminal [4-5] of the parking brake switch are connected.

Current energizes the relay [3] coil and the relay is opened.

Current to the parking brake solenoid is blocked and the parking brake is locked.

At the same time, the monitor indicator lights.

T2-3-22

30_42ZV-2

SYSTEM / Electrical System

Relay (4) Relay (1)

Relay (3)

Parking Brake Switch

Alternator

Fuse

Shift Lever

Parking Brake Solenoid Valve Parking Brake Solenoid

[F] Solenoid

[R] Solenoid HST Pump

T4EK-02-03-019

T2-3-23

30_42ZV-2

SYSTEM / Electrical System 3. Parking brake switch from ON1 to OFF).

Current from terminal [1-2] of the parking brake switch is blocked and relay [3] is closed.

Current is sent to the parking brake solenoid and the parking brake is released.

At the same time, the monitor indicator goes off.

Relay (3)

Relay (1)

Relay (4)

Parking Brake Switch

Alternator

Fuse

Shift Lever

Parking Brake Solenoid Valve Parking Brake Solenoid

[F] Solenoid

[R] Solenoid HST Pump

T4EK-02-03-020

T2-3-24

30_42ZV-2

SYSTEM / Electrical System LIGHT CIRCUIT Meter Panel

Flasher Flasher Unit Unit

Fuse Box

Indicator

05

06

Fuel Gauge

Parking Brake Switch Coolant Temperature Gauge

Shift Lever

01

15

01

15

08

02 Hazard Switch

06

07 02

License Light (Optional)

Combination Light Switch Clearance Light (5W)

Turn Signal Light R.H (21W)

Stop Light Switch Turn Signal Light R.H (21W)

23

10

09

Tail Light (5W) Reverse Light (21W) Stop Light (21W)

Head Light (55W)

Turn Signal Light R.H (21W) Head Light (55W) Turn Signal Light L.H (21W)

Tail Light (5W) Stop Light (21W)

Battery

24

Clearance Light (5W)

T4EK-02-03-021

NOTE: Refer to the Electrical Circuit (pp.T2-3-2 and T2-3-3) and the coupler position (p.T2-3-4) for the indicated coupler numbers.

T2-3-25

30_42ZV-2

SYSTEM / Electrical System

Hazard Switch

HORN CIRCUIT

Dimmer Switch

07

10 Fuse Box

Horn Switch

Combination Light Switch

Steering Column

Horn

10

10

T4EK-02-03-022

AUTO LEVELER CIRCUIT 32

C/V Tilt Detent

Auto Leveler Proximity Switch

Diode

33

01

01

Fuse Box

10

T4EK-02-03-023

NOTE: Refer to the Electrical Circuit (pp.T2-3-2 and T2-3-3) and the coupler position (p.T2-3-4) for the indicated coupler numbers.

T2-3-26

30_42ZV-2

SECTION 3

COMPONENT OPERATION Group 1 HST Pump

CONTENTS

Group 5 Orbitrol

HST Circuit...............................................T3-1-1

Power Steering (Orbitrol) ..........................T3-5-1

HST Pump ...............................................T3-1-2

Operation in Neutral .................................T3-5-3

High-Pressure Relief Valve.......................T3-1-4

Right Turn Operation ................................T3-5-5

HST Pump Characteristic Curve ...............T3-1-6

Relief Valve Operation ..............................T3-5-6

DA Control................................................T3-1-7 Displacement Angle Return Force

Group 6 Control Valve

and Advance.........................................T3-1-16

Control Valve ............................................T3-6-1

Inching Valve..........................................T3-1-17

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

Automatic Transmission Function ...........T3-1-18

Operation of Tilt Section ...........................T3-6-4

Torque Control Function .........................T3-1-18

Operation of Lift Section ...........................T3-6-7 Detent Operation .................................... T3-6-11

Group 2 HST Motor

Relief Valve ............................................T3-6-12

HST Motor................................................T3-2-1 Pilot Pressure Proportional Control (HD Control) ...........................................T3-2-2

Anti-Void Valve .......................................T3-6-14

Group 7 Main Pump

Constant Pressure Control .......................T3-2-2

Main Pump ...............................................T3-7-1

HD Control ...............................................T3-2-3

Return Filter .............................................T3-7-2

Group 3 Axle Axle..........................................................T3-3-1 Differential Assembly................................T3-3-2 Limited Slip Differential (LSD) ..................T3-3-3 Final Drive Assembly ................................T3-3-5

Group 4 Brake Service Brake...........................................T3-4-1 Parking Brake ..........................................T3-4-4 Towing Machine Method (In Emergency) .......................................T3-4-6 Wet Type Brake Assembly in Reduction Gear ......................................T3-4-7 Master Cylinder ........................................T3-4-8

T-3-1

30_42ZV-2

(Blank)

T-3-2

30_42ZV-2

COMPONENT OPERATION / HST Pump HST CIRCUIT HST is the hydraulic drive device to transfer the driving force to the wheels by using oil.

HST provides both functions of the clutch and transmission. The variable conversion can be performed by the hydraulic control.

HST uses basically slow and high-pressurized oil. HST is the oil circulation type closed circuit composed of the pump and the motor.

HST of this machine is equipped with the variable displacement type axial piston pump and the variable displacement type motor.

The mechanical power from the engine is converted to hydraulic pressure by the pump. This hydraulic pressure is converted the mechanical power by the motor again. The mechanical power is transmitted to the wheels.

There are three elements to control HST. By controlling these three elements, the machine can travel smoothly.

Oil Delivery Flow Rate o Vehicle Speed Oil Flow Direction o Forward and Reverse Travel (FNR) Oil Pressure o Driving Force

Operational Principle From Engine Pump

Swash Plate

To Wheel

Motor

Piston

Cylinder Block

(Forward) Piston

(Stop)

(Reverse)

As the input shaft rotational direction of the pump is always the same direction and the delivery pressurized oil direction from the pump is changed according to tilting the swash plate, the output shaft rotational direction of the motor is changed.

Therefore, FNR control is performed according to tilting the swash plate.

Slow Speed

Torque is large.

Cylinder block large tilt angle

In addition, the fast-slow selection is performed by changing the cylinder block tilt angle.

Fast

Torque is small.

Cylinder block small tilt angle

T4EK-03-01-001

T3-1-1

30_42ZV-2

COMPONENT OPERATION / HST Pump HST PUMP The cylinder block connects to the drive shaft and rotates. Then, the piston installed in the cylinder block reciprocates according to the swash plate, and the volumetric change occurs.

In addition, the gear pump is installed to the drive shaft and used for charging oil in the closed circuit and for the pilot of displacement angle control.

The pumping actions such as suction and delivery are performed. The suction and delivery operation is continuously performed by rotating the drive shaft, as each nine piston performs one stroke of suction and delivery on every one revolution.

Drawing

A

Drive Shaft B Swash Plate

Piston

Cylinder Block

Delivery T4EK-03-01-002

DA Controller

High-Pressure Relief Valve

DA Valve

Charge Pump

Low-Pressure Relief Valve

T3-1-2

T4EK-03-01-003

30_42ZV-2

COMPONENT OPERATION / HST Pump HST Pump Drain Port T2 (G1/2 O-Ring Port)

High-Pressure Gauge Port Ma (G1/4 O-Ring Port)

DA Valve

Charge Pressure Port G (G1/4 O-Ring Port) Low-Pressure Relief Valve Pilot Pressure Port Ps (G1/4 O-Ring Port)

High-Pressure Gauge Port (Reverse) Mb (G1/4 O-Ring Port)

Solenoid “b”

Pilot Pressure Measuring Port (Forward) X2 (G1/4 O-Ring Port)

Pilot Pressure Measuring Port (Reverse) X1 (G1/4 O-Ring Port)

Solenoid “a”

High-Pressure Relief Valve Drain Port T1 (G1/2 O-Ring Port)

High-Pressure Main Port (Reverse) B (SAE Flange High-Pressure 3/4)

HST Lubrication Pump and Main Pump Mounting Part

High-Pressure Main Port (Forward) A (SAE Flange High-Pressure 3/4)

High-Pressure Relief Valve

Filter Port Fa (G3/8 O-Ring Port)

T4EK-03-01-004

T3-1-3

30_42ZV-2

COMPONENT OPERATION / HST Pump HIGH-PRESSURE RELIEF VALVE The high-pressure relief valve regulates the circuit maximum pressure and protects the circuit on the high-pressure side.

In addition, the high-pressure relief valve has a built-in check valve for charging.

When the flow rate to the suction circuit is insufficient, the charging pressure is routed to the suction circuit.

1

2 3 4 5 6 A

7 8

B 1 - Rod 2 - O-Ring 3 - Spring

4 - Hexagon socket screw 5 - O-Ring 6 - Adjust Spring

7 - Poppet 8 - Valve Seat

T4EK-03-01-005

AB-

HST High-Pressure (Low-Pressure) Circuit Charging Circuit

< Relief Operation > As the hydraulic pressure in high-pressure circuit [A] is greatr than the spring force applied by spring (6), poppet (7) is pushed down (as illustrated) and the high-pressure circuit [A] is routed to the charging circuit [B].

A

6 7 B

T4EK-03-01-006

T3-1-4

30_42ZV-2

COMPONENT OPERATION / HST Pump < Bypass Operation > When the hydraulic pressure in low-pressure circuit [A] and the spring force applied by spring (3) are smaller than the hydraulic pressure in charging circuit [B], the valve seat (8) is pushed upward (as illustrated) and the charging circuit [B] is routed to the low-pressure circuit [A].

3

A

8

B

T4EK-03-01-007

< Towing Operation (Engine stops) > 1

By tightening rod (1), poppet (7) is pushed down (as illustrated) and the high-pressure circuit [A] is routed to the charging circuit [B].

A

7 B

T4EK-03-01-008

Low Pressure Relief Valve The low-pressure relief valve always operates during operation and regulates charging pressure.

The relieved oil returns to the tank through the pump housing for lubrication and cooling.

T3-1-5

30_42ZV-2

COMPONENT OPERATION / HST Pump HST PUMP CHARACTERISTIC CURVE

T4EK-03-01-010

2

NOTE: 1 kgf/cm =14.2 psi

T3-1-6

30_42ZV-2

COMPONENT OPERATION / HST Pump DA CONTROL Advantages

DA Valve

1. The delivery direction of pressurized oil can be changed by the selector solenoid.

FNR selection can be performed with one switch.

The gear pump is coaxially connected to HST pump for charge and pilot.

2. The delivery flow rate is controlled according to the engine speed. The vehicle speed can be controlled by the accelerator control only.

3. The torque constant control method is adopted.

When the load increases, the torque constant control limits the delivery flow rate to prevent the engine overload.

The gear pump flow rate is changed in proportion to the engine speed. All flow goes to the charging circuit through the orifice of DA valve. DA valve decreases charging pressure to generate control pressure by using the signals based on the pressure difference between the front and rear of the orifice, generated by the flow rate change.

Thus, the pump displacement angle is controlled by the pressure proportional to the engine speed.

The charging pump delivery flow rate proportional to the engine speed flows to charging circuit [C] through port [A].

DA valve decreases the pressure in the charging circuit [C] to generate control pressure in control circuit [B] by using the signals based on the spring force applied by spring (4) and the pressure difference caused by the flow rate change between the front and rear of orifice (6).

123456-

3

Control Cartridge O-Ring Set Screw Adjust Spring Differential Piston Orifice

1 4

A- DA Valve Primary Side (From Charging Pump) B- DA Valve Secondary Side (To Control Circuit) C- DA Valve Secondary Side (To Charging Circuit) D- DA Valve Drain

C

2

Charging Circuit

5

D

Control Circuit Drain

B 6 Pump Circuit

T3-1-7

A T4EK-03-01-011

30_42ZV-2

COMPONENT OPERATION / HST Pump DA Valve

Main Circuit Pressure PH

Engine Displacement Angle Return Force

Control Pressure

Spring

(DA Valve)

To Charge Circuit

Low-Pressure Relief Valve

T4EK-03-01-012

T3-1-8

30_42ZV-2

COMPONENT OPERATION / HST Pump < Idle Operation > As the charging pump delivery flow rate is low, the pressure difference between the front and rear of orifice (6) is small.

Differential piston (5) is located in the illustrated position.

Consequently, the flow passage between charging circuit [C] and control circuit [B] is narrow, and the low control pressure is routed to control circuit [B].

C

Charging Circuit

5

Control Circuit

B 6

T4EK-03-01-013

< High Idle Operation > As the charging pump delivery flow rate is high, the pressure difference between the front and rear of orifice (6) is large.

Differential piston (5) is pushed upward as illustrated.

Consequently, the flow passage between charging circuit [C] and control circuit [B] widens, and the high control pressure is routed to control circuit [B].

C

Charging Circuit

5

Control Circuit

B

6

T4EK-03-01-014

T3-1-9

30_42ZV-2

COMPONENT OPERATION / HST Pump DA Control 4 3 5

To Inching Valve

To Parking Brake

12 17

1

6 G

To Motor X

C

F

9

PS

2

X2

15

11

16 13 7

18

D

19

14

B 16

8

A

11 X1

10 E

15

17

12

T4EK-03-01-015

1234567-

Low-Pressure Relief Valve O-Ring DA Valve Set Screw Adjust Spring O-Ring Differential Piston

8 - Orifice 9 - Solenoid Valve [b] 10 - Solenoid Valve [a] 11 - O-Ring 12 - O-Ring 13 - Control Piston

14 - Displacement Angle Piston 15 - Guide Ring 16 - Turcon® Glyd Ring® 17 - O-Ring 18 - Swash Plate 19 - Slide Ring

ABCDEF-

T3-1-10

DA Valve Primary Side (From Charging Pump) DA Valve Secondary Side (To Control Circuit) DA Valve Secondary Side (To Charging Circuit) DA Valve Drain Displacement Angle Piston (x1) Displacement Angle Piston (x2)

30_42ZV-2

COMPONENT OPERATION / HST Pump < Neutral Operation >

T4EK-03-01-016

T3-1-11

30_42ZV-2

COMPONENT OPERATION / HST Pump < Forward Travel Operation > When the shift lever is set to “Forward” position, solenoid valve [a] (10) is energized and control piston (13) connected to the solenoid valve is pushed up (as illustrated below).

Control circuit [B] generated from DA valve (3) is routed to right chamber [F] of the displacement angle piston.

Consequently, the hydraulic pressure proportional to the pressure in control circuit [B] acts on displacement angle piston (14) and the piston moves down (as illustrated below).

Swash plate (18) is connected to displacement angle piston (14) through slid ring (19).

HST pump delivers oil to the forward direction travel circuit by rotating swash plate (18) in clockwise direction to the illustrated position.

3

F

13 19 14

B

10

18

T4EK-03-01-017

T3-1-12

30_42ZV-2

COMPONENT OPERATION / HST Pump < Reverse Travel Operation > When the shift lever is set to “Reverse” position, solenoid valve [b] (9) is energized and control piston (13) connected to the solenoid valve is pushed down (as illustrated below).

Control circuit [B] generated from DA valve (3) is routed to left chamber [E] of the displacement angle piston.

Consequently, the hydraulic pressure proportional to the pressure in control circuit [B] acts on displacement angle piston (14) and the piston moves up (as illustrated below).

Swash plate (18) is connected to displacement angle piston (14) through slid ring (19).

HST pump delivers oil to the reverse direction travel circuit by rotating swash plate (18) in counterclockwise direction to the illustrated position.

3

9

13 14 19 B 18

E

T4EK-03-01-018

T3-1-13

30_42ZV-2

COMPONENT OPERATION / HST Pump Displacement Angle Mechanism The displacement angle piston is connected to the swash plate pin.

The displacement angle piston has a built-in spring.

The built-in spring force acts to return the displacement angle piston to the neutral position (the delivery flow rate is zero.).

The displacement angle piston position, the pump flow rate in other words, is determined by the control pressure change routed to the displacement angle cylinder.

The energized solenoid and the pump delivery direction of the direction selector valve are: <Pressure Generating Port When Applying Current to Solenoid>

Energized Solenoid

Delivery Port

Pilot Port

Solenoid (a)

A (Forward Direction)

X2

Solenoid (b)

B (Reverse Direction)

X1

T3-1-14

30_42ZV-2

COMPONENT OPERATION / HST Pump Control Pressure P3 sol.a

sol.b X1

X2 Pin

Spring

Displacement Angle Piston

Swash Plate Pin

sol.b

sol.a T; Displacement Angle

S

S

S

q Displacement

Drawing

Delivery

P3 Control Pressure

T4EK-03-01-019

T3-1-15

30_42ZV-2

COMPONENT OPERATION / HST Pump DISPLACEMENT ANGLE RETURN FORCE AND ADVANCE The hydraulic pressure acts on the swash plate via the piston.

The eccentric pin on the adjusting screw end is connected to the groove on the control plate.

As the high/low-pressure shifting point of the control plate is installed in the rotation direction with an advanced angle, the point of action on the high-pressure part applied on the piston is displaced from the pivot of swash plate.

The advance adjustment of the control plate can be performed according to the amount of this eccentricity by turning the adjusting screw.

Force F acts to return the displacement angle according to displacement “e” between this pivot and the point of action. (Displacement angle return force is known as self-recovery force.)

T = 2q

P

Advance is Small.

T = 4q

T = 6q

Advance Adjusting Screw (Adjusting Range 4 r 2°)

Piston

Swash Plate

Piston

Advance is Large. q

Control Plate

T

Swash Plate Pivot

Pivot

F

e

e

High-Pressure Part

Swash Plate

Swash Plate (Viewed from Drive Shaft)

T4EK-03-01-020

T3-1-16

30_42ZV-2

COMPONENT OPERATION / HST Pump INCHING VALVE The inching valve is separated from the HST pump and connected through the link and rod of brake.

As port (P) is connected to the DA pilot pressure circuit, pilot pressure becomes low by draining to the hydraulic tank.

The pump displacement angle is decreased.

When depressing the brake pedal, the lever rotates.

When the lever rotates, the spool also rotates and the oil passage on the spool is connected to the oil passages of port (P) and port (T).

Brake Pedal (Right)

Inching Valve

Lever

B B T

P

Section B-B T4EK-03-01-021

Use this function when you want to change vehicle

speed slowly, or to stop the vehicle traveling while in creasing the engine speed and the operation speed.

P3 (Control Pressure)

P3 (Control Pressure)

Inching Lever Angle is large N (Engine Speed)

N (Engine Speed) T4EK-03-01-022

T3-1-17

30_42ZV-2

COMPONENT OPERATION / HST Pump AUTOMATIC TRANSMISSION FUNCTION The direction selector valve selects the displacement angle cylinder direction.

The control pressure proportional to the engine speed is routed from DA valve to the displacement angle cylinder.

The control pressure is smaller than the spring force of the displacement angle piston while engine idling. The pump stops in neutral. q

The control pressure increases and bends the spring according to increase in the engine speed and changes the pump displacement angle.

Therefore, as the pump delivery flow rate is changed according to the engine speed, the vehicle speed control can be performed continuously by operating the accelerator.

P3

V

qmax

P3

N

N

T4EK-03-01-023

q: Pump Displacement P3: Control Pressure N: Engine Speed V: Vehicle Speed

TORQUE CONTROL FUNCTION When increasing pressure, the displacement angle return force increases and the pump displacement angle is decreased.

The approximate torque constant control is adopted.

As the setting torque is determined by the balance between the displacement angle return force and the force by the control pressure and the spring, the setting torque is changed according to the engine speed.

When the excessive load to exceed the engine torque is applied on the engine, the engine speed level decreases from N1 to N2 shown below.

When the engine speed decreases, the pump driving torque is reduced.

The pump displacement angle is balanced depending on the engine torque.

When the engine speed decreases due to the increased load, HST pump automatically performs the displacement angle control to apply the engine torque efficiently without an engine stall.

P

P

P, T N = N1 N Large N = N2

Q

T

Engine Torque

T = Constant N Small q

q

Q Flow Rate

T4EK-03-01-024

T3-1-18

30_42ZV-2

COMPONENT OPERATION / HST Motor HST MOTOR Motor Operation The connected port of pressurized oil (A or B) determines the rotation direction of drive shaft.

Seven pistons are installed to the cylinder block in a circle under running HST motor.

When pressurized oil flows to the cylinder block, the piston pushes the drive shaft to rotate. A piston moves one stroke per one revolution to suck and drain oil. The drive shaft can rotate smoothly by operating seven pistons continuously.

In addition, as larger the displacement angle, the more suction increases, and the speed decreases.

The control plate is connected to the control piston via the connecting rod. The displacement angle is determined according to the control piston position.

F; Component Force of Hydraulic Pressure FP

FP F

As the component force of hydraulic pressure becomes the rotational force, larger displacement angle generates stronger rotational force.

T Drive Shaft

Cylinder Block

T; Displacement Angle

A B

Piston

Control Piston

qmin

qmax

Drive Shaft

Connecting Rod Cylinder Block

Control Plate

T4EK-03-02-001

T3-2-1

30_42ZV-2

COMPONENT OPERATION / HST Motor PILOT PRESSURE PROPORTIONAL CONTROL (HD CONTROL)

CONSTANT PRESSURE CONTROL

Pressurized oil from each high-pressure side (A or B) flows to the small diameter side of control piston (cyclic area) through the check valve.

The rotary group is pushed to the maximum displacement angle position.

Primary side pressure of control bushing is connected to the cutoff valve and facing to the cutoff pressure adjusting spring.

Pressurized oil from each high-pressure side (A or B) then flows to the primary side of control bushing.

When high-pressure oil in the main circuit exceeds this spring force, the spool moves and pressurized oil in the large diameter side of control piston is returned to the hydraulic tank.

The secondary side of control bushing is connected to the large diameter side of control piston through the cutoff valve.

Then, as the motor tilts to the maximum displacement angle side, the driving torque increases and increase in the main circuit pressure is temporarily prevented.

When pilot pressure from port X exceeds the initial load of the adjust spring set by the adjusting screw, the pilot piston moves to the spring side. The oil passages of control bushing on both the primary side and the secondary side open. The high-pressure oil in the main circuit flows into the large diameter side of control piston.

At this time, the main circuit pressure is kept at constant until the motor becomes to the maximum displacement angle side.

In addition, when the load increases and main circuit pressure is cutoff pressure or more, the motor is held at the maximum displacement angle.

Then, the control piston moves to the minimum displacement angle (qmin). As the displacement becomes small, torque is small and the speed is high.

Thus, the movement of control piston is changed according to the displacement angle. When the control piston moves to the qmin direction, the feedback spring is compressed in proportion to the changed amount.

Therefore, a new balance is generated between thrust force based on pilot pressure and feedback spring force. The oil passages of control bushing on both the primary side and the secondary side close. The displacement angle is held by the pilot pressure.

When pilot pressure is decreased and the feedback spring force exceeds it, the pilot piston is moved backward. The secondary side of control bushing is routed to the hydraulic tank and pressurized oil in the large diameter side of control piston returns to the hydraulic tank.

Thus, the displacement angle moves to the large diameter side by pressurized oil in the small diameter side of control piston and the feedback spring force.

The displacement angle is changed to the new displacement angle according to pilot pressure.

T3-2-2

30_42ZV-2

COMPONENT OPERATION / HST Motor HD CONTROL

2

1 Px

11 G

Movement of Pilot Piston

A PH (=PA or PB)

10 9 B

3

PA

4

A

PB

(Forward)

(Reverse)

8 B

qmin qmax Pc

12 Movement of Control Piston

13

14

C D

5 6

Movement of Cutoff Valve M1

7

T4EK-03-02-002

12345-

Pilot Piston Set Screw Adjust Spring Feedback Spring Control Piston

6 - O-Ring 7 - Restriction Valve 8 - Check Valve 9 - O-Ring 10 - Backup Ring

11 - O-Ring 12 - Cutoff Valve 13 - Adjust Spring 14 - Set Screw

T3-2-3

ABCD-

Control Bushing Primary Side Control Bushing Secondary Side Control Piston Small Diameter (Cyclic) Side Control Piston Large Diameter Side

30_42ZV-2

COMPONENT OPERATION / HST Motor HD Control (When Machine Stops (Idle Operation)) As hydraulic pressure by pilot pressure “Px” is smaller than springs (3) and (4) force, pilot piston (1) is located in the illustrated position. Pressure in the control bushing primary side [A] is blocked.

Also, as the hydraulic pressure in the control bushing primary side [A] acting on cutoff valve (12) is smaller than spring (13) force, cutoff valve (12) is located in the illustrated position.

Px

Pressurized oil in the control piston large diameter side [D] is released to the hydraulic tank.

Consequently, hydraulic pressure, which varies depending on the pressure in the control piston small diameter side [C], acts on control piston (5).

Control piston (5) is kept onto the large displacement angle side as illustrated below.

1 A

3

4

qmax

12

13

C 5 D

T4EK-03-02-003

T3-2-4

30_42ZV-2

COMPONENT OPERATION / HST Motor HD Control (Automatic Travel) As hydraulic pressure by pilot pressure “Px” in the control bushing primary side [A] is greater than springs (3) and (4) force, pilot piston (1) is located in the illustrated position. Pressure in the control bushing primary side [A] is routed to the control bushing secondary side [B].

Pressurized oil in the control bushing secondary side [B] is routed to the control piston large diameter side [D].

Consequently, the hydraulic pressure, which varies depending on the difference in the pressure receiving areas between the control piston large diameter side [D] and the small diameter side [C], acts on control piston (5).

As hydraulic pressure in the control bushing primary side [A] acting on cutoff valve (12) is smaller than spring (13) force, cutoff valve (12) is located in the illustrated position.

Control piston (5) moves to the small displacement angle side as illustrated.

Px

1 A B

3

4

qmin

12 5

13

C D

T4EK-03-02-004

T3-2-5

30_42ZV-2

COMPONENT OPERATION / HST Motor HD Control (At Maximum Traction Power) As hydraulic pressure by pilot pressure “Px” in the control bushing primary side [A] is greater than springs (3) and (4) force, pilot piston (1) is located in the illustrated position. Pressure in the control bushing primary side [A] is routed to the control bushing secondary side [B].

As hydraulic pressure in the control bushing primary side [A] acting on cutoff valve (12) is greater than spring (13) force, cutoff valve (12) is located in the illustrated position.

Px

Pressurized oil in the control bushing secondary side [B] is blocked and pressurized oil in the control piston large diameter side [D] is released to the hydraulic tank.

Consequently, hydraulic pressure, which varies depending on the pressure in the control piston small diameter side [C], acts on control piston (5).

Control piston (5) is moved to the large displacement angle side as illustrated.

1 A

3

4

qmax

12

13

C

D 5

T4EK-03-02-005

T3-2-6

30_42ZV-2

COMPONENT OPERATION / Axle AXLE The axle consists of the axle tube, the differential assembly, the final drive assembly (final reduction gear) and the drive shaft. The wheels are installed to the drive shaft.

Power from the reduction gear is transmitted to the front axle and the rear axle via the propeller shaft.

Inside the axle, power is transmitted to the differential assembly, divided into right and left, and transmitted to the final drive assembly (final reduction gear) through the drive shaft to drive the axle shaft and the wheels.

The front axle is directly secured to the front chassis with the bolts.

The rear axle adopts the cradle pin support type, which supports the front and rear of the rear axle to the rear chassis by the axle support.

Therefore, the rear axle oscillates around the front and rear cradle pins depending on unevenness on the road.

Front Axle

Rear Axle T4EK-03-03-001

T3-3-1

30_42ZV-2

COMPONENT OPERATION / Axle DIFFERENTIAL ASSEMBLY The differential assembly consists of the reduction gear device and the actuator as one unit.

The differential assembly changes the direction of power through the propeller shaft at right angle by using the drive pinion and the ring gear.

Also, the differential assembly reduces the gear speed and transmits to the drive shaft.

Operation of Differential Gear When traveling straight, the pinion gear in the differential case does not rotate and the ring gear, the differential case and the side gear solidly rotate.

The same speed powers from the right and left gears are transmitted to the wheels through the axle shaft respectively.

When changing the machine direction (turning machine) and moving on the uneven working surface, as the right and left wheels speed are different, the pinion gear in the differential case rotates according to the difference between the right and left side gear speeds in order to travel smoothly.

2

1

Speed is High

Speed is Low

3

4 5

7

6

When Traveling Straight

When Turning T4EK-03-03-002

1 - Pinion Gear 2 - Side Gear

3 - Drive Shaft 4 - Differential Case

5 - Spider 6 - Drive Pinion

T3-3-2

7 - Ring Gear

30_42ZV-2

COMPONENT OPERATION / Axle LIMITED SLIP DIFFERENTIAL (LSD) Operational Principle The wheel loader is often operated on slippery ground as when used in sand and muddy soil applications. In places like these, the tires will slip due to tractive conditions.

LSD is designed so that the clutch discs are inserted between the case and the pressure ring supporting the spider with the cam, which restricts the movement of the two axle shafts and helps keep tire speeds close to the same.

The variation of the tractive force transmitted to the left and right tires is greater than TPD.

As traction force may be transmitted to the slipping tire and not to the tire firmly contacting the work site surface, not only is the function of the wheel loader made less efficient but tire life is also shortened.

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.

Ring Gear Pressure Ring Side Gear

Pressure Plate Clutch Disc Case Spider

Pinion Gear

T4GB-03-10-003

T3-3-3

30_42ZV-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 to TPD.

Traveling on Ground with Less Traction (Different Road Resistances to Left and Right Tires) Tractive force is transmitted to the differential gear case, pressure ring and spider from the ring gear.

When this happens, the spider having the cam construction pushes the pressure ring with thrust force (P). The clutch disc is geared with the differential gear case through the pressure ring.

The side gears are fixed to the clutch discs by splines normally, the left and right gears rotate at the same speed.

Clutch Disc P

P

Pressure Plate

Spider Pressure Ring T4GB-03-10-004

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.

On such ground with less traction, the tractive force increases by 1.5 times the value for TPD if LSD is provided.

T3-3-4

30_42ZV-2

COMPONENT OPERATION / Axle FINAL DRIVE ASSEMBLY The final drive assembly (final reduction gear) is the planet torque-multiplying device to reduce the speed in the power transmitted from the differential assembly.

Operation of Planetary Gear Device As for power transmission, power from the differential assembly is transmitted from the shaft, rotates three planetary gears in the ring gear, and transmits rotation of the planetary gear to the axle shaft through the planet carrier with the drive power increased.

8

To Wheel

3

7

6

5

4

3

2

4 6 Flow of Power

5

1

10 5 Section A-A (Operation of Planetary Gear)

10

6 9

4

TE804-03-03-003

1 - Drive Pinion 2 - Differential 3 - Gear and Shaft

4 - Planet Shaft 5 - Planet Gear 6 - Ring Gear (Stationary)

7 - Planet Carrier 8 - Drive Shaft

T3-3-5

9 - Ball 10 - Needle Bearing

30_42ZV-2

COMPONENT OPERATION / Axle (Blank)

T3-3-6

30_42ZV-2

COMPONENT OPERATION / Brake SERVICE BRAKE When brake is applied: 1. When depressing brake pedal (1) (either right or left), HST pump inching valve (2) operates at first.

The braking force is generated as well as the drive force stops in order to stop the oil feed from HST pump. (HST brake function)

3. Therefore, service brake piston (6) moves and pushes brake disk (7) to generate the brake force.

4. In addition, brake light switch (8) is turned ON and the stop light lights.

2. In addition, push rod (3) operates and the piston in master cylinder (4) is pushed. Pressurized oil generated from the piston is sent to service brake cylinder chamber (5) in the reduction gear.

8

ON

Depressing Brake Oil Tank

1

2

3 HST Pump

4

Reduction Gear

Parking Brake Solenoid Valve

7

6

5 Parking Brake Piston T4EK-03-04-001

T3-4-1

30_42ZV-2

COMPONENT OPERATION / Brake When brake is released: 1. When releasing brake pedal (1) (either right or left), push rod (3) in master cylinder (4) is pulled out in initial conditions. Brake oil in service brake cylinder chamber (5) in the reduction gear is returned to the master cylinder.

3. HST pump inching valve (2) lever is returned to the original position. The inching (HST brake function) is released.

4. Brake light switch (8) is turned OFF and the stop light goes off.

2. Service brake piston (6) is free and brake disk (7) is released.

8

Release

1

OFF

Brake Oil Tank

3

2

HST Pump

4

Reduction Gear

7

6

Parking Brake Solenoid Valve

5

Parking Brake Piston T4EK-03-04-002

T3-4-2

30_42ZV-2

COMPONENT OPERATION / Brake (Blank)

T3-4-3

30_42ZV-2

COMPONENT OPERATION / Brake PARKING BRAKE The parking brake uses the wet type disc in combination with the service brake and consists of the HST charge hydraulic circuit as hydraulic source and the electrical circuit such as the parking brake switch and the parking brake solenoid valves.

Operation of Parking Brake 1. When pushing parking brake switch (9) by hand to turn ON, hydraulic oil in parking brake cylinder chamber (11) is drained by parking brake solenoid valve (10).

In order to operate the parking brake, operate the parking brake switch on the right side of the meter panel.

2. Parking brake piston (12) moves to the left by spring force (13). Service brake piston (6) is pushed and wet type disc brake (7) operates.

HST Pump

Parking Brake Operation Reduction Gear Parking Brake Switch ON

9 HST Charge Hydraulic Pressure

7

6

11

12

13

10 T4EK-03-04-003

T3-4-4

30_42ZV-2

COMPONENT OPERATION / Brake Unlock 1. When pushing parking brake switch (9) by hand to turn OFF, HST charge hydraulic pressure in parking brake cylinder chamber (11) acts on parking brake piston (12).

2. Parking brake piston (12) overcomes spring force (13) and moves to the right. Service brake piston (6) is free and wet type disc brake (7) is released.

HST Pump

Parking Brake Release Reduction Gear Parking Brake Switch OFF

9 HST Charge Hydraulic Pressure

7

6

11

12

13 10 T4EK-03-04-004

T3-4-5

30_42ZV-2

COMPONENT OPERATION / Brake TOWING MACHINE METHOD (IN EMERGENCY) Manual Release Method of Parking Brake As the parking brake release is performed with hydraulic pressure, even if the parking brake switch is turned to the OFF position, the parking brake is not released.

When towing the machine with the engine stopped, forcibly release (manual) the parking brake.

CAUTION: Do not tow with the parking brake forcibly released (manual) except for emergency.

A

1. Remove Bolt (1). (Releasing Bolt M10uL55) 2. Remove plug (2).

3. Tighten bolt (1) into the port A, replacing with the removed plug (2).

1

2

Parking Brake Piston

The parking brake piston is pulled back and parking brake is released in order to move the machine.

1

Disconnect HST Pump Hydraulic Circuit

High-Pressure Relief Valve

1. Loosen the relief valves (2 places) three times.

Short the circuit between high-pressure side and low-pressure side.

CAUTION: Do not loosen the relief valves (2 places) three times or more in order to prevent oil leaks.

High-Pressure Relief Valve T4EK-03-04-005

T3-4-6

30_42ZV-2

COMPONENT OPERATION / Brake WET TYPE BRAKE ASSEMBLY IN REDUCTION GEAR Natural Lubrication Mechanism In Wet Type Brake Reduction gear provides the wet type disc brake installed to the input shaft and uses the service brake and the parking brake in combination.

This mechanism is to pass pressurized oil into seal retainer (7) through oil hole (A) and lubricate pressurized oil in the reduction gear to the brake part by using splash lubrication.

Air Bleeder (For Bleeding Brake Air)

B From Parking Brake Solenoid Valve

From Master Cylinder

12

8

7

6

5

4

3

9

10

2

13

11

1

A

T4EK-03-04-006

1234-

Cap Piston Housing Wave Spring Brake Disc

5 - Brake Plate 6 - Brake Housing 7 - Seal Retainer

8 - End Plate 9 - Service Brake Piston 10 - Disc Hub

T3-4-7

11 - Spring 12 - Input Shaft 13 - Parking Brake Piston

30_42ZV-2

COMPONENT OPERATION / Brake MASTER CYLINDER The master cylinder is operated by operating the brake pedal and supplies the pressurized brake oil to the wet type disc brake in the reduction gear.

WARNING: Use the specified mineral brake oil for the brake oil tank in the master cylinder.

Do not use non-mineral (plant system) oil for automobiles.

Brake in Reduction Gear

6

From Brake Pedal

7

5

3

2

1

4

T4EK-03-04-007

1 - Cylinder 2 - Piston Assembly

3 - S Cup 4 - P Cup

5 - Snap Spring 6 - Bleeder Valve

T3-4-8

7 - Rod

30_42ZV-2

COMPONENT OPERATION / Orbitrol POWER STEERING (ORBITROL) The selection of the oil passage is performed with the orbitrol by operating (rotating by hand) the steering wheel. This hydraulic pressure allows the steering operation easily.

The rotor set is installed under the control valve and performs the metering function as an oil motor at normal operation.

The machine can be manually steered as the hand pump in emergency.

The orbitrol consists of the control valve and the rotor set. The control valve uses the rotary valve to select the oil passage to the steering cylinder by rotation.

R Port

8

P Port

A

To LS Check

EF Port

3

10

C C

T Port

L Port

A

7 6

9

5

4

2

1

Section A-A

Section C-C Main Relief Part

1

3

LS Check Part

4

10 3 8

9

T4EK-03-05-001

1 - Rotor 2 - Drive 3 - Sleeve

4 - Spool 5 - Pin 6 - Housing

7 - Center Ring Spring 8 - Spool

T3-5-1

9 - Relief Valve 10 - LS Check Valve

30_42ZV-2

COMPONENT OPERATION / Orbitrol When rotating the steering wheel, spool (4) is turned through the steering shaft. The relative displacement angle between spool (4) and sleeve (3) arises and the selection of the oil passage is performed.

Pressurized oil is sent to the steering cylinder through rotor (1). Sleeve (3) is turned by rotor (1) rotation through drive (2) and pin (5).

When sleeve (3) rotates according to spool (4) rotation, sleeve (3) closes the oil passage and stops.

When the steering wheel (spool) rotates, then sleeve (3) rotates in equal amount of rotation. By performing this operation continuously, the steering operation is performed.

Emergency Operation When pressurized oil is not supplied due to the faulty pump or the engine stop, the orbitrol provides the emergency steering functions in order to operate the steering.

NOTE: Unlike normal operation, the steering wheel operation becomes considerably heavy in emergency operation.

T3-5-2

30_42ZV-2

COMPONENT OPERATION / Orbitrol x Priority Valve (PV) Priority valve is built in the orbitrol and composes the load sensing system combining with the orbitrol.

Priority valve divides hydraulic oil delivered from main pump into the steering device and the loading device.

Priority valve also functions as relief valve in steering hydraulic circuit.

Section F-F Check Valve

F

To LS Check

EF Port P Port

F

To Main Relief

To LS Check T4EK-03-05-002

x Load Sensing System When the steering wheel is in neutral or in relief, almost all of total delivery flow from main pump is sent to the shovel device. When the steering wheel is turned, the flow rate according to the steering wheel rotation is sent to the steering device. The redundant oil is sent to the work device.

x Dynamic signal system This load sensing system uses the dynamic signal system built in LS line check system and CF line check valve in order to prevent the handle kick phenomenon.

T3-5-3

30_42ZV-2

COMPONENT OPERATION / Orbitrol OPERATION IN NEUTRAL The pressurized oil from the main pump is sent to the priority valve via port P.

At this time, priority valve spool (8) moves to the right according to the balanced force between the orifice force and the control spring. Then, almost all of the oil from the main pump flows to control valve via port EF as shown below.

Pressurized oil flows from priority valve spool (8) to orbitrol spool (4) through check valve (10), and returns to the hydraulic tank via port T through the return filter.

Power Steering (Orbitrol and Priority Valve)

V

4

Steering Cylinder

10 L R

17.2 MPa (175.4 kgf/cm 2, 2500 psi)

Pressure Port

T

P

Orifice

8

EF

Control Spring

Main Pump

0.15 MPa (1.5 kgf/cm 2, 22 psi) To Control Valve Port P

10 P Return Filter

0.05 MPa (0.5 kgf/cm 2, 7.3 psi)

Hydraulic Tank

T4EK-03-05-003

T3-5-4

30_42ZV-2

COMPONENT OPERATION / Orbitrol

T3-5-5

30_42ZV-2

COMPONENT OPERATION / Orbitrol RIGHT TURN OPERATION When turning the steering wheel to the right, the oil passage in the orbitrol circuit is changed as illustrated.

Pressurized oil flow from the main pump goes to the passage from spool (8) to spool (4), and also the passage from LS check valve (10) to spool (4).

Then, these flows are combined and send to the steering cylinder through rotor (1).

At this time, priority valve spool (8) moves to the left according to the balanced force between the orifice force and the control spring.

With the movement of spool (4), the flow rate according to the rotation of the steering wheel is sent to the steering cylinder and the rest is sent to the control valve.

1

V

4

Steering cylinder

10

L R

17.2 MPa (175.4 kgf/cm 2, 2500 psi)

Pressure Port

T

Power Steering (Orbitrol)

P

EF

8 Main Pump

0.15 MPa (1.5 kgf/cm 2, 22 psi) To Control Valve Port P

10 P Return Filter

Hydraulic Tank

T4EJ-03-05-004

T3-5-6

30_42ZV-2

COMPONENT OPERATION / Orbitrol RELIEF VALVE OPERATION When the steering cylinder reaches the stroke end or relief valve (9) set pressure while trying the steering wheel to turn, relief valve (9) operates.

Pressurized oil from the main pump flows from the orifice at priority valve spool (8) to the hydraulic tank through relief valve (9).

Power Steering (Orbitrol)

V

Steering Cylinder

L R

17.2 MPa (175.4 kgf/cm 2, 2500 psi)

Pressure Port

9 T

P

Orifice

EF Main Pump

0.15 MPa (1.5 kgf/cm 2, 22 psi) To Control Valve Port P 0.05 MPa (0.5 kgf/cm 2, 7.3 psi)

10 P Return Filter Hydraulic Tank

T4EJ-03-05-005

T3-5-7

30_42ZV-2

COMPONENT OPERATION / Loading Control Valve LOADING CONTROL VALVE The loading control valve consists of inlet section (7), lift section (2), tilt section (3), and outlet section (1).

The loading control valve is 2-spool valve to control the direction and pressure level of pressurized oil sent from the main pump.

Relief Valve

Detent Mechanism

The main relief valve is installed to the loading control valve. The main relief valve controls operating pressure and protects the total hydraulic circuit mechanism of the working device.

The valve detent mechanism is electromagnetic type detent (auto leveler device) installed to the tilt section.

The overload relief valves are installed to the both ports connected to the tilt cylinder.

When the abnormal load is applied on the tilt cylinder and cylinder port pressure exceeds the preset pressure, the excessive pressurized oil is released to protect the cylinder and piping.

Port A2

Port B2

Port B1

Port T

1 5 2 3 6

4

5

8 7 Port P

Port A1

T4EK-03-06-001

1 - Outlet Section 2 - Lift Section 3 - Tilt Section 4 - Main Relief Valve (20.6r0.5 MPa) (210r5.1 kgf/cm2, 2995r72.2 psi)

5 - Overload Relief Valve (22.6r0.5 MPa) (230r5.1 kgf/cm2, 3285r72.2 psi) 6 - Anti-Void Valve 7 - Inlet Section 8 - Electromagnetic Detent

T3-6-1

A1- Tilt Cylinder Rod Side A2- Lift Cylinder Rod Side B1- Tilt Cylinder Bottom Side B2- Lilt Cylinder Bottom Side

P- Pump T- Oil Tank

30_42ZV-2

COMPONENT OPERATION / Loading Control Valve OPERATION Each spool slides and the oil passage is selected by operating the control lever. The pressurized oil from the priority valve is sent to the tilt cylinder circuit or the lift cylinder circuit.

When operating the control lever to the “Float” position, detent mechanism installed to the lift spool (2) holds the position mechanically. Even if the lever is released, the spool is not returned to the neutral position.

When operating the control lever from the “Bucket Dump” position to the “Bucket Roll Back” position, electromagnetic detent mechanism (8) installed to tilt spool (3) holds the position electrically. Even if the lever is released, the spool is not returned to the neutral position until the bucket auto leveler is operated.

In other position, when the lever is released, the spool is returned to the neutral position automatically.

2

B2 A2

D.C.12V B1 A1

5 (DET) 22.6 MPa (230 kgf/cm 2, 3285 psi)

20.6 MPa (210 kgf/cm 2 2995 psi)

22.6 MPa (230 kgf/cm 2 3285 psi)

P

4

T

3

8

5 T4EK-03-06-002

T3-6-2

30_42ZV-2

COMPONENT OPERATION / Loading Control Valve (Blank)

T3-6-3

30_42ZV-2

COMPONENT OPERATION / Loading Control Valve OPERATION OF TILT SPOOL In Neutral position: 1. As the tilt spool is in the neutral position, the cylinder ports of A (rod side) and B (bottom side) are completely closed by the spool.

2. Pressurized oil to the loading control valve flows from the inlet section to the tilt spool and to the neutral (return) flow passage of the lift spool.

Pressurized oil is routed to the low-pressure flow passage in the outlet section and flows out from the inlet section.

1

B1

2

A1

2

3

4

2 T4EK-03-06-003

1 - Check Valve

2 - Delivery Oil from Pump

3 - Neutral (Return) Flow Passage Opened to Lift Section

T3-6-4

4 - Drain (Low-Pressure Return) Flow Passage Opened to Tank Port

30_42ZV-2

COMPONENT OPERATION / Loading Control Valve Bucket Roll Back position: 1. When the control lever is set to the “Bucket Roll Back” position, the tilt spool moves as shown below.

2. The neutral circuit is closed by the spool. The pressurized oil pushes to open the load check valve. The pressurized oil is delivered to cylinder port (B1) and sent to the tilt cylinder bottom side.

3. In addition, hydraulic oil delivered from the tilt cylinder rod side flows from cylinder port (A1) to the low-pressure flow passage and returns to the hydraulic tank.

1

B1

2

A1

2

3

4

2 T4EK-03-06-004

1 - Check Valve

2 - Delivery Oil from Pump

3 - Neutral (Return) Flow Passage Opened to Lift Section

T3-6-5

4 - Drain (Low-Pressure Return) Flow Passage Opened to Tank Port

30_42ZV-2

COMPONENT OPERATION / Loading Control Valve Bucket Dump position: 1. When the control lever is set to the “Bucket Dump” position, the tilt spool moves as shown below.

2. The neutral flow passage is closed by the spool.

The pressurized oil pushes to open the load check valve. The pressurized oil is delivered to cylinder port (A1) and sent to the tilt cylinder rod side.

3. In addition, hydraulic oil delivered from the tilt cylinder bottom side flows from cylinder port (B1) to the low-pressure flow passage.

1

B1

2

A1

2

3

4

2 T4EK-03-06-005

1 - Check Valve

2 - Delivery Oil from Pump

3 - Neutral (Return) Flow Passage Opened to Lift Section

T3-6-6

4 - Drain (Low-Pressure Return) Flow Passage Opened to Tank Port

30_42ZV-2

COMPONENT OPERATION / Loading Control Valve OPERATION OF LIFT SPOOL In Neutral position: 1. As the lift spool is in the neutral position, the cylinder ports of A (rod side) and B (bottom side) are completely closed by the spool.

2. Pressurized oil to the loading control valve flows from the inlet section to the neutral flow passage of the lift spool.

Pressurized oil is routed to the low-pressure flow passage in the outlet section and flows out from the inlet section.

1

B2

2

A2

2

4

3

2 T4EK-03-06-006

1 - Check Valve

2 - Delivery Oil from Pump

3 - Neutral Flow Passage Opened to Outlet Section

T3-6-7

4 - Drain (Low-Pressure Return) Flow Passage Opened to Tank Port

30_42ZV-2

COMPONENT OPERATION / Loading Control Valve Boom Raise position: 1. When the control lever is set to the “Boom Raise” position, the lift spool move as shown below.

2. The neutral flow passage is closed by the spool.

The pressurized oil pushes to open the load check valve. The pressurized oil is delivered to cylinder port (B2) and sent to the lift cylinder bottom side.

3. In addition, hydraulic oil delivered from the lift cylinder rod side flows from cylinder port (A2) to the low-pressure flow passage and returns to the hydraulic tank.

1

2

B2

A2

T4EK-03-06-007

2 1 - Check Valve

2 - Delivery Oil from Pump

4

3

2

3 - Neutral Flow Passage Opened to Outlet Section

T3-6-8

4 - Drain (Low-Pressure Return) Flow Passage Opened to Tank Port

30_42ZV-2

COMPONENT OPERATION / Loading Control Valve Boom Down position: 1. When the control lever is set to the “Boom Down” position, the lift spool moves as shown below.

2. The neutral flow passage is closed by the spool.

The pressurized oil pushes to open the load check valve. The pressurized oil is delivered to cylinder port (A2) and sent to the lift cylinder rod side.

3. In addition, hydraulic oil delivered from the lift cylinder bottom side flows from cylinder port (B2) to the low-pressure flow passage.

1

2

B2

A2

2

4

3

2 T4EK-03-06-008

1 - Check Valve

2 - Delivery Oil from Pump

3 - Neutral Flow Passage Opened to Outlet Section

T3-6-9

4 - Drain (Low-Pressure Return) Flow Passage Opened to Tank Port

30_42ZV-2

COMPONENT OPERATION / Loading Control Valve Boom Float position: 1. When the control lever is lowered from the “Boom Down” position to the “Float” position, the lift spool moves as shown below.

2. The neutral circuit is opened. Pressurized oil flow is similar to that in the neutral condition.

In addition, both cylinder ports (A2) and (B2) are connected to the low-pressure flow passage.

Therefore, the lift arm operates up and down freely according to unevenness on the road.

Pressurized oil from the lift cylinder rod side freely flows to the bottom side and pressurized oil from the lift cylinder bottom side freely flows to the rod side respectively through the low-pressure flow passage in the loading control valve.

1

2

B2

A2

2

3

4

2 T4EK-03-06-009

1 - Check Valve

2 - Delivery Oil from Pump

3 - Neutral Flow Passage Opened to Outlet Section

T3-6-10

4 - Drain (Low-Pressure Return) Flow Passage Opened to Tank Port

30_42ZV-2

COMPONENT OPERATION / Loading Control Valve DETENT OPERATION Lift Side 1. When pushing the control lever forward and set to the “Float” position, lift spool (1) is fully pulled out.

Detent pin (2) installed to the spool end moves.

Detent ball (3) is dropped in the groove on detent sleeve (4).

3. In order to deactivate the detent operation, pull the control lever to release detent ball (3).

2. As detent ball (3) is pushed by spring (5), lift spool (1) keeps the position and the detent operates.

1

5

2

3

4

Float

Operation of Lift Side Detent

T4EK-03-06-010

Tilt Side 1. The tilt side detent is the electromagnetic type.

The electrical circuit is connected from the battery to the proximity switch of the auto leveler through coil assembly (4) of the tilt cylinder.

2. When the bucket position is declined forward, the proximity switch is closed and energizes coil assembly (4).

3. When operating the control lever fully to the “Bucket Roll Back” position, tilt spool (1) is fully pushed.

Detent pin (2) installed to the spool end is pushed.

Plate (3) contacts to coil (4). The position of tilt spool (1) is held and the detent operates.

4. To deactivate the detent, set the proximity switch to “open” and de-energize the coil assembly, or operate the control lever by hand.

Proximity Switch

Battery

1

2

3

4 Fuse

Declined Backward

Contact

T3-6-11

T4EK-03-06-011

30_42ZV-2

COMPONENT OPERATION / Loading Control Valve RELIEF VALVE The main relief valve (1 used) and the overload relief valves (2 used) are used for the loading control valve.

Main Relief Valve The main relief valve is located on the circuit between port P (pump side) and port T (tank side) in order to prevent the loader circuit pressure from exceeding the set pressure.

The main relief valve is installed between the neutral flow passage and the low-pressure flow passage (return flow passage).

Pressurized oil in port P acts on pilot poppet (8) through orifice (2) in main poppet (1) and orifice (7) in sleeve (6).

The overload relief valves are installed between both cylinder ports of overload relief valve and tilt cylinder and the low-pressure flow passage (return flow passage).

If loader circuit pressure exceeds the set pressure of spring (9), pilot poppet (8) is opened and a small amount of pressurized oil flows to port T through the outer circumference of sleeve (3). At this time, a pressure difference occurs between port P and spring chamber (5) due to orifice (2).

When this pressure difference increases and the force pushing main poppet (1) to the right exceeds spring (4) force, main poppet (1) is opened so that pressurized oil in port P flows directly to port T. When pressure in port P decreases, main poppet (1) is closed again by spring (4) force.

1

2

3

4

6

5

7

8

9

T4EK-03-06-012

1 - Main Poppet 2 - Orifice 3 - Sleeve

4 - Spring 5 - Spring Chamber

6 - Sleeve 7 - Orifice

T3-6-12

8 - Pilot Poppet 9 - Spring

30_42ZV-2

COMPONENT OPERATION / Loading Control Valve Overload Relief Valve The overload relief valve is located in the circuit between the cylinder and port T (tank side).

The overload relief valve controls pressure in the circuit that is caused by an external force as when driving against and pushing the bucket.

Pressure on the cylinder side acts on pilot poppet (5) through the internal passage of poppet valve (1).

When circuit pressure reaches the set pressure of spring (6), pilot poppet (5) is opened and a small amount of pressurized oil flows to port T through the outer circumference of sleeve (3).

When pilot poppet (5) opens, pressure in the chamber decreases and a pressure difference occurs between the cylinder side and chamber (4).

When poppet valve (1) moves to the right due to this pressure difference, poppet valve (2) is opened so that pressurized oil in the cylinder side flows directly to port T. When pressure in the cylinder side circuit becomes negative, this overload relief valve draws the pressurized oil from port T (hydraulic tank side) to prevent cavitation or a void (Make-up function).

1

2

3

4

5

6

T4EK-03-06-013

1 - Poppet Valve 2 - Main Poppet

3 - Sleeve 4 - Chamber

5 - Pilot Poppet

T3-6-13

6 - Spring

30_42ZV-2

COMPONENT OPERATION / Loading Control Valve ANTI-VOID VALVE When pressure in the lift cylinder rod side becomes negative, the anti-void valve (make-up valve) provides the function to deliver pressurized oil from the tank port to the lift cylinder rod side directly.

Operation LP

1. Pressurized oil in cylinder port (HP) is sent to anti-void valve through the hole on poppet (1).

Poppet (1) is located in the illustrated position due to the difference in the pressure area between (A) and (B).

HP

LP (To tank)

1

2. When cylinder port (HP) pressure is lower than tank port (LP) pressure, poppet (1) moves to the right due to the difference in the pressure area between (A) and (B).

At this time, enough pressurized oil flows from tank port (LP) to cylinder port (HP) and prevents cavitation or a void from forming in the cylinder.

B

A

LP B A

HP

1

T3-6-14

LP (To tank)

T4EK-03-06-014

30_42ZV-2

COMPONENT OPERATION / Main Pump MAIN PUMP It is 2-spool gear pump consists of the 1st pump (main pump) and the 2nd pump (charging pump).

The main (1st) pump and the charging (2nd) pump draw hydraulic oil from the hydraulic tank and fill the spaces between the gear teeth bottom and the housing inner surface, which is made by the suction force when the drive gear and the driven gear are meshed and rotate together.

Hydraulic oil is delivered to the outlet port at the restart point to mesh.

The charging pump is installed to HST pump through the coupling and rotates together with the engine.

The main (1st) pump doubles as the main hydraulic circuit and the steering hydraulic circuit.

The main (1st) pump draws hydraulic oil to the hydraulic tank and deliver through the priority valve.

In addition, the main pump uses bushing to prevent oil leaks from the gap between the gear and the side plate.

In order to increase the pump efficiency (volumetric efficiency), route delivery pressure to this bushing surface to balance pressure and reduce the gap.

Hydraulic oil is divided into the main hydraulic circuit and into the steering hydraulic circuit in the orbitrol assembly with the priority valve.

1

2

3

4

5

6

7

8

9

14

13

12

11

10 T4EK-03-07-001

1234-

Rear Cover Bushing Driven Gear (2nd Pump) Bushing

5678-

Body Driven Gear (1st Pump) Bushing Front Cover

9 - Oil Seal 10 - Bushing 11 - Drive Gear (1st Pump)

12 - Bushing 13 - Drive Gear (2nd Pump) 14 - Bushing

Bushing

Driven Gear

Outlet Port

Inlet Port

Bushing Housing

Driven Gear

T4EK-03-07-002

T3-7-1

30_42ZV-2

COMPONENT OPERATION / Main Pump Head Assembly

RETURN FILTER The return filter is provided in the return circuit of the main hydraulic circuit.

IN

OUT

Pressurized oil flows from the inlet port and is filtered by the element inside, and sent out to the hydraulic tank via the outlet port.

If the return filter clogs and inlet port side pressure increases, when the difference between inlet port side pressure and outlet port side pressure is 0.14 MPa 2 (1.43 kgf/cm , 20.3 psi) or more, the bypass valve is opened and pressurized oil flows from the inlet port to the outlet port directly, and does not flow through the element, that means the oil is not filtered.

This return filter uses the cartridge type. Replace the filter cartridge assembly when replacing the element.

T3-7-2

Filter Cartridge T4EK-03-07-003

30_42ZV-2