50ZV (Ex F&S) A4 (93205 00151)

93205-00151
June 2009
Foreword
To ensure good machine performance, reduce failures or problems, and prolong the service life of each component,
it is necessary to operate the machine as is directed in the Operator and Maintenance Manual.
To effectively diagnose and repair the machine, it is important to follow the guidelines laid out in this Shop Manual.
General Information
Function and structure
For the engine, refer to the engine Shop Manual provided by the engine manufacturer.
The purpose of this manual is to provide information on the product and the correct maintenance and repair meth-
ods. Please read this manual to ensure correct troubleshooting and good repair service.
This manual will be periodically reviewed and revised for more satisfactory content. If you have any opinion or
requests, please inform us.
Safety Symbols
An accident may occur if you disregard safety rules.
In this manual, several expressions are used according to levels of danger for inspection and repair work as shown
below. Read the work procedures and cautions described in this manual, and take preventive measures against
possible problems before starting service work.
DANGER
This danger symbol identifies special warnings or
procedures which, if not strictly observed, will result
in death or serious injury.
WARNING
This warning symbol identifies special warnings or
procedures which, if not strictly observed, could result
in death or serious injury.
CAUTION
This caution symbol identifies special instructions or
procedures which, if not strictly observed, may result
in minor or moderate injury.
IMPORTANT
This important symbol identifies special instructions
or procedures which, if not correctly followed, may
result in serious machine damage.
We cannot predict all possible accidents or incidents that may occur during service work. Therefore, an accident that
is not specifically mentioned in this manual may occur. To protect yourself from all accidents, be careful when doing
service work.
CONTENTS
50ZV General Information ..................................................................................................................................... 00-1
How to Use Manual ........................................................................................................................................... 00-2
Safety precautions ...................................................................................................................................... 00-2
Symbols ...................................................................................................................................................... 00-3
Outline ............................................................................................................................................................... 00-4
Layout of main components ........................................................................................................................ 00-4
Inspection and maintenance table .............................................................................................................. 00-5
Recommended lubricants ........................................................................................................................... 00-8
Coolant ..................................................................................................................................................... 00-10
Lubrication chart ........................................................................................................................................00-11
Weight of main components ..................................................................................................................... 00-12
Bolt tightening torque ................................................................................................................................ 00-13
Hose band tightening torque ..................................................................................................................... 00-17
Liquid gasket and screw lock agent .......................................................................................................... 00-18
Cautions regarding welding repair service ................................................................................................ 00-20
50ZV Measurement for Performance Check ......................................................................................................... 03-1
Cautions on Safety ............................................................................................................................................ 03-2
Standard Measurement Values for Performance Check ................................................................................... 03-3
50ZV Function & Structure Chassis Group ........................................................................................................... 12-1
Front Chassis .................................................................................................................................................... 12-2
Loading linkage ........................................................................................................................................... 12-2
Loading linkage pin ..................................................................................................................................... 12-3
Rear Chassis .................................................................................................................................................... 12-4
Fuel tank ..................................................................................................................................................... 12-4
Floor board mount ....................................................................................................................................... 12-5
Center Pin ......................................................................................................................................................... 12-6
Upper center pin ......................................................................................................................................... 12-6
Lower center pin ......................................................................................................................................... 12-6
Dust seal ..................................................................................................................................................... 12-7
50ZV Check & Adjustment Chassis Group ........................................................................................................... 13-1
Linkage Pin ....................................................................................................................................................... 13-2
Liner ............................................................................................................................................................ 13-2
Center Pin ......................................................................................................................................................... 13-4
Adjusting shim (#5) ..................................................................................................................................... 13-4
Installing bearing cover (#3) ........................................................................................................................ 13-4
50ZV Function & Structure Power Group .............................................................................................................. 22-1
Power Line ........................................................................................................................................................ 22-2
Engine / Transmission ....................................................................................................................................... 22-3
Engine / transmission mount ....................................................................................................................... 22-3
Accelerator pedal ........................................................................................................................................ 22-4
Fuel control ................................................................................................................................................. 22-5
Radiator ............................................................................................................................................................. 22-6
Radiator mount ............................................................................................................................................ 22-7
Propeller Shaft .................................................................................................................................................. 22-8
Second propeller shaft assembly ................................................................................................................ 22-9
Third propeller shaft assembly .................................................................................................................. 22-10
Axle Assembly ................................................................................................................................................. 22-11
Axle Support .................................................................................................................................................... 22-12
Differential Gear .............................................................................................................................................. 22-14
Function of T.P.D ....................................................................................................................................... 22-15
Operation of T.P.D ..................................................................................................................................... 22-16
50ZV Check & Adjustment Power Group .............................................................................................................. 23-1
Engine ............................................................................................................................................................... 23-2
Measuring engine speed ............................................................................................................................. 23-2
Measuring engine oil pressure .................................................................................................................... 23-2
Propeller Shaft .................................................................................................................................................. 23-3
Propeller shaft phase .................................................................................................................................. 23-3
Second propeller shaft alignment ................................................................................................................ 23-3
Tightening torque ........................................................................................................................................ 23-4
Axle ................................................................................................................................................................... 23-5
Axle ............................................................................................................................................................. 23-5
Differential gear ........................................................................................................................................... 23-6
50ZV Function & Structure Torque Converter and Transmission Group ............................................................... 32-1
Torque Converter .............................................................................................................................................. 32-2
Torque converter structure .......................................................................................................................... 32-2
Power flow path ........................................................................................................................................... 32-2
Torque multiplication ................................................................................................................................... 32-2
Torque Converter Gear Pump ........................................................................................................................... 32-3
Gear pump specifications ............................................................................................................................ 32-3
Transmission ..................................................................................................................................................... 32-4
Gear arrangement ....................................................................................................................................... 32-4
Valve location .............................................................................................................................................. 32-5
Clutch Pack ....................................................................................................................................................... 32-6
Forward and 2nd speed clutch .................................................................................................................... 32-6
Reverse and 1st speed clutch ..................................................................................................................... 32-7
3rd speed clutch .......................................................................................................................................... 32-8
Clutch specifications ................................................................................................................................... 32-8
Power Flow Path in the Transmission ............................................................................................................... 32-9
Forward ....................................................................................................................................................... 32-9
Reverse ..................................................................................................................................................... 32-10
Hydraulic System Diagram ..............................................................................................................................32-11
Hydraulic Circuit Diagram ............................................................................................................................... 32-12
Oil Flow ........................................................................................................................................................... 32-13
Oil flow in the torque converter line ........................................................................................................... 32-13
Oil flow to the clutch .................................................................................................................................. 32-13
Shift Lever ....................................................................................................................................................... 32-14
Control Valve ................................................................................................................................................... 32-15
System diagram ........................................................................................................................................ 32-16
Oil port layout ............................................................................................................................................ 32-17
Modulation Mechanism ................................................................................................................................... 32-19
Clutch control oil pressure curve ............................................................................................................... 32-19
Before the shift lever is moved (travelling or stop condition) .................................................................... 32-20
When the shift lever is moved (1) ............................................................................................................. 32-21
When the shift lever is moved (2) ............................................................................................................. 32-22
Accumulator .................................................................................................................................................... 32-23
Accumulator for 1st speed clutch .............................................................................................................. 32-23
Solenoid Valve ................................................................................................................................................ 32-25
Clutch cut-off solenoid valve ..................................................................................................................... 32-25
50ZV Check & Adjustment Torque Converter and Transmission Group ............................................................... 33-1
Clutch Oil Pressure ........................................................................................................................................... 33-2
50ZV Function & Structure Hydraulic Group ......................................................................................................... 42-1
Flushing Hydraulic Circuit ................................................................................................................................. 42-2
Purpose of flushing ..................................................................................................................................... 42-2
Cautions on Hydraulic Parts Replacement ....................................................................................................... 42-3
Hydraulic Circuit Symbols ................................................................................................................................. 42-4
Hydraulic lines ............................................................................................................................................. 42-4
Pumps & motors .......................................................................................................................................... 42-4
Cylinders ..................................................................................................................................................... 42-4
Operation methods ...................................................................................................................................... 42-5
Pressure control valve ................................................................................................................................. 42-5
Flow control valve ....................................................................................................................................... 42-5
Directional control valve .............................................................................................................................. 42-6
Check valve ................................................................................................................................................. 42-6
Miscellaneous hydraulic symbols ................................................................................................................ 42-7
Hydraulic System Operation ............................................................................................................................. 42-8
Hydraulic system operation outline ............................................................................................................. 42-8
Layout of Hydraulic Units .................................................................................................................................. 42-9
Hydraulic Tank ................................................................................................................................................. 42-10
Hydraulic tank breather valve (tank cap) ................................................................................................... 42-11
Hydraulic tank specifications ..................................................................................................................... 42-12
Hydraulic oil level check ............................................................................................................................ 42-12
Hydraulic Pump ............................................................................................................................................... 42-13
Hydraulic pump specifications ................................................................................................................... 42-13
Hydraulic pump principle ........................................................................................................................... 42-14
Hydraulic pump wear plate ........................................................................................................................ 42-15
Hydraulic pump bushing lubrication .......................................................................................................... 42-15
Hydraulic Cylinder ........................................................................................................................................... 42-16
Boom cylinder ........................................................................................................................................... 42-16
Bucket cylinder .......................................................................................................................................... 42-17
Steering cylinder ....................................................................................................................................... 42-17
Hydraulic cylinder specifications ............................................................................................................... 42-18
Return Filter .................................................................................................................................................... 42-19
Return filter specifications ......................................................................................................................... 42-19
Loading System .............................................................................................................................................. 42-20
Multiple Control Valve ..................................................................................................................................... 42-21
Multiple control valve specifications .......................................................................................................... 42-23
Multiple control valve main relief valve ..................................................................................................... 42-24
Multiple control valve overload relief valve (with make-up function) ......................................................... 42-26
Multiple control valve make-up valve ........................................................................................................ 42-28
Multiple control valve bucket spool ........................................................................................................... 42-29
Multiple control valve boom spool ............................................................................................................. 42-31
Valve Control ................................................................................................................................................... 42-34
Steering System .............................................................................................................................................. 42-35
Priority Valve ................................................................................................................................................... 42-37
Priority valve specifications ....................................................................................................................... 42-37
Priority valve operation ............................................................................................................................. 42-38
Orbitrol® .......................................................................................................................................................... 42-41
Orbitrol® construction ................................................................................................................................ 42-41

Orbitrol® specification ............................................................................................................................... 42-42
Orbitrol® operation .................................................................................................................................... 42-43
Orbitrol® feed-back mechanism operation ................................................................................................ 42-45

Steering speed and flow rate control ........................................................................................................ 42-46
Hydraulic pump oil amount and steering force .......................................................................................... 42-46
Orbit rotor operation principle ................................................................................................................... 42-47
Auxiliary valves ......................................................................................................................................... 42-48
Emergency check valve ............................................................................................................................ 42-50
Inlet check valve ....................................................................................................................................... 42-50
Cushion Valve ................................................................................................................................................. 42-51
Cushion valve specifications ..................................................................................................................... 42-52
Cushion valve operation ........................................................................................................................... 42-52
50ZV Check & Adjustment Hydraulic Group ......................................................................................................... 43-1
Loading/Steering Circuit Relief Valve ................................................................................................................ 43-2
Loading circuit relief valve setting pressures .............................................................................................. 43-2
Steering circuit relief valve setting pressures .............................................................................................. 43-6
Valve Control ..................................................................................................................................................... 43-9
Hydraulic Cylinder ........................................................................................................................................... 43-10
Cylinder natural drift .................................................................................................................................. 43-10
50ZV Function & Structure Brake Group .............................................................................................................. 52-1
Brake Units Layout ............................................................................................................................................ 52-2
Brake Circuit ...................................................................................................................................................... 52-3
Hydraulic Servo Master Cylinder ....................................................................................................................... 52-4
Hydraulic servo master cylinder specifications ........................................................................................... 52-5
Performance diagram .................................................................................................................................. 52-5
Hydraulic servo master cylinder operation .................................................................................................. 52-6
Service Brake .................................................................................................................................................... 52-8
Service brake operation .............................................................................................................................. 52-8
Service brake friction plate .......................................................................................................................... 52-9
Service brake steel plate ............................................................................................................................. 52-9
Brake circuit air bleeding procedure .......................................................................................................... 52-10
Parking Brake .................................................................................................................................................. 52-12
Brake Control .................................................................................................................................................. 52-13
Service brake linkage ................................................................................................................................ 52-13
Parking brake linkage ................................................................................................................................ 52-14
Brake Oil Reservoir ......................................................................................................................................... 52-15
Brake oil reservoir specifications ............................................................................................................... 52-15
50ZV Check & Adjustment Brake Group ............................................................................................................... 53-1
Hydraulic Servo Master ..................................................................................................................................... 53-2
Hydraulic servo master performance inspection ......................................................................................... 53-2
Service Brake .................................................................................................................................................... 53-4
Service brake performance check ............................................................................................................... 53-4
Service brake friction plate wear measurement .......................................................................................... 53-5
Parking Brake .................................................................................................................................................... 53-6
Parking brake performance check .............................................................................................................. 53-6
Parking brake clearance adjustment ........................................................................................................... 53-7
Brake Control .................................................................................................................................................... 53-9
Adjusting brake pedal and switch ................................................................................................................ 53-9
Parking brake cable adjustment ................................................................................................................ 53-11
50ZV Function & Structure Electrical Group ......................................................................................................... 62-1
How to Use Electrical Wiring Diagram .............................................................................................................. 62-2
Electrical Cable Color Codes ............................................................................................................................ 62-3
Electrical Circuit Symbols .................................................................................................................................. 62-4
Sensor Mount .................................................................................................................................................... 62-5
Fuse .................................................................................................................................................................. 62-6
Fuse box ..................................................................................................................................................... 62-6
Fusible link .................................................................................................................................................. 62-7
Engine Start Circuit ........................................................................................................................................... 62-8
Engine start circuit diagram ........................................................................................................................ 62-8
Neutral starter ............................................................................................................................................. 62-9
Starter switch ............................................................................................................................................ 62-10
Battery relay ...............................................................................................................................................62-11
Alternator R terminal wire ......................................................................................................................... 62-12
Diode unit .................................................................................................................................................. 62-12
Neutral switch ........................................................................................................................................... 62-13
Magnet switch ........................................................................................................................................... 62-14
Voltage relay ............................................................................................................................................. 62-15
Power Generating/Charging Circuit ................................................................................................................ 62-16
Alternator .................................................................................................................................................. 62-16
Engine Stop Circuit ......................................................................................................................................... 62-18
Fuel solenoid ............................................................................................................................................. 62-18
Fuel solenoid relay .................................................................................................................................... 62-18
Instrument Panel and Switch .......................................................................................................................... 62-19
Instrument panel ....................................................................................................................................... 62-19
Instrument panel rear surface ................................................................................................................... 62-20
Gauge circuit ............................................................................................................................................. 62-21
Fuel level sensor ....................................................................................................................................... 62-23
Monitoring system ..................................................................................................................................... 62-24
Transmission Electrical Circuit ........................................................................................................................ 62-27
Transmission cut off (Declutch) switch ...................................................................................................... 62-27
Inching switch ........................................................................................................................................... 62-28
Solenoid valve ........................................................................................................................................... 62-28
Electrical Detent Circuit ................................................................................................................................... 62-29
Bucket detent ............................................................................................................................................ 62-29
Diode Unit Circuit ............................................................................................................................................ 62-31
Diode inspection ....................................................................................................................................... 62-31
Stop Light Switch Circuit ................................................................................................................................. 62-34
Parking Switch ................................................................................................................................................ 62-35
Back-up Light Switch Circuit ........................................................................................................................... 62-36
Horn Circuit ..................................................................................................................................................... 62-37
Diode ............................................................................................................................................................... 62-38
Diode check method ................................................................................................................................. 62-39
Caution for diode check method ............................................................................................................... 62-39
Surge voltage and surge suppression diodes ........................................................................................... 62-41
50ZV Check & Adjustment Electrical Group .......................................................................................................... 63-1
Cautions Regarding Electric Circuit Check ....................................................................................................... 63-2
Disconnecting or reinstalling connector ...................................................................................................... 63-2
How to attach the probes of the circuit tester .............................................................................................. 63-4
Electrical Circuit Check ..................................................................................................................................... 63-5
Transmission control circuit check .............................................................................................................. 63-5
Bucket positioner electrical circuit check ..................................................................................................... 63-6
Diode unit circuit check ............................................................................................................................... 63-7
Gauge circuit electrical circuit check ........................................................................................................... 63-8
50ZV Function & Structure Operator Station Group .............................................................................................. 72-1
Cabin (OPT) ...................................................................................................................................................... 72-2
Cabin connection diagram .......................................................................................................................... 72-3
Wiper motor ................................................................................................................................................. 72-4
Operator Seat .................................................................................................................................................... 72-6
Seat assembly ............................................................................................................................................. 72-6
Suspension assembly ................................................................................................................................. 72-7
Air Conditioner (OPT) ........................................................................................................................................ 72-8
Air conditioner mount .................................................................................................................................. 72-8
Air conditioner line ....................................................................................................................................... 72-9
Air conditioner structure ............................................................................................................................ 72-10
Function of cooling mechanism ................................................................................................................. 72-15
Cooling circuit ............................................................................................................................................ 72-18
Air conditioner function of components ..................................................................................................... 72-19
Charge of refrigerant ................................................................................................................................. 72-47
50ZV Check & Adjustment Operator Station Group .............................................................................................. 73-1
Air Conditioner .................................................................................................................................................. 73-2
Adjustment of lubricating oil quantity when components of air conditioner are replaced ............................ 73-2
Water valve and air mix damper adjustment ............................................................................................... 73-5
Adjustment of air gap (between hub and rotor) in compressor magnetic clutch ......................................... 73-6
Compressor V-belt adjustment .................................................................................................................... 73-7
Parts to be replaced periodically ................................................................................................................. 73-8
50ZV Drawing & Diagrams .................................................................................................................................... 92-1
Axle Assembly .................................................................................................................................................. 92-2
Torque Converter and Transmission ................................................................................................................. 92-3
Loading/Steering Hydraulic Line ....................................................................................................................... 92-4
Brake Circuit ..................................................................................................................................................... 92-5
Electrical Wiring Diagram (1/2) ......................................................................................................................... 92-6
Electrical Wiring Diagram (2/2) ......................................................................................................................... 92-7
Electrical Connection Diagram .......................................................................................................................... 92-8
Electrical Wiring Diagram (CAB) ....................................................................................................................... 92-9
Electrical Equipment Layout ........................................................................................................................... 92-10
Electrical Circuit Diagram (Cabin Air Conditioner) .......................................................................................... 92-14
Electrical Wiring Diagram (Cabin Air Conditioner) .......................................................................................... 92-15
00-1
50ZV General Information

00-2
How to Use Manual
How to Use Manual
Safety precautions - Contact tire manufacturer's local dealer for tire ser-
vicing and changing.
The most important point in providing repair service is - Always store the tools in good condition, and use
safety. To ensure safety, observe the general cautions them properly.
described below.
- Keep the work area clean. Clean up spills immedi-
- This manual is intended for properly trained and ately.
equipped service technicians.
- Avoid the use of flammable solvents and cleaners.
- Any work on the machine must be performed by the
trained personnel only. - When working outdoors keep work areas, ladders,
steps, decks and work platforms clear of snow, ice,
- Carefully read this manual to thoroughly understand and mud.
the operation method before you operate or repair
the machine. - Use safe work platforms to reach higher areas of the
machine.
- Be sure to wear appropriate clothes and protectors,
such as safety boots, hard hat and goggles.
- Place the machine on level and solid ground, and

place chocks against the wheels to prevent move-
ment.
- Remove the cable from the battery before starting

the service work, and attach a "DO NOT OPER-
ATE!" tag to the steering wheel.
- Be sure to release the internal pressure before you

remove a pipe, such as the hydraulic oil, air, or
engine coolant pipe.
- Be sure to apply the articulation stopper before start-

ing work.
- While supporting the bottom of the chassis using a

jack, be sure to support the chassis using the blocks.
- When the boom or bucket is raised or when a unit is

lifted by a crane, be sure to place a stand or ade-
quate cribbing under the unit to prevent unexpected
dropping.
- Do not start to work in an enclosed area if adequate

ventilation is not provided.
- To remove a heavy unit (20 kgf (40 lbs) or more), be

sure to use a crane or other lifting device.
- Just after stopping operation, be careful not to

directly touch a hot component. You may get burned.
00-3
How to Use Manual
Symbols
For safe and effective service work, the following sym-
bols are used for notes and useful information in this
manual.
Symbol Item Description
Shows the condition or procedure that will be useful

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

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

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

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

Drainage
amount.
IMPORTANT
If the specified conditions are not satisfied or the specified procedure is not
observed, there is a strong possibility that the product will be damaged or the per-
formance of the product will be reduced.
The message shows the preventive measures.
Abbreviation
To save space, abbreviations are used in sentences. To understand the contents of this manual, refer to the follow-
ing abbreviation list.
E/G ........... Engine B ............Battery 1st ............1st speed

T/C ........... Torque converter R ............Rear or Reverse 2nd ............2nd speed
T/M ........... Transmission RH ............Right hand side 3rd ............3rd speed
SOL ........... Solenoid valve LH ............Left hand side 4th ............4th speed
SW ........... Switch H ............High DD ............Dynamic damper
F ........... Front or Forward L ............Low M/C ............Machine
QUAD......... Quick up and down shift GND ............Ground min-1 ............RPM
A/M ........... Auto/Manual OPT ............Option
Assy ............Assembly
00-4
Outline
Outline
Layout of main components
3 14
4 5 2 1 7 8 9
10 12 6 13 11 15
50ZVA00001
1. Engine assembly (Cummins 4B4·5T) 9. Radiator

2. Transmission/Torque converter assy 10. Front axle assembly
3. Hydraulic pump 11. Rear axle assembly
4. Multiple (loader) control valve 12. 2nd propeller shaft
5. Orbitrol® 13. 3rd propeller shaft
6. Parking brake 14. T/C charging pump
7. Air cleaner 15. T/C oil cooler (lower tank of radiator)
8. Muffler
00-5
Outline
Inspection and maintenance table
IMPORTANT
Severe applications require more frequent mainte-
nance.
Severe conditions include heavy dust, extremely
abrasive material, caustic chemicals, extremely wet
conditions or abnormally hot or cold ambient temper-
atures.
: First time replacement or cleaning only

Operating hours
When
Section Item for check
Required
10 50 250 500 1000 2000
Check Engine Oil Level
Check Engine Coolant Level
Check Warning Lamps
Check Exhaust Gas
Drain Water and Sediment from Fuel Filter
Check Fuel Level
Check Drive Belt
Check Air Intake System
Check Cooling Fan
Drain Water and Sediment from Fuel Tank

Engine
Replace Engine Oil and Oil Filter Cartridge
Replace Fuel Filter Cartridge
Clean Fuel Prefilter
Inspect Automatic Belt Tensioner Pulley
Clean Fuel Tank
Check and Adjust Valve Lash Clearance
Clean or Replace Air Cleaner Element
Clean Radiator Fins
Clean or Replace Air Cleaner Element After six cleanings or once a year
Replace Coolant Every 2 years or 3000 hours
Check Transmission Oil Level

Transmission
Replace Transmission Oil Filter Cartridge
&
Torque
Replace Transmission Oil
Converter
Clean or Replace Transmission Breather
00-6
Outline

Operating hours
When
Required
10 50 250 500 1000 2000
Check Tire for Damage, Air and Tread Depth
Check Tire Air Pressure
Greasing (Axle support)
Check Differential Gear Oil

Axle system
Greasing (2nd Propeller Shaft)
Greasing (3rd Propeller Shaft)
Check Tightness of Wheel Bolts
Replace Differential Gear Oil
Check Steering Wheel Operation

Steering
system
Greasing (Steering Cylinder)
Check Brake Oil Level
Check Service Brake Operation
Check Parking Brake Operation

Brake
system Adjust Parking Brake Lining
Check Service Brake Disk Wear
Overhaul Brake Master Cylinder
Check Hydraulic Oil Level
Greasing
Replace Hydraulic Oil Return Filter

Loading
Replace Hydraulic Oil, Clean Filter
system
Replace Filter in the Hydraulic Tank Cap
Replace Bucket Teeth (option)
Replace Cutting Edge (option)
Adjust and Check Rear View Mirrors
ROPS (Roll Over Protective Structure) (option)
Greasing (Center Pin)

Chassis
Check Vibration Damper Accumulator (option)
Check and/or Replace Seat Belt
Check Windshield Washer Fluid

00-7
Outline

Operating hours
When
Required
10 50 250 500 1000 2000
Check Monitor Panel Operation
Check Horn Operation
Electrical Check Back-up Alarm Operation

system
Check Wiring Harnesses
Check Battery Electrolyte Level
Check or Replace Fuses
Check and Adjust Air Conditioner Belt (option)
Clean Air Conditioner Filter Element (option)
Air Check Air Conditioner Refrigerant (option)

Conditioner
(option) Replace Air Conditioner Filter Elements (option)
Clean Air Conditioner Condenser (option)
Replace Air Conditioner Receiver Dryer (option) Every 3 years or 6000 hours
Others Walk-Around Inspection

00-8
Outline
Recommended lubricants
Ambient Temperature Change

Refill capacity
Kind of Oil Interval
(Approximate) -30ºC -20 -10 0 10 20 30 40
(Hours)
SAE10W
Engine oil ∗3
Engine 11 liter SAE10W-30
500
(CH4)
SAE15W-40
ATF or Multi-Purpose ATF

Transmission 20 liter 1,000
Engine oil (CD) SAE10W
∗1 ISO VG32
Hydraulic tank 48.3 liter Hydraulic oil ISO VG46
2,000
Differential & Engine oil SAE40 or SAE50

36 liter Engine oil (CD) 2,000
Planetary
∗2 SAE 5W or 5W-20
Brake oil tank 0.35 liter Engine oil (CD) -
ASTM D975 No.1

Fuel tank 120 liter Diesel fuel ASTM D975 No.2
daily
Note: ∗1 shows "Hydraulic tank oil capacity at level gauge center."

∗2 shows "Brake oil tank capacity." 2 liter required for brake system totally.
Engine Use oil that meets engine oil classification API CH4 or CG4.
∗3. Change engine oil every 250 hours unless CH4 is used.
Engine oil drain intervals need to be reduced by 50% when fuel sulfur content exceeds
0.5 %.
Transmission Use engine oil classification API CD or A.T.F. (Auto Transmission Fluid).
Never mix engine oil and ATF.
Hydraulic System Use industrial-type hydraulic oils which are certified by suppliers having anti-wear, anti-foam,
anti-rust and anti-oxidation additive properties for heavy duty use. Use of the wrong viscosity
of oil can cause improper operation of hydraulic functions or premature pump failure.
Differential & Use class API CD engine oil with 5% "Antichatter" additive or friction modifier.
Planetary
Brake oil Use engine oil classification API CD, SAE 5W or 5W-20 only.
Lubricating Grease Use multipurpose-type EP/MOLY grease for most applications.

NLGI NO.2 grease is suitable for most temperatures.
NLGI NO.1 or NO.0 grease for extremely low temperature.
Use lithium base grease for a needle bearing.
00-9
Outline
Diesel Fuel Requirements for diesel fuel

Specifications
Grade No.1-D Grade No.2-D
Flash Point ºC. min. 38 52
Water and Sediment % vol. max. 0.05 0.05
Distillation Temperature ºC 90 % vol. recovered max. 288 338
2
Kinematic Viscosity mm /s at 40ºC min. 1.3 1.9
max. 2.4 4.1
Ash % mass max. 0.01 0.01
Sulfur % mass max. 0.50 0.50
Cetane Number min. 40 40
Carbon residue on 10 % distillation residue % mass max. 0.15 0.35
00-10
Outline
Coolant
Coolant specification
The machine is originally filled with Long Life Coolant

(non-Amin type ethylene glycol) which need not be
replaced for the first two years or 3000 hours.
Do not use Amin type Long Life Coolant in cooling sys-

tem. It may cause a corrosion against radiator or heater
core.
If standard antifreeze (not Long Life Coolant) is used for

the replacement, it should be replaced every six
months.
Recommended mixture of antifreeze
Expected Minimum
-35ºC -30ºC -25ºC -20ºC -15ºC
Ambient Temperature
Pure Water liter 19.7 21.8 23.9 26.0 28.1
Antifreeze liter 22.3 20.2 18.1 16.0 13.9
Mixture Ratio (%) 53 48 43 38 33
- Too much antifreeze in the coolant mixture may

cause engine overheating.
Keep 33 % antifreeze mixture (same as the mixture

for a minimum ambient temperature of -15ºC) if the
engine overheats in a high ambient temperature.
- Do not use hard water or water with high levels of

calcium and magnesium ions as the coolant water.
IMPORTANT
Do not mix different brands of antifreeze because
they each contain special additives.
Careless mixing often diminishes the effect of these
additives and causes packing damage or water leak-
age.
00-11
Outline
Lubrication chart
BRAKE OIL TANK

HYDRAULIC TANK DIFF & GEAR BOX
TRANSMISSION
TO EVERY 1000Hr HO GO EVERY 2000Hr
LINK STEERING
SYSTEM SYSTEM TO
EVERY DAY
HO BO GO
EVERY 250Hr
G G
EVERY 50Hr
G EVERY 50Hr
EO
G G AXLE SUPPORT
EO G G EVERY 250Hr
BUCKET CENTER PIN
ENGINE OIL PAN 3RD
PROPELLER SHAFT
2ND
PROPELLER SHAFT
60ZV00002
G HO
Grease point Multipurpose grease Hydraulic oil
GO TO
Check and add if necessary Gear oil Engine oil
EO
Oil replacement Engine oil
00-12
Outline
Weight of main components
Item Approx. Approx.

weight weight Remarks
Unit name Part name (kg) (lb)
Bucket 435 960 GSN bucket
Boom 490 1,080
"Z" -Lever 120 265
Link (Bucket to Lever) 22 50
Chassis Engine room assmbly 155 340
Hydraulic tank 50 110 Excluding oil
Fuel tank 80 175 Excluding fuel
Floor board 135 300
Cab 550 1,230 ROPS cab
Engine 395 870 Including oil
Radiator 135 300 Excluding water and oil
Transmission 380 840 Excluding oil
Second propeller shaft 25 55
Power line
Third propeller shaft 5 10
Front axle assembly 380 840 Excluding tires and oil
Rear axle assembly 440 970 Excluding tires and oil (Including axle support)
Differentials 105 230 Weight each (Both Front and Rear)
Multiple control valve 20 45
Steering valve (Orbitrol®) 5 10
Gear pump 5 10
Hydraulic system
Boom cylinder 55/pc 120/pc Excluding oil
Bucket cylinder 45 100 Excluding oil
Steering cylinder 15/pc 35/pc Excluding oil
Tire 140/pc 310/pc With rim (16.9-24-10PR); No Hydro Inflation
Other
Battery 35/pc 80/pc
00-13
Outline
Bolt tightening torque

Hexagon bolt
1. Thread type
Metric thread, Unified thread
2. Bolt strength
8.8 (8T) ~ 10.9 (11T)
3. Thread pitch
Metric thread: Coarse pitch thread (C), fine pitch thread (F)
Unified thread: Coarse pitch thread (UNC), fine pitch thread (UNF)
(N-m)
Bolt size Bolt strength
Type Nominal Nominal
Pitch 8.8 (8T) 10.9 (11T)
dimension dia.
M8 8 (C) 1.25 26 38
(C) 1.5 53 76
M10 10
(F) 1.25 55 80
(C) 1.75 90 132
M12 12
(F) 1.25 96 142
(C) 2.0 142 206
M14 14
(F) 1.5 152 221
(C) 2.0 216 314
M16 16
(F) 1.5 226 330
(C) 2.5 299 436
M18 18
(F) 1.5 324 476
Metric thread (C) 2.5 417 608
M20 20
(F) 1.5 451 662
(C) 2.5 559 814
M22 22
(F) 1.5 598 878
(C) 3.0 721 1,030
M24 24
(F) 2.0 770 1,128
(C) 3.0 1,030 1,520
M27 27
(F) 2.0 1,128 1,618
(C) 3.5 1,422 2,109
M30 30
(F) 2.0 1,569 2,256
(C) 3.5 1,912 2,844
M33 33
(F) 2.0 2,059 3,040
5/16 05 18 UNC 25 35
3/8 06 16 UNC 44 65
7/16 07 14 UNC 71 103
1/2 08 13 UNC 103 147
Unified thread 9/16 09 12 UNC 147 216
5/8 10 11 UNC 201 294
3/4 12 10 UNC 358 525
7/8 14 9 UNC 554 809
1 16 8 UNC 868 1,275
Note: Tighten the bolts according to the above list, unless otherwise specified.
00-14
Outline
(kgf-m)
Pitch 8.8 (8T) 10.9 (11T)
dimension dia.
M8 8 (C) 1.25 2.7 3.9
(C) 1.5 5.4 7.8
M10 10
(F) 1.25 5.6 8.2
(C) 1.75 9.2 13.5
M12 12
(F) 1.25 9.8 14.5
(C) 2.0 14.5 21.0
M14 14
(F) 1.5 15.5 22.5
(C) 2.0 22.0 32.0
M16 16
(F) 1.5 23.0 33.7
(C) 2.5 30.5 44.5
M18 18
(F) 1.5 33.0 48.5
Metric thread (C) 2.5 42.5 62.0
M20 20
(F) 1.5 46.0 67.5
(C) 2.5 57.0 83.0
M22 22
(F) 1.5 61.0 89.5
(C) 3.0 73.5 105.0
M24 24
(F) 2.0 78.5 115.0
(C) 3.0 105.0 155.0
M27 27
(F) 2.0 115.0 165.0
(C) 3.5 145.0 215.0
M30 30
(F) 2.0 160.0 230.0
(C) 3.5 195.0 290.0
M33 33
(F) 2.0 210.0 310.0
5/16 05 18 UNC 2.5 3.6
3/8 06 16 UNC 4.5 6.6
7/16 07 14 UNC 7.2 10.5
1/2 08 13 UNC 10.5 15.0
Unified thread 9/16 09 12 UNC 15.0 22.0
5/8 10 11 UNC 20.5 30.0
3/4 12 10 UNC 36.5 53.5
7/8 14 9 UNC 56.5 82.5
1 16 8 UNC 88.5 130.0
00-15
Outline
(lb-ft.)
Pitch 8.8 (8T) 10.9 (11T)
dimension dia.
M8 8 (C) 1.25 19.5 28
(C) 1.5 39 56
M10 10
(F) 1.25 40 59
(C) 1.75 66 97
M12 12
(F) 1.25 70 105
(C) 2.0 105 150
M14 14
(F) 1.5 110 160
(C) 2.0 160 230
M16 16
(F) 1.5 165 245
(C) 2.5 220 320
M18 18
(F) 1.5 235 350
Metric thread (C) 2.5 305 450
M20 20
(F) 1.5 330 490
(C) 2.5 410 600
M22 22
(F) 1.5 440 650
(C) 3.0 530 760
M24 24
(F) 2.0 565 830
(C) 3.0 760 1,120
M27 27
(F) 2.0 830 1,190
(C) 3.5 1,050 1,550
M30 30
(F) 2.0 1,160 1,660
(C) 3.5 1,410 2,100
M33 33
(F) 2.0 1,520 2,240
5/16 05 18 UNC 18.0 26
3/8 06 16 UNC 32 47
7/16 07 14 UNC 52 76
1/2 08 13 UNC 76 105
Unified thread 9/16 09 12 UNC 110 160
5/8 10 11 UNC 150 215
3/4 12 10 UNC 265 385
7/8 14 9 UNC 410 595
1 16 8 UNC 640 940
00-16
Outline
Flanged hexagon bolt
1. Bolt type: Metric thread
2. Bolt strength: 8.8 (8T)
3. Thread pitch: Coarse pitch thread (C)
(N-m)
Type Nominal
Pitch 8.8 (8T)
dimension
M5 0.8 7
M6 1 12
M8 1.25 28
M10 1.5 53
Metric thread
M12 1.75 94
M16 2 231
M20 2.5 441
M24 3 765
(kgf-m)
Type Nominal
Pitch 8.8 (8T)
dimension
M5 0.8 0.7
M6 1 1.2
M8 1.25 2.9
M10 1.5 5.4
Metric thread
M12 1.75 9.6
M16 2 23.5
M20 2.5 45.0
M24 3 78.0
(lb-ft)
Type Nominal
Pitch 8.8 (8T)
dimension
M5 0.8 5.0
M6 1 8.6
M8 1.25 20.9
M10 1.5 38.9
Metric thread
M12 1.75 69.1
M16 2 169.2
M20 2.5 324.0
M24 3 561.6
00-17
Outline
Hose band tightening torque
Low pressure hose

(heat resisting hose) Tightening torque Tightening torque Tightening torque
Hose band
(N-m) (kgf-cm) (lb-ft)
Inner dia. (mm) Outer dia. (mm)
6.3 16.5
7.9 18.5 69002-02200 1.6 16 1.2
9.5 20.5
12.7 24.5 69002-02700
15.9 29.9
69002-03100
19.0 30.0
25.4 38.0 69002-04400
31.8 45.8 69002-05200 4 40 2.9
38.1 52.1 69002-05700
50.8 67.8 69002-07100
60.5 76.0 69002-08200
75.5 93.0 69002-09500
Low pressure hose Tightening torque Tightening torque Tightening torque

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

pipe protrusion
10~20 mm 70ZV00003
00-18
Outline
Liquid gasket and screw lock Cautions regarding reassembly

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

Note
® A piece of hardened lock agent may be peeled off and
AA01 Loctite Plastic Gasket 568
remain in the component. The remaining piece may
Liquid
Gasket
AA02 Loctite® Hydraulic sealant cause malfunction during fastener installation.
AA03 Three Bond Three Bond 1215
AB01 Loctite® Loctite® 262 To bond a plane or to fit a shaft
Screw Lock
AB02 Three Bond Three Bond 1327
Agent Remove the hardened lock agent using a wire brush or
AB03 Three Bond Three Bond 1374 the like, and polish the surface using sand paper. Use of
a loctite primer like Locquic ® Primer T cleans threads
and speeds curing time.
Cautions regarding parts removal Antiseize Agent
Code Manufacturer Product name

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

to soften the agent (200~250°C) using a soldering iron
or gas torch.
Caution
If there is a seal near the screw or shaft to be removed,

carefully use the heating method for removal, to avoid
damage to the seal.
If heat has been used to remove the bolt a new bolt

should be used during reassembly.
00-19
Outline
Screw lock agent application procedure How to wind a seal tape

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

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

65ZV00002 2 screws from the end of the thread and start threading
it clockwise.
Blind hole
Apply screw lock agent all-round on the female threads

at 1/3 of the female thread length from the bottom.
H
Abt 1/3H
65ZV00003
00-20
Outline
Cautions regarding welding repair

service
If welding is needed to repair the chassis, observe the
following precautions to protect the hydraulic cylinders,
hydraulic units, gear sets, and electrical units from pos-
sible damage.
Cautions
1. Turn the starter switch OFF. 4. To ground the welder, check that the electric current
will not flow through the cylinders.
2. Remove the battery terminals both positive and Cylinder head covers for some models have a low-
negative sides from the battery. conductive metal that will cause spark if the welding
current flows. The spark may damage the cylinder
3. Ground the welder near the section to be welded. rod.
Example 1
Section to be welded
Do not ground this section.

Electric current may flow
through the cylinders.
Ground this section.
(correct grounding)
35C00002
Example 2
Do not ground this section.

Electric current may flow Section to be welded Ground this section.
through the cylinders. (correct grounding)
35C00006
00-21
Outline
5. The weld spattered on the hydraulic cylinders and

on the plated sections of pins will damage the cylin-
ders and pins. There are other parts that may be
damaged by the spatter; hydraulic units, har-
nesses, hydraulic hoses, and nylon tubes.
Be sure to mask these units and parts before weld- Section to
ing. Hydraulic hose be welded
Nylon tube Remove
Harness and if
necessary
Hydraulic cylinder wrap
Chassis
35C00005
Plated section (Mask this section.)

(c) Hydraulic hoses, nylon tubes, or harnesses are
easily damaged by the heat during welding. To pro-
tect them from the heat, remove them from the sec-
Pin section with pin tion to be welded to make enough clearance.
temporarily inserted
Pin
Plated section (Mask this section.)

35C00003
(a) Plated section
Cover the plated sections with heat-resistant cloth,

such as glass wool or canvas.
Note
The weld spattered on the plated sections causes corro-
sion.
Scrap material, etc.

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

nesses, hydraulic hoses, nylon tubes, etc. with
heat-resistant cloth (glass wool or canvas) or scrap
material to protect them from spatter.
00-22
MEMO
03-1
50ZV Measurement for Performance Check
50ZV Measurement for

Performance Check
03-2
Cautions on Safety
Cautions on Safety
WARNING CAUTION
Unexpected movement of the machine may cause an Touching the fan or the V belt of the engine or the hot
accident resulting in injury or death. area while the engine is running may cause severe
Therefore, to provide repair service with the engine accidents.
running, be sure to observe the following items: Make sure to stop the engine before opening the
- Park the machine on level ground. engine room side cover.
- Apply the parking brake.
- Block the tires with chocks to prevent the tires from
moving.
- Determine the signals between the service man.
- Prohibit any person from walking into dangerous
areas.
- Near articulation areas of the machine
- Under the machine
- Around the engine
- In front of or behind the machine
WARNING
Operation under the boom or the bucket may lead to
severe accidents.
Make sure to apply the safety lock of the boom and
the bucket control lever provided in the cab, remove
the starter key, and attach a "DO NOT OPERATE!"
tag to the cab.
CAUTION
Be careful not to be burnt by bursting high pressure
oil.
Release the pressure remaining inside the circuit and
open the cap of the hydraulic tank before removing
the plug from the pressure measurement port so that
the internal pressure of the hydraulic tank is released
and burst of the high pressure oil can be prevented.
WARNING
Entering the articulation area of the machine body
while the engine is running may cause severe acci-
dents.
Make sure to stop the engine, pull out the starter key,
and attach a "DO NOT OPERATE!" tag to the cab
before entering the articulation area.
03-3
Standard Measurement Values for Performance Check

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

ment values for perfor- Remarks
System Measurement item mance check
Minimum no-load speed, Low Idle (LI) 800±50
Maximum no-load speed, High Idle (HI) 2,300±50
Maximum speed in torque converter stall mode 2,150±100
Engine
Engine speed
(min-1) (rpm) Maximum speed in multiple control valve relief mode 2,170±100
Maximum speed in torque converter stall plus multiple

1,830 +150
- 100
control valve relief mode
Clutch pressure Idling (LI) 0.8 (8) (114) or more

Transmission
Engine speed
MPa (kgf/cm2) (psi) Maximum (HI) 1.3~1.6 (13~16) (185~228)
Clutch time lag Neutral→Forward 1st speed

0.2~0.3 Before wheels move
(sec) (engine speed: 2,000 min-1 (rpm))
Cylinder drift Boom cylinder 3 (1/8) or less

(when boom and
bucket are horizon-
tal and with no load)
(mm/min) (in/min) Bucket cylinder 2 (5/64) or less
Idling (LI) 18±2.0

Boom rising time
-1
(no load) Engine speed 1,500 min (rpm) 9±1.0
(sec)
Maximum (HI) 5.4±0.5
Hydraulic pressure
Idling (LI) 3.2±0.5

Full steering time -1
Engine speed 1,500 min (rpm) 2.2±0.3
(sec)
Maximum (HI) 2.2±0.3
20.6±0.5 (210±5)
Loading line main relief pressure (HI)
(2,986±71)
Run engine at lowest

24.5±0.5 (250±5)
Loading line overload relief pressure (LI) possible speed
Relief valve (3,555±71)
while setting
setting pressure
MPa (kgf/cm2) (psi) 17.2±0.5 (175±5)
Steering line main relief pressure (HI)
(2,489±71)
Run engine at lowest

20.6±0.7 (210±7)
Steering line overload relief pressure (LI) possible speed
(2,986±100)
while setting
03-4
Item Standard measure-

ment values for perfor- Remarks
System Measurement item mance check
Shift lever Slowly increase the

2nd speed reverse engine speed, and
position Right brake pedal fully
Performance of check that the machine
depressed and held
service brake does not move at the
down during test.
Engine speed Maximum (HI) maximum engine
speed.
Brake
Shift lever Before brake check, be

3rd speed reverse
position sure to disconnect the
Performance of
↑ cable connector of
parking brake
parking brake limit
Engine speed Maximum (HI) switch
12-1
50ZV Function & Structure Chassis Group
50ZV Function & Structure

Chassis Group
12-2
Front Chassis
Front Chassis
Loading linkage
4 5
50ZV12001J
1. Bucket
2. Link
3. Lever
4. Bucket cylinder
5. Boom
6. Boom cylinder
12-3
Front Chassis
Loading linkage pin

mm (in)
1. Bucket - Boom 2. Boom - Lever 3. Boom - Boom cylinder
4. Front chassis - Boom 5. Bucket - Rod 6. Lever - Rod
7. Lever - Bucket cylinder 8. Bucket cylinder - 9. Boom cylinder -

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

Steering cylinder Rear chassis
7 8 4
11
3
10
1 50ZV12001
12-4
Rear Chassis
Rear Chassis
Fuel tank
EMPTY
FULL
1
25
4 2 5
30
3
6 7
(140 L)
217
View A
50ZV12003a
1. Fuel tank
2. Fuel level sensor
3. Fuel tank filler assembly
4. Drain plug
5. Inspection hole cover
6. Suction pipe
7. Fuel return pipe
12-5
Rear Chassis
Floor board mount Viscous mount
Floor board
1
1
2
60ZV12007
5
1. Floor board
2. Viscous mount
6
7
8 9
70ZV12007
The floor board is supported by a viscous mount in four

positions so that vibrations, impacts and sounds gener-
ated in the chassis are not transmitted to the inside of
cabin.
1. Stud
2. Cushion rubber
3. Case
4. Cap
5. Damping plate
6. Plain washer
7. Head bolt
8. Silicon oil
9. Plug
12-6
Center Pin
Center Pin
Upper center pin Lower center pin
1 4 10
3
8 1 4
Front chassis
6
2
Front
7 chassis Rear
chassis
2 11
9 Rear chassis
Upper 50ZV12004 Lower 50ZV12005
Upper Lower
1. Center pin 1. Center pin

2. Cover 2. Dust seal
3. Bearing cover 3. Bolt
4. Sleeve 4. Plate
5. Shim
6. Bearing assembly
7. Dust seal
8. Bushing
9. Bolt
10. Bolt
11. Washer
12-7
Center Pin
Dust seal
Center
pin
Dust seal position

70ZV12008
When installing the dust seal, check that the lip faces
toward the outside. If the lip faces toward the outside,
the dust will not be drawn through the seal.
12-8
MEMO
13-1
50ZV Check & Adjustment Chassis Group
50ZV Check & Adjustment

Chassis Group
13-2
Linkage Pin
Linkage Pin
WARNING CAUTION
Unexpected movement of the machine may cause an Unexpectedly dropped parts may cause an accident
accident resulting in injury or death. resulting in injury.
Before starting adjustment work, be sure to observe - Before liner insertion, be sure to lift the cylinder
the following items: using a crane to prevent the cylinder from unex-
- Park the machine on level ground. pectedly dropping during liner insertion.
- Apply the parking brake. - Wear protective clothes like work gloves and steel
- Remove the starter key, and hang a "DO NOT toed shoes.
OPERATE!" tag on the steering wheel.
moving.
Liner
50ZV13001
Adjustment
1 2 3 4 5
portion
Liner hole dia. 51 71 56 61 36
mm (in) (2.00) (2.80) (2.20) (2.40) (1.42)
13-3
Linkage Pin
Adjustment
* *
95ZV12005
Adjust the clearance (*) to 1.2 mm (0.05 in) or less

between the bosses using liner of 1 mm (0.04 in) thick-
ness.
For the steering cylinder, be sure to adjust the clear-

ance on the rear chassis side first and then on the front
chassis side while checking that the cylinder is not
inclined.
13-4
Center Pin
Center Pin
Adjusting shim (#5) Installing bearing cover (#3)
1 4 10
8
3 Front
Grease hole
6 60ZV13001
Front
7 chassis Rear
chassis Install the bearing cover so that the grease nipple
2 11 mounting hole is positioned as shown in the figure.
9
Upper 50ZV12004
The clearance between the front chassis and bearing

cover (#3) is 0.5±0.5 mm (0.02±0.02 in) before shim
adjustment.
Add shims so that the clearance is 0.1±0.05 mm (0.004

±0.002 in).
: (9): 319 N-m (32.5 kgf-m) (235 lb-ft)

(with lubrication oil)
: (10): 230 N-m (23.5 kgf-m) (170 lb-ft)
22-1
50ZV Function & Structure Power Group

Power Group
22-2
Power Line
Power Line
2 1 9 10 3
6 4 8 5 7 11
50ZVA22001
1. Engine The power output from the engine is transmitted to the

2. Torque converter and transmission transmission through the torque converter (combined
3. Radiator with the transmission). The speed and direction are
4. 2nd propeller shaft changed according to the engagement of the transmis-
5. 3rd propeller shaft sion clutches. The power is then transmitted through the
6. Front axle differential gear second and third propeller shafts to the differential
7. Rear axle differential gear gears of front and rear axles.
8. Parking brake
9. Air cleaner Finally the power is transmitted through the planetary
10. Muffler gears to the axles, and tires to move the machine.
11. Torque converter oil cooler (bottom tank of radiator)
On the back side of the engine, there is a radiator. The
radiator incorporates engine coolant, torque converter
oil cooler. On the second propeller shaft side of the
transmission, a parking brake is installed.
22-3
Engine / Transmission
Engine / transmission mount
A
Rear axle C/L
4
Flexible
plate
3
Trans-
mission Front Rear
1
Flywheel
1 2
Clearance 1 mm Clearance 1 mm
2
A-A B-B Setting face of T/M & E/G
50ZV22002
1. Bushing Bolts are used to connect the engine flywheel housing

2. Washer to the transmission housing, and a flexible plate is used
3. Bracket to transmit the engine power to the transmission. There-
4. Engine bracket fore no thrust load is placed on the engine flywheel or
crankshaft.
Rubber cushions are used to mount the engine and the

transmission on the chassis.
22-4
Accelerator pedal
1
25
2 11
10
10
12
9 13
2
7
3
8
3
8
4
4
6
Stroke
5 44.5 6 5
(1.8 in)
(mm)
1. Accelerator pedal (in)
44.5
2. Rod 40 (1.8)
3. Lever (1.6)
Lever stroke
4. Plate 30
(1.2)
5. Cable support 20
6. Clevis (0.8)
7. U bolt 10
(0.4)
8. Nut
9. Return spring
0 10 20
10. Bellows
Pedal angle
11. Adjusting bolt
12. Lock nut
13. Bearing 65ZV22003
22-5
Fuel control
Idling
Accelerator pedal Control cable
B
Full
A
50ZV22003
12 mm (0.5 in)
Rotational (cable screw
de pth)
center
39 mm 117 mm (4.61 Carefully *tighten the nut to

(1.53 in)
in) prevent the control cable
At low idle from distortion or damage.
Stroke
*Torque value
54 N-m (5.5 kgf-m) (39 lb-ft)
Detail of A Detail of B
50ZV22004
Adjusting accelerator pedal

Press the accelerator pedal at full stroke, and check that
Idle the accelerator pedal comes in contact with the top of
the adjusting bolt (1). If not, adjust the accelerator pedal
and lock it with the lock nut (2).
Full stroke
65ZV22005
: (2): 9 N-m (0.9 kgf-m) (6.5 lb-ft)

22-6
Radiator
Radiator
2 Coolant IN
3
1 5
C
B
Drain Coolant OUT 6

T/C oil cooler OUT T/C oil cooler IN
50ZV22005
1. Radiator assembly The radiator incorporates the engine coolant and torque
2. Cap converter oil cooler. For the engine coolant, the air-cool-
3. Upper tank (Soldered) ing system is used. For the torque converter oil, the
4. Lower tank (Soldered) watercooling system is used.
5. Fan shroud
6. Torque converter oil cooler
22-7
Radiator
Radiator mount
A-A B-B Detail of C
60ZV22021
Capacity in radiator:
Cooling water 30 L (8 gal)
Torque converter oil 1 L (1/4 gal)
Dry weight 135 kg (300 lbs)

22-8
Propeller Shaft
Propeller Shaft
1 3 4 2
50ZV22006
1. 2nd propeller shaft The engine power transmitted to the torque converter,
2. 3rd propeller shaft (fixed type) the transmission and is then transmitted to the second
3. Pillow block and the third propeller shafts to the front and the rear
4. Slip joint axle.
For the second propeller shaft, the universal joint and

slip joint type spline shaft are used for smooth power
transmission at any steering angle or change in propel-
ler shaft length.
The third propeller shaft is the fixed type with universal

joints.
22-9
Propeller Shaft
Second propeller shaft assembly

Front differential – Transmission
Transmission
5 1
2
Front
differential
50ZV22007
1. Flange yoke
2. Journal spider assembly
IMPORTANT
3. Sleeve yoke assembly Never reuse universal joint or driveline bolts or locks.
4. Propeller shaft assembly Always use new bolts and secure with loctite® 262
5. Journal spider assembly and primer.
6. Pillow block
22-10
Propeller Shaft
Third propeller shaft assembly

Transmission – Rear differential
2
2
1
Rear differential
Transmission
50ZV22008
1. Flange yoke
2. Journal spider assembly
IMPORTANT
3. Coupling yoke Never reuse universal joint or driveline bolts or locks.
Always use new bolts and secure with loctite® 262
and primer.
22-11
Axle Assembly
Axle Assembly
24
9
11 14
14 1
19 21
22 8
6
22
21
7 18
26
16
14 20 17
15
14 3 15
5 10
2
4
10
15
12
13
23
24
25
50ZV22010
1. Differential assembly 14. Straight pin

2. Axle housing assembly 15. Spring pin
3. Internal gear 16. Plane washer
4. Spider (planetary carrier) 17. Shim
5. Axle shaft 18. O-ring (inner)
6. Piston 19. O-ring (outer)
7. Sun gear 20. Brake retainer
8. Planetary gear 21. Wear ring
9. Separation disc 22. Needle cage
10. Planetary pin 23. Oil seal
11. Friction disc 24. Plug
12. Taper roller bearing 25. Bolt
22-12
Axle Support
Axle Support
Front
10
1
2 3
A-A
7
Grease pipe (Front) (Rear)
5 8
connection port
Large Small
6 chamfer chamfer Large Small
chamfer chamfer
4 9
11
A A
4 11 5 6
#6, #11 mounting direction

(Large chamfer faces to the machine front side)
2
3
9
#9 mounting method
50ZV22013
1. Rear axle assembly

2. Rear axle support (front)
3. Rear axle support (rear)
4. Seal
5. Seal
6. Bushing
7. Plate
8. Bolt
9. Seal
10. Breather
11. Bushing
22-13
Axle Support
10
7
9
6
8
Grease piping
9 3
Grease piping
5
1 Rear differential
11
4
50ZV22012
1. Rear differential
2. Rear axle support (front)
3. Rear axle support (rear)
4. Seal
5. Seal
6. Bushing
7. Plate
8. Bolt
9. Seal
10. Breather
11. Bushing
22-14
Differential Gear
Differential Gear
21 15 12
14
13
16
29
18
20 17
5 11
17
19 8
22 7
10 6
4
3 23
50ZV22003J
1. Nut 16. Flange

2. Ring 17. Nut
3. Flange yoke 18. Taper roller bearing
4. Sleeve 19. O-ring
5. Bevel gear 20. Housing assy
6. Housing 21. Bevel gear
7. Shim 22. O-ring
8. Housing 23. Ring
9. Taper roller bearing
10. Oil seal The figure shows the front differential gear.
11. Roller bearing
12. Gear set The only difference between the front and rear differen-
13. Wear ring tial gears is the shapes and dimensions of the flange
14. Wear ring yoke (3) housing (6) and housing (8).
15. Spider
22-15
Differential Gear
Function of T.P.D Contact between pinion and side gear
The differential gear used for the machine is the torque T.P.D. Conventional
proportioning type. Compared with the conventional dif- differential
ferential, the torque proportioning differential (T.P.D.)
can reduce tire slippage on sandy or muddy ground.
This prevents some of the reduction in rim - pull and tire

wear caused by tire slippage.
R2
R1
Difference in gear shapes Shaft center of side gear
95ZV22018
Conventional differential
Conventional
differential There is little change in distance from the shaft center of
the side gear.
T.P.D.
The contact point varies as the gear rotates. The dis-
tance between the contact point and the shaft center of
the side gear also varies in the range of R1~R2.
T.P.D. 95ZV22014
Conventional differential
Standard bevel gear
T.P.D.
Special bevel gear
The gear width is 35~50% longer than the conventional
differential.
22-16
Differential Gear
Operation of T.P.D
Rotational direction
Pinion
Pinion
Side gear
R2
L R L R2 R1 R L R1 R
R1 R2
[A] [B] [C]

The surface resistance values The surface resistance of the The surface resistance of the
of the right and left wheels are left wheel is low due to sandy right wheel is low.
identical to each other. ground or the like.
95ZV22015
The function of the T.P.D. is as follows: If the surface (slipping occurs), the driving force of the right wheel
resistance values of the right and left wheels differ from will be increased to limit the reduction in the total
each other, engagement position of the pinion gear with amount of the driving force.
the side gears will be automatically shifted to transmit
different torque to the right and left wheels. Different Assuming that the driving torque of the right wheel is TR,
torque in right and left wheels prevents the tires from and that of the left wheel is TL, the relation between TR
slipping. and TL can be expressed as follows:
The number of pinion gear teeth is an odd number, and TR R

the pinion gear operate as follows. ------ = ------1
TL R2
1. When the traction of the right and left wheels are The value obtained from the above formula is referred
identical to each other, the pinion and side gears to as the bias ratio. The limit of the bias ratio is 1.4. In
will be engaged as shown in figure [A]. In this case, other words, until the difference in the surface resis-
the torque arms of both side gears are identical to tance between the right and left tires is increased to 40
each other (R1 = R2). As a result, identical driving %, the pinion gear will be properly engaged with the
force will be applied to both the right and left shifted side gears, and driving force will be properly
wheels. applied to both the side gears to prevent the tires from
slipping.
2. If the left wheel loses traction the engagement posi-
tion between the pinion and side gears will be 3. If the surface resistance of the right wheel is
shifted as shown in figure [B] to quickly rotate (spin) reduced, the engagement position between the pin-
the left wheel. As a result, the torque arms of the ion and side gears will be shifted as shown in figure
both side gears differ from each other (R1> R2), and [C] above. In this case, the right and left sides are
the driving force of the left wheel is small. As a reversed compared with the above description.
result, tire slipping can be reduced.
When the driving force of the left wheel is reduced
23-1
50ZV Check & Adjustment Power Group

Power Group
23-2
Engine
Engine
Measuring engine oil pressure
WARNING
Measurement instrument
Unexpected movement of the machine may cause an
accident resulting in injury or death.
Therefore, to provide repair service with the engine - Pressure gauge
running, be sure to observe the following items:
- Park the machine on level ground.
- Block the tires with chocks to prevent the tires from Install position
moving.
- Determine the signals between the service men. 1. Location (A)
- Prohibit any person from walking into dangerous Remove the oil pressure switch and install the pres-
areas. sure gauge.
- Near articulation area of the machine
- Under the machine 2. Measuring port: PF 1/8
- Around the engine
- In front of or behind the machine 3. Oil pressure gauge: 1.0 MPa (10 kgf/cm2) (142 psi)
CAUTION
Do not touch the fan or V-belt of the engine or high- Standard measurement value
temperature section if the engine is running.
An accident resulting in injury may occur. Engine speed Service standard
Be sure to stop the engine before you open the side Idle 0.18 MPa (1.8 kgf/cm 2) (26 psi)
cover of the engine room. Full 0.36 MPa (37 kgf/cm2) (53 psi)
Keep all guards in place. [Engine coolant temperature 50ºC (120ºF)]
Avoid high temperature components even when the
engine is stopped.
A
Use a photo tachometer when checking engine revo-
lution.
Measuring engine speed

- Tachometer
Standard measurement value

4B4.5T Engine 50ZV23001J
-1
Low idle (min ): 800±50
High idle (min-1): 2,300±50

23-3
Propeller Shaft
Propeller Shaft
Propeller shaft phase
Third propeller shaft

Second propeller shaft
Front differential Transmission Rear differential
95ZV22007
Adjust the yokes of the second and third propeller shafts

to the same direction (phase).
- The propeller shaft attaches to the transmission

shaft. The shaft from the front differential to the rear
differential is referred to as the propeller shaft. The
propeller shaft articulates as the machine turns.
When the propeller shaft is articulated due to
machine steering, differences in the yoke phases
(directions) will cause unbalance between the trans-
mission torque and the reaction force. As a result,
the propeller shaft extremely vibrates, and the ser-
vice life of the shaft will be shortened.
Second propeller shaft alignment
Top view
Differential side (C) (B) (A) Transmission side
Side view
95ZV22008
- As misalignment may produce an abnormal noise,

be sure to align points (A), (B), and (C) of the yokes
when reassembling the propeller shaft.
23-4
Propeller Shaft
Tightening torque
Pillow block 3rd propeller

(Center bearing) shaft
2nd propeller
shaft
Front diff. 1 4 2 3 Rear diff. 50ZV23002
IMPORTANT
Never reuse universal joint or driveline bolts or locks.
Always use new bolts and secure with loctite® 262
and primer.
: N-m (kgf-m) (lb-ft)
1. 80 (8.15) (59)
2. 142 (14.5) (105)
3. 137 (14.0) (101)
4. 230 (23.5) (170)
#1, 2, 3, 4: Screw lock agent (Three Bond 1327)

23-5
Axle
Axle
Axle
16 7 4 20 11 9 6 1
17
26
13 5 2 24
23
10
15
12
25•B
21 8 22 14 (A) 18
3 19
50ZV23003
1. Differential assembly 13. Taper roller bearing : Bolt tightening torque

2. Axle housing 14. Straight pin
assembly 15. Spring pin (25): 206 N-m (21.0 kgf-m) (152 lb-ft)
3. Internal gear 16. Plane washer (26): 314 N-m (32.0 kgf-m) (232 lb-ft)
4. Spider 17. Shim
(planetary carrier) 18. O-ring (inner)
5. Axle shaft 19. O-ring (outer) #25, 26: Screw lock agent (Three Bond 1327)
6. Piston 20. Brake retainer
7. Sun gear 21. Wear ring (A): Liquid gasket (Three Bond 1215)
8. Planetary gear 22. Needle cage
9. Separation disc 23. Oil seal Adjust the preload on bearing (12) (13) to 52~73 N
10. Planetary pin 24. Plug (5.3~7.4 kgf) (11.6~16.3 lbs) at #25 bolt hole using
11. Friction disc 25. Bolt shims (17).
23-6
Axle
Differential gear
21 15
12
28, 29
Differential retainer bolt

14
13
16
24
29
18
20 17
5 11
17
27
25
9
19
8
22
26 7
10 6
4
1 3 23
50ZV23004
: Tightening torque for bolts and nuts

#24, 25, 26, 27, 28, 29:
(1): 363 N-m (37.0 kgf-m) (268 lb-ft) Screw lock agent (Three Bond 1327)
(24): 26 N-m (2.7 kgf-m) (20 lb-ft)
(25): 206 N-m (21.0 kgf-m) (152 lb-ft) #10: Liquid gasket (Three Bond 1215)
(26)(27)(28)(29): 133 N-m (13.5 kgf-m) (98 lb-ft)
Adjust the preload on bearing (9) to 16~30 N (1.6~3.1
kgf) (3.5~6.8 lbf) measured at #6 bolt hole using spac-
ers (23).
23-7
Axle
Adjusting tooth contact
Tooth contact Possible cause Adjusting method
A Correct
Loosen the bearing adjuster on the rear

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

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

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

check that manual rotation of the gear is possible. After
that, paint blue or red on the tooth surface of ring gear,
and check the tooth contact. To adjust the tooth contact,
adjust the thickness of the shim between the pinion and
cage, and turn the adjustment nut.
23-8
Axle
Three types of tooth contact shown below are

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

factory, we will wrap the bevel gear and drive pinion as
a unit. Therefore, replace the bevel gear and drive pin-
ion as a unit.
Note
Single sale of the bevel gear or the drive pinion is not
possible.
32-1
50ZV Function & Structure Torque Converter and Transmission Group

Torque Converter and Transmission Group
32-2
Torque Converter
Torque Converter
Torque multiplication
Torque ratio (t)

Output Input
3
P T 1
95ZV32002
0.5 1.0
Speed ratio (e)
95ZV32003
Torque converter structure
If the engine speed/pump impeller speed stays the
The torque converter is between the engine and trans- same but the turbine impeller speed is reduced due to
mission, and consists of three impellers as shown in the the transmission load-output torque is increased. This is
figure. The three impellers are pump (P), turbine (T), "torque multiplication". Heat is also generated.
and stator (S) impellers.
Turbine impeller speed (min –1 ) (rpm)
Speed ratio(e)= ------------------------------------------------------------------------------------------------
-
Pump impeller speed (min – 1 ) (rpm)
Power flow path

The pump is connected to the engine flywheel, and
rotates together with the engine.
The turbine is connected to the torque converter output

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

area of the impellers is filled with oil. When the engine is
started, the pump impeller rotates, therefore the oil will
circulate to rotate the turbine impeller (circulation order:
pump→turbine→stator→pump). Oil is redirected by the
fixed stator impeller back to the pump impeller. When
the turbine impeller rotates, the power will be transmit-
ted to the output shaft.
32-3
Torque Converter Gear Pump
Torque Converter Gear Pump

Gear pump specifications
3 1 10 8 6 9 2 5 6 Theoretical discharge volume 34.7 cc/rev
Max. discharge pressure 2.9 MPa (30 kgf/cm2) (427 psi)
Max. pump speed 3,000 min-1 (rpm)
Actual discharge
pump rev. 1,800 min-1 (rpm)
oil temp. at 50ºC 54 L/min (14.4 gal/min.)
(discharge pressure 2.9 MPa
(30 kgf/cm2) (427 psi))
Oil viscosity Engine oil 10W (CD)
6 5 7 9 4 6
60ZV32002
1. Front frame
2. Rear frame
3. Drive gear
4. Driven gear
5. Side plate
6. Metal bushing
7. O-ring
8. Oil seal
9. Pin
10. Snap ring
32-4
Transmission
Transmission
Gear arrangement
16 17 13 12 11 10 9
22 24
19
25
28
26
30
60ZV32003
No. Gear name Number of teeth No. Gear name Number of teeth
9 P.T.O. gear 35 19 Forward clutch gear 26
10 P.T.O. idler 52 22 Counter gear B 46
11 P.T.O. drive gear 41 24 Counter gear C 61
12 Input shaft gear 32 25 2nd speed clutch gear 22
13 Reverse clutch gear 26 26 3rd speed clutch gear 42
16 Counter gear A 46 28 Counter gear D 49
17 1st speed clutch gear 32 30 Output shaft gear 42
32-5
Transmission
Valve location
Accumulator
(for 1st speed)
T/C oil
temperature
switch
T/C inlet pressure
regulator valve Clutch pressure
T/C outlet pressure
regulator valve regulator valve
Transmission control valve
Lubrication oil valve
50ZV32001E
32-6
Clutch Pack
Clutch Pack
Forward and 2nd speed clutch
11
8 16 7 6 1 4 5 2 12 3 9 14
2ND F
10
15
13
60ZV32006
1. Clutch drum assembly

2. Clutch piston
3. Check ball
4. Friction plate
5. Steel plate
6. Back plate
7. Conical plate
8. Return spring
9. Forward clutch gear
10. 2nd speed clutch gear
11. Counter gear C
12. Counter gear B
13. Washer
14. Snap ring
15. Seal ring
16. Snap ring
32-7
Clutch Pack
Reverse and 1st speed clutch
10 8 15 7 6 1 4 5 2 11 3 9 13
1ST R
14
12
60ZV32005
1. Clutch drum assembly

2. Clutch piston
3. Check ball
4. Friction plate
5. Steel plate
6. Back plate
7. Conical plate
8. Return spring
9. Reverse clutch gear
10. 1st speed clutch gear
11. Counter gear A
12. Washer
13. Snap ring
14. Seal ring
15. Snap ring
32-8
Clutch Pack
3rd speed clutch
13 10 2 5 4 1 6 14 12
3RD
3 8 7 9 11
60ZV32007
1. Clutch drum assembly 8. Return spring

2. Clutch piston 9. 3rd speed clutch gear
3. Check ball 10. Counter gear D
4. Friction plate 11. Washer
5. Steel plate 12. Snap ring
6. Back plate 13. Seal ring
7. Conical plate 14. Snap ring
Clutch specifications
Friction plate Steel plate Conical plate Return spring
Kind Quantity Kind Quantity Thickness (mm) Quantity Set load N (kgf) (lbs)
Forward clutch 6 6 1
Reverse clutch 6 Same dia. 6 1
1,765
Paper same dia. (Thickness: 2.8
1st speed clutch 6 6 1 (180)
(ø158 mm) 2 mm) (0.11 in)
(396 lbs)
2nd speed clutch 6 (0.08 in) 6 1
3rd speed clutch 6 6 1
32-9
Power Flow Path in the Transmission
Forward Forward 2nd speed
Forward 1st speed 1
3
4 1st R
2
1st R
7 5
8
6
7 2nd F
5
2nd F
10
10
3rd
3rd
11
11
60ZV32009
60ZV32008 - When the forward clutch and the 2nd speed clutch
are engaged, power from the torque converter is
- When the forward clutch and the 1st speed clutch transmitted via the input shaft gear (1) to the forward
are engaged, power from the torque converter is clutch gear (5) and 2nd speed clutch gear (7), then
transmitted via the input shaft gear (1) to the forward to counter gear D (10). Because the forward clutch
clutch gear (5), and via the counter gear (6) to and the 2nd speed clutch are the only clutches
counter gear A (3) and the 1st speed clutch gear (4). engaged, the power is then transmitted via the out-
From there, it is transmitted via counter gear C (8) to put shaft gear (11) to the output shaft.
the 2nd speed clutch gear (7). Because the forward
clutch and the 1st speed clutch are the only clutches
engaged, the power is then transmitted via counter
gear D (10) to the output shaft gear (11), then to the
output shaft.
Note
In the illustration here, the input shaft gear (1) and for-
ward clutch gear (5) are not meshed. But as shown ear-
lier in the "Gear Arrangement" diagram, the input shaft
gear (1) is meshed with the forward clutch gear (5) as
well as the reverse clutch gear (2).
32-10
Forward 3rd speed Reverse

1 Reverse 1st speed
1st R 4
2
6 1st R
5
8
2nd F 7
2nd F
10 9
3rd 10
3rd
11
11
60ZV32014
- When the forward clutch and the 3rd speed clutch 60ZV32015
are engaged, power from the torque converter is

transmitted via the input shaft gear (1) to the forward - When the reverse clutch and the 1st speed clutch
clutch gear (5), and via the counter gear (6) to the are engaged, power from the torque converter is
3rd speed clutch gear (9), and on to counter gear D transmitted via the input shaft gear (1) to the reverse
(10). clutch gear (2), and via the 1st speed clutch gear (4)
Because the forward clutch and the 3rd speed clutch to counter gear C (8), and on to the 2nd clutch gear
are the only clutches engaged, the power is then (7). From there on, the power is transmitted in the
transmitted via the output shaft gear (11) to the out- same way as for forward first gear. Namely the
put shaft. power is transmitted via counter gear D (10) to the
output shaft gear (11) to the output shaft.
Reverse 2nd and 3rd speeds
Refer to the transmission routes of the above reverse

1st speed and the forward 2nd and 3rd speeds.
32-11
Hydraulic System Diagram
Hydraulic System Diagram
Fixed orifice
13
From regulator valve
15
16
11 12
To reverse clutch
14
To F clutch
To 2nd speed clutch
To 3rd speed clutch
To 1st speed clutch
17
7
3
10
8
4
To T/C outlet
To T/C inlet
5 6
R
F
1
Note
Numbers below correspond to page 32-12.
60ZV32001E
32-12
Hydraulic Circuit Diagram
Hydraulic Circuit Diagram

Neutral position
17
Accumulator (1st speed) 13

5 11
4 7 12
10
8
14
9
R 1st 16 15
6 Temp.
3 switch
F 2nd
3rd
2
1
Clutch
60ZV32002E
1. Transmission case
2. Suction strainer
3. Torque converter pump
4. Line filter
5. Regulator valve
6. Torque converter inlet pressure regulator valve
7. Torque converter
8. Torque converter outlet pressure regulator valve
9. Oil cooler
10. Lubricating-oil valve
11. Pressure detection valve
12. Accumulator
13. Solenoid valve
14. Clutch cut-off valve
15. Forward/Reverse selection spool
16. Speed selection spool
17. Accumulator (For 1st speed, installed separately)
32-13
Oil Flow
Oil Flow
Oil flow in the torque converter Oil flow to the clutch

line
To forward and reverse clutches
From the torque converter pump to torque
converter Oil maintained at a specified pressure 1.3~1.6 MPa
(13~16 kgf/cm2) (185~228 psi) by the regulator valve (5)
flows through the fixed orifice, pressure detection valve
Oil from the pump (3) flows through the line filter (4) and
(11) and clutch cut-off valve (14), into the forward/
clutch pressure regulator valve (5), moving the regulator
reverse selection spool (15).
piston to the left against the spring force, to the torque
converter (7). The torque converter inlet pressure regu-
When the transmission shift lever is shifted to the for-
lator valve (6) installed between the regulator valve (5)
ward, the oil maintained at a specified pressure flows to
and the torque converter (7) maintains the torque con-
the forward clutch piston chamber and the oil in the
verter inlet oil pressure at a specified value set at
reverse clutch piston chamber flows through the shift
0.3~0.7 MPa (3~7 kgf/cm2) (43~100 psi).
spool passage and drains into the transmission case.
From torque converter to cooling circuit To speed clutches

Return oil from the torque converter flows through the
The neutral position is available for forward/reverse.
torque converter housing into the torque converter out-
However there is no neutral position for speed clutches.
let pressure regulator valve (8), moving the spool to the
Therefore, after engine starting, the oil fed from the
right side against the spring force, opening the cooler
pump is regulated to the specified pressure by the
port to adjust torque converter oil pressure to the speci-
clutch pressure regulator valve, and then directed,
fied pressure 0.15~0.5 MPa (1.5~5 kgf/cm2) (21~71
through the fixed orifice and pressure detection valve,
psi).
then through the speed range shift spool (16) to one of
the speed clutch piston chambers.
Note
From cooler to lubrication circuit The engine will not start if the shift lever is set to the for-
ward or reverse position. The shift lever must be set to
Oil cooled by the oil cooler (9) flows through the lubrica- the neutral position to start the engine. Therefore, the
tion oil passages in the transmission housing to lubri- machine will not move when the engine is started.
cate all the bearings and to cool the clutch plates. After
that, the oil is drained into the oil pan. When the 1st speed position, which involves a high
reduction ratio, is selected, a certain amount of shock
would occur.
To prevent this, the accumulator (17) just for the 1st

speed clutch is used to raise the clutch pressure slowly
when the 1st speed clutch is engaged (detailed expla-
nation later).
32-14
Shift Lever
Shift Lever
A A
1
Speed F/R change

change
3 F
11 LH
For speed 8
5 selection 2 N
11 RH
1 R
For forward/reverse A-A

6 selection
FN
5 R
(Yellow ring)
3
2
1
T/M control valve

To T/M control valve
K60V2J72001
Forward/Reverse selection Speed selection
When shift lever (4) is moved forward, control cable (6) Turn shift lever (4) to select the desired machine speed.
pushes the T/M control valve spool in. As a result, the Control cable (5) pushes and pulls the transmission
transmission forward clutch is engaged. speed selection spool by turning shift lever (4).
The machine does not move when shift lever is in N One of the speed clutches is always engaged when
(neutral) position. starting the engine.
32-15
Control Valve
Control Valve
Identification mark
Identification mark
Section B-B
Section C-C Section D-D

(F/R shift) (Speed shift)
Section A-A
Speed selection spool
D D 1 2 3
Back light switch
Main pressure Neutral

R N F
B measuring port switch B
F/R selection spool
C C
60ZV32003E
32-16
Control Valve
System diagram
To 1st speed clutch
To 2nd speed clutch

To 3rd speed clutch
17
16
From
regulator valve
11
12
To reverse clutch
15
13
To F clutch 14
60ZV32004E
1. — 11. Pressure detection valve

2. — 12. Accumulator
3. — 13. Solenoid valve
4. — 14. Clutch cut-off valve
5. — 15. Forward/Reverse selection spool
6. — 16. Speed selection spool
7. — 17. Accumulator
8. — (For 1st speed, installed separately)
9. —
10. —
32-17
Control Valve
Oil port layout

Control valve
B: Bolt hole To 3rd speed clutch

D: Drain port leading to transmission case To 2nd speed clutch
To 1st speed clutch
B B B
d 3 2 1 D
P c D
D a
b
B B
D R g F D
D D
B B B
To reverse clutch To forward clutch

60ZV32005E
32-18
Control Valve
Sub-plate
B B B
D To 3rd speed
clutch Plate installation
hole
To 1st speed clutch
Plate installation hole D
From
D
To 2nd regulator valve
speed clutch D
B B
To forward To reverse
clutch clutch
D
D
D
D
B B B
60ZV32006E
32-19
Modulation Mechanism
When forward/reverse or speed changing, the modula- Clutch control oil pressure curve
tion mechanism works to reduce the time required for
clutch engagement (time lag), to prevent the shock at
clutch engagement, to improve the work efficiency and
durability of the power system, and to ensure operator's
comfort.
Clutch pressure
For such effects, the modulation mechanism controls MPa (kgf/cm2)
the clutch oil pressure rising time as follows:
P3
P2
P1
t1 t2 Time (sec)
Pressure High pressure

High Initial oil increase holding
pressure feeding
holding
70ZV32020
P: MPa (kgf/cm2) (psi)

t : sec
Std. value
P1 P2 P3 t1 t2
Speed range
1st speed 0.1~0.4 1.5~1.9

0.6~0.9 1.0~1.4
2nd speed (1~4) (6~9) (10~14) 1.0~1.4 0.2
(14~57) (85~128) (142~199)
3rd speed 1.0~1.4
(Engine speed at 1,600 min-1)
32-20
Before the shift lever is moved

(travelling or stop condition)
High pressure holding
Orifice A
Pressure detection valve (1)
(4) (2) (3)

Orifice B
To forward / reverse and

speed clutches
Accumulator
60ZV32020a
The pressure detection valve spool is constantly being

pushed to the right by the return spring, but during travel
the spool is pressed by clutch oil pressure to the
extreme left. With the spool in this position, oil from the
regulator valve flows through passage (1), then the
spool, then passage (2), then the speed range shift
spool, and into the clutch piston chamber. The oil also
flows into the accumulator, filling it.
32-21
When the shift lever is moved (1)

Initial oil feeding to clutch piston chamber
Orifice A (C)
(4) (2) (3)

Orifice B

speed clutches
Accumulator (discharging)
60ZV32021a
When the shift lever is moved, the circuit pressure Under this condition, oil from the regulator valve flows
between the fixed orifice A and the clutch drops until oil through the fixed orifice A, passage (1) and orifice (C) in
fills the piston chamber of the clutch that is engaged the spool, passage (3) and the fixed orifice B and into
and force the piston against the clutch plates. the clutch piston chamber, and this keeps the low oil
pressure in the piston chamber.
This drop in circuit pressure causes a drop in the pres-
sure forcing the accumulator piston to the right, so the
spring moves the piston to the left, and the oil in the
accumulator is directed to the piston chamber of the
clutch that is engaged.
At this time, oil discharged from the accumulator flows

through passages (4) and (2) into the clutch piston
chamber.
At the same time, the pressure forcing the pressure

detection valve spool to the left drops and the return
spring moves the spool to the right.
32-22
When the shift lever is moved (2)

Pressure increase
Orifice A (C)
(4) (2) (3)

Orifice B

speed clutches
Accumulator (being filled)
60ZV32022
After oil from the accumulator initially fills the clutch pis-
ton chamber, the oil from the regulator valve flows
through passage (1) and orifice (C) in the spool, pas-
sage (3) and the fixed orifice B, and into the accumula-
tor, filling it.
Consequently, clutch oil pressure rises gradually to

transmit torque smoothly.
As clutch oil pressure rises, the force on the pressure

detection valve spool also increases gradually and
moves the spool to the left.
When the clutch oil pressure reaches about 0.8 MPa (8

kgf/cm2) (114 psi), passages (1) and (2) are connected,
maintaining the specified clutch oil pressure.
The oil in the accumulator which is filled is now ready to

be supplied to the clutch piston chamber the next time
the clutch is shifted.
32-23
Accumulator
Accumulator
Accumulator for 1st speed clutch During shifting to 1st speed (A)
When the 1st speed position, which involves a high 1 4 3

reduction ratio, is selected, a certain amount of shock
would occur.
To prevent this, an accumulator just for the 1st speed

[1]
clutch is used to raise the clutch pressure slowly when
1st speed clutch is engaged.
Before shifting to 1st speed

To 1st clutch From 1st speed solenoid 60ZV32011
1 1st accumulator 4 3 2
Oil from the 1st speed solenoid valve flows through the
pressure detection valve (4) and passage [1] into the 1st
5
speed accumulator, pushing the piston (1) to the right
against the stopper (3). (Charging of the accumulator.)
Pressure
detection valve
To 1st clutch From 1st speed solenoid 60ZV32010a
Because there is no clutch oil pressure acting on the 1st

speed clutch piston, the piston of the 1st speed accu-
mulator (1) and the spool of the pressure detection
valve (4) are forced to the left by springs (2) and (5)
respectively.
32-24
Accumulator
During shifting to 1st speed (B) When shifting to 1st speed is completed
1 4 3 4
[1]
[2]
To 1st clutch From 1st speed solenoid 60ZV32012 To 1st clutch From 1st speed solenoid 60ZV32013
When the piston of 1st speed accumulator (1) has been After the oil in the accumulator has been discharged
stopped by the stopper (3), oil from passage [2] starts to into the drain port, there is still oil pressure in the clutch
move the spool of the pressure detection valve (4) to port. Therefore, the spool of the pressure detection
the right. valve (4) remains at the right with the oil pressure and
the force of spring (5) balanced.
Consequently, the oil filling the accumulator flows
through passage [1] and the pressure detection valve
(4) and drains into the drain port. (Discharging of the
accumulator.)
32-25
Solenoid Valve
Solenoid Valve
Clutch cut-off solenoid valve At clutch cut-off
Clutch cut-off solenoid valve operation From regulator valve
P
During travel
T
From pressure From regulator valve

detection valve A
Solenoid
P valve
Clutch cut-off
valve T
From forward/reverse shift valve

A
At clutch cut-off
60ZV32008E
When the clutch and brake pedal, or the parking brake

To forward/reverse shift valve
is operated, the solenoid valve is energized, moving the
During travel solenoid valve spool to the left. Oil from the regulator
60ZV32007E
valve flows through port (P) and port (A), and into the
cut-off valve, in which the oil moves the valve spool to
The solenoid valve is de-energized and oil from the reg- the left.
ulator valve is blocked at port (P) of the solenoid valve.
Therefore, the clutch cut-off valve piston is forced to the Consequently, the pressure detection valve port is
extreme right by the spring and oil flows to the forward/ blocked and oil acting on the forward/reverse clutch
reverse clutch. drains into the tank, placing the clutch in neutral.
Port (A) of the solenoid valve is open to port (T), and oil
leaking from the cut-off valve drains to the tank.
32-26
MEMO
33-1
50ZV Check & Adjustment Torque Converter and Transmission Group

Torque Converter and Transmission Group
33-2
50ZV Check & Adjustment Torque Converter and Transmission Group
Clutch Oil Pressure
Clutch Oil Pressure

1
5
6
9
4
7
2
9
8 3
50ZV33001E
WARNING
Therefore, to provide repair service with the engine
running, be sure to observe the following items :
moving.
- Determine the signals between the service men.
areas.
- Near articulation area of the machine
- Under the machine
- Around the engine
- In front of or behind the machine
Oil pressure MPa (kgf/cm2) (psi)

Measuring
No. Measuring port location Engine revolution (min-1) (rpm) Shift lever position
port size
800 2,300
1 Torque converter inlet pressure PT1/4 0.1 (1.3) or more 0.3~0.7 (3~7) All speed range
2 Torque converter outlet pressure ↑ 0.1 (1.0) or more 0.15~0.5 (1.5~5) ↑
3 Main oil press. PT1/8 0.8 (8) or more 1.3~1.6 (13~16) All speed range
4 F PT1/4 0.8 (8) or more 1.3~1.6 (13~16) F
5 Clutch oil R ↑ ↑ ↑ R
6 pressure 1ST ↑ ↑ ↑ 1
7 2ND ↑ ↑ ↑ 2
8 3RD ↑ ↑ ↑ 3
9 Lub. oil pressure PT1/8 0.002~0.05 (0.02~0.5) 0.08~0.2 (0.8~1.7) All speed range
42-1
50ZV Function & Structure Hydraulic Group

Hydraulic Group
42-2
Flushing Hydraulic Circuit
Flushing Hydraulic Circuit
Purpose of flushing
Debris
To tank
95ZV42001
If the inside of a cylinder, pump, or a valve of the

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

valves, cylinders, or pipes. Therefore, even if the dam-
aged cylinder or valve is replaced, the debris sticking in
other valves, cylinders, or pipes will break loose and
then is fed into the cylinders, where the debris may
damage the inside of the cylinders, or stick into the
valve spools or relief valves, and cause another mal-
function. To prevent such problems, be sure to remove
all the debris from the system.
42-3
Cautions on Hydraulic Parts Replacement
Cautions on Hydraulic Parts Replacement

After oil or a part is replaced, malfunction or seizure
may occur during running-in. Such trouble is often
caused by faulty air bleeding or lubrication after replace-
ment.
After replacing oil or a part, be sure to observe the fol-

lowing work procedure to prevent occurrence of trouble.
Work procedure
1. In the case of new oil pump, lubricate its inside with

new oil prior to installation, and confirm that it can
be turned smoothly by hand.
2. After the oil pump or cylinder was made empty for

oil replacement, repair, etc., restart the operation
as follows.
(a) Before installing pipes, pour new oil into the pump
or the cylinder.
(b) Operate the engine at low-idling speed for 5 min-

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

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

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

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

(2) mnemonic symbol
42-5
Operation methods Pressure control valve
Single flow
Spring path valve,
Normally closed
Single flow
Adjustable spring path valve,
Normally open
Control methods
Pressure
Lever
relief valve
Push button
Unloading valve
Pedal or treadle
Mechanical
control
Sequence valve
Plunger
Pressure
Spring
reducing valve
Solenoid
control
Single acting
solenoid Flow control valve
Double acting Flow control
solenoid valve, Adjustable
non-compensated
Electric motor
control Pressure
compensated flow
control valve
Unidirectional M
fixed
Bidirectional M
variable
Detent
Flow dividing
valve
42-6
Directional control valve Check valve
Two position
Check valve
Two ports
Three position Check valve

Four ports Pilot operated
Four ports
Shuttle valve
with restrictor
Two position
Two ports
Mechanical
control
Spring offset
Pressure
control
Two position
Three ports
Pressure control
Spring offset
Solenoid
control
Restrictor
Two ports
Three ports
Four ports
Servo valve
42-7
Miscellaneous hydraulic symbols
(1)
Hydraulic tank
(1) Vented
(2) Pressurized (2)
Manual
shut off
valve
Pressure
switch
Accumulator
Electric
motor M
Internal
combustion M
Power source
Filter or
strainer
Heater
Cooler
Pressure
gauge
Temperature
gauge
Flow meter
42-8
Hydraulic System Operation
Hydraulic System Operation
Hydraulic system operation out- Steering system

line
The steering system consists of the following compo-
The hydraulic system consists of the following systems: nents.
- Loading system - Hydraulic pump (1)

- Priority valve (2)
- Steering system - Orbitrol® (3)
- Steering cylinder (7)(8)
- Cushion valve (12)
Loading system Oil from pump (1) flows to Orbitrol® (3) through the pri-
ority valve (2).
The loading system consists of the following compo-
nents. All numbers base on page 92-4. When the steering wheel is turned, an amount of oil pro-
portional to the turning speed is sent from the pump (1)
- Hydraulic pump (1) to the steering cylinder (7)(8) through the priority valve
- Priority valve (2) (2) and the Orbitrol® (3).
- Multiple control valve (4)
- Boom cylinders (5) When the steering wheel is not operated, almost all of
- Bucket cylinder (6) the hydraulic oil discharged from the pump (1) is sup-
plied to the loading circuit.
Oil from pump (1) flows to priority valve (2). The priority
valve functions to distribute oil discharged from only one Priority valve (2) detects the resistance of the hydraulic
pump adequately to both steering and loading circuits oil passing through the Orbitrol® (3), namely the speed
plus relieve excessive hydraulic pressure for steering. of the steering wheel’s rotation and the amount of oil,
and then distributes oil to the loading and steering cir-
When the steering wheel is not operated, almost all cuits.
hydraulic oil discharged from pump (1) is sent to multi-
ple control valve (4) through priority valve (2). Cushion valve (12) is provided to prevent shock at the
time of starting and stopping the steering wheel.
When the steering wheel is turned, an amount of oil pro-
portional to the turning speed is sent from pump (1) to While the steering wheel is not turned, almost all
steering cylinders (7)(8) through priority valve (2) and hydraulic oil from the steering pump (1) is sent to the
Orbitrol® (3). loading line by the action of the flow control spool.
Excessive oil is sent to multiple control valve (4). Oil returns from the steering cylinders (7)(8) flows
through Orbitrol® (3) and returns to the hydraulic tank.
Oil from pump (1) is then directed through multiple con-
trol valve (4) to boom cylinders (5) and bucket cylinder Finally it returns to the tank through the return filter (9).
(6).
Return oil from the cylinders flows through the multiple

control valve to the oil cooler, return filter (9) and into
the hydraulic tank.
42-9
Layout of Hydraulic Units
Layout of Hydraulic Units
5 6 1 2 7 4 2
7
50ZV42001E
1. Multiple control valve

2. Orbitrol®
3. Hydraulic pump
4. Priority valve
5. Bucket cylinder
6. Boom cylinder
7. Steering cylinder
42-10
Hydraulic Tank
Hydraulic Tank
2
2
Pump
Return
4
4
5
1. Oil tank
2. Oil level gauge
3. Breather valve (tank cap)
4. Drain plug
5. Inspection port 50ZV42003J
42-11
Hydraulic Tank
Hydraulic tank breather valve When the pressure inside the hydraulic tank drops
below the outside air pressure, the outside air flows
(tank cap) through the filter element (6). The suction valve (3) is
then opened to let the air flow into the tank.
6 1
2 When the air pressure inside the hydraulic tank rises to
3 a certain point 78.5 kPa (0.8 kgf/cm2) (11.4 psi), the dis-
charge valve (2) is lifted (opened) so that the air can
flow out of the tank through the filter element (6).
7
One cycle (down and up) of the boom applies pressure
to the inside of the tank.
Therefore 78.5 kPa (0.8 kgf/cm2) (11.4 psi) pressure is

always applied to the inside of the hydraulic tank.
5 The pressure applied to the inside of the hydraulic tank

prevents the dust and dirt from being drawn into the
tank and improves performance of the pump.
4
The positive pressure pushes the oil to the pump reduc-
ing the possibility of pump cavitation.
To release the internal pressure from the hydraulic tank,

pull the knob (7) and turn the cap (1) counter clockwise.
50ZVA42010
1. Cap
2. Discharge valve
3. Suction valve
4. Strainer
5. Key (Allen 4 mm (5/32 in))
6. Filter element
7. Knob
42-12
Hydraulic Tank
Hydraulic tank specifications
Type Semi-closed type

Capacity (at center of oil level sight gauge) L 48.3
Suction valve setting pressure (kPa) (kgf/cm2) 5±1.0 (0.05±0.01)
Breather valve 2
Discharge valve setting pressure (kPa) (kgf/cm ) 80±16 (0.8±0.16)
(tank cap)
Filtration particle size (µm) 10
Hydraulic oil level check

Before checking the hydraulic oil level, observe the fol-
lowing items:
- Check that the machine is on level ground.
- Check the hydraulic oil level before operation (when

oil is not warm).
- Lower the boom to the lowest limit, and set the

bucket level on the ground.
Bucket on ground
Check that the oil level is at the center of the oil level
sight gauge.
Hydraulic tank
Oil level sight gauge Oil amount

48.3 L
48.3 L
50ZV42003
42-13
Hydraulic Pump
Hydraulic Pump
4 5 1
5
6
10
8 9
60ZV42005J
1. Drive gear 6. Dowel pin

2. Driven gear 7. Bracket
3. Oil seal 8. Gear case
4. Bushing 9. Housing
5. Wear plate (floating type) 10. Bolt
Hydraulic pump specifications
Type SAR2-45A
Theoretical discharge cm3/rev 34.7
Maximum operation pressure MPa (kgf/cm2) 20.6 (210)
-1
Maximum speed min (rpm) 2,420
Measurement conditions:
Oil temperature 50~80ºC (120~180ºF)

Hydraulic oil ISO VG46
42-14
Hydraulic Pump
Hydraulic pump principle
Inlet Outlet
Inlet Outlet
Inlet Outlet
95ZV42040
The oil at the inlet area is taken in the cavities between

the gear teeth right after disengagement and transferred
towards the outlet area enclosed in between the teeth
and the gear casing.
When the gear teeth mesh again, the oil is extruded out
of the tooth cavities and forwarded to the outlet.
42-15
Hydraulic Pump
Hydraulic pump wear plate Both sides of the gear consists of floating type pressure
plates having balancing functions. The pressure plates
maintain optimum clearance on both sides of the gear
(pressure balance mechanism) so that the high volu-
metric efficiency is ensured.
General structure of pressure plate
Rotating gears feed the pressurized oil along the cir-

Suction cumference of the case to the outlet port. The pressur-
ized oil is also sent to the high-pressure area in the rear
of the pressure plate. The pressure plate is pressed to
the gear side so that the clearance between the pres-
sure plate and the side surface of the gear is kept very
small. The pressing force to the plate is adjusted to an
appropriate value by setting the optimum high-pressure
area of the plate.
Discharge
The high-pressure area in the rear of the pressure plate

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

O-ring
tion
The lubrication system uses the oil fed from the pressur-
Suction ized tank.
Part of the oil fed from the inlet port is sent to the bush-
ings to lubricate them. After that, the oil is returned to
Oil groove for
lubricating bearing the inlet side and then sent to the discharge side.
Bushings require lubrication to maintain a long service

life. Avoid bushing damage due to a lack of lubrication
Suction
oil by:
Starting up a new pump with oil supplied to it.
- Allow new pump to idle (low rpm/no load) for 5 min-

utes.
Confinement
prevention groove - Use the proper viscosity for the coldest possible start
up temperature. Change viscosity if seasonal tem-
perature changes are great (more than 20°C (68°F)).
Discharge
115ZV42006
42-16
Hydraulic Cylinder
Hydraulic Cylinder
1. Piston 9. Backup ring 17. Set screw

2. Piston rod 10. O-ring 18. Ball
3. Cylinder tube 11. Wear ring 19. Wiper ring
4. Rod cover 12. Piston nut 20. U-ring
5. Dust seal 13. Bushing 21. Clip
6. Packing 14. Dust seal 22. Buffer ring
7. Bushing 15. Seal ring assembly 23. Snap ring
8. O-ring 16. Slipper ring
Boom cylinder
9,10 15 11 12
1
9 6 3 2 13,14
7
8
5
4 A B
15 11
5, 23 8 7 9 9 10 6
A-Detail B-Detail 50ZV42002E
: Piston nut (12): 2,157 N-m (220 kgf-m)

: Rod cover (4): 863 N-m (88 kgf-m)
42-17
Hydraulic Cylinder
Bucket cylinder
8 6 22 9 8
9
7
4 21
5
A-Detail
4 3 2 1 11 6 11 12
A B
B-Detail
50ZVA42005
: Piston nut (12): 1,520 N-m (155 kgf-m)

Steering cylinder
8 4 7 20 9 10 2 3 1 15 16 17 18
19
13, 14 13, 14
50ZV42006
: Piston (1): 392 N-m (40 kgf-m)

: Set screw (17): 6.80 N-m (0.7 kgf-m)
42-18
Hydraulic Cylinder
Hydraulic cylinder specifications

mm (in)
ø100 x ø55 x 593
Inner dia. x rod dia. x stroke
(3.94 x 2.36 x 23.25)
Boom ø55 x 153
Piston rod
cylinder Pin hole (2.17 x 6.02)
(inner dia. x width) ø55 x 82
Cylinder
(2.17 x 3.23)
ø100 x ø50 x 462
(3.94 x 1.97 x 18.19)
Bucket ø50 x 85
Piston rod
Cylinder
(1.97 x 3.15)
ø60 x ø35 x 340
(2.36 x 1.38 x 13.39)
Steering ø35 x 45
Piston rod
Cylinder
(1.38 x 1.77)
42-19
Return Filter
Return Filter
Return filter
50ZV42003E
2 3
Return filter specifications
Type Cartridge type
Filtration area 5,100 cm2 (791 in2)
Filtration degree 10 µ
IN OUT
0.15±0.03 MPa
Bypass valve cracking pressure (1.5±0.3 kgf/cm2)
1 (21.3±4.3 psi)
60ZV42007
1. Filter cartridge
2. Head cover
3. Bypass valve
42-20
Loading System
Loading System
When the control lever is operated, the multiple control
valve spool is moved by the control cable.
Oil from the priority valve is then directed to the boom

cylinder and/or the bucket cylinder.
Return oil from the cylinder flows through the multiple

control valve to the return filter and into the tank.
Boom movement and bucket movement can be con-

trolled by one control lever. Move the lever forward to
lower the boom, move it rearward to raise the boom.
Move the lever to the right to dump the bucket, move it
to the left to roll back the bucket.
Control lever
Control
cable
Multiple
control valve
Steering Priority
circuit valve
Return
P filter
60ZV42009J
42-21
Multiple Control Valve
8 9 11
7 10
1 5
A2 B2 Boom spool
A1 B1 Bucket spool
2
4 P T
3
6
IN OUT
OU
T
K60V2J42005
1. Spool assy (Boom)

2. Spool assy (Bucket)
3. Main relief valve
4. Relief valve
5. Make-up valve
6. Inlet section assy
7. Outlet section assy
8. Nut
9. Tie rod
10. Nut
11. Tie rod
42-22
5 Boom cylinder Boom cylinder
A2 B2
A1 T P B1
To tank From pump
Bucket Bucket
cylinder cylinder
4 4
60ZV42010J

2. Spool (Bucket) B2
3. Spool (Boom) A2
4. Overload relief valve (with make-up valve)
5. Make-up valve (Boom circuit)
6. Load check valve B1
7. Detent magnet A1
8. Detent steel ball

P
Hydraulic circuit diagram 60ZV42012J

42-23
The bucket priority line is used for the multiple control Multiple control valve specifica-
valve, and consists of the following units:
tions
Model 2000H-2-MD
Relieves the pressure when the working pressure 20.6 MPa
exceeds the relief setting pressure. Main relief valve setting pressure (210 kgf/cm2)
(2,986 psi)
2. Bucket spool 24.5 MPa

Overload relief valve setting pressure (250 kgf/cm2)
(3,555 psi)
Used for bucket operation, such as roll back, hold- Rod side Installed
ing a tilt angle, and dumping. OLRV Bucket
Bottom side Installed
installation
point Rod side Non-installed
3. Boom spool Boom
Bottom side Non-installed
Rod side Installed
Used for the boom operation, such as raising, hold- Bucket
MUV Bottom side Installed
ing height, lowering, and floating. installation
point Rod side Installed
Boom
4. Overload relief valve Bottom side Non-installed
(With make-up function, on the bucket side)
Relieves the high pressure from the cylinder if the

pressure is extremely high. Protects the cylinders
from a vacuum (negative pressure.)
5. Make-up valve (On the boom side)
Protects the cylinders from a vacuum (negative

pressure).
6. Load check valve
Prevents the reversed oil flow or momentary "load

drop".
42-24
Multiple control valve main relief Main relief valve operation

valve
The main relief valve is installed between the pump and To tank Sleeve Seat
the control spool. When the cylinder comes to the stroke
end, or if the pressure is above the set pressure, the oil
fed from the pump will be discharged into the tank
through this valve (main relief valve) to prevent pump
From pump
and pipe damage.
Chamber A
Main poppet Orifice1 Orifice2 Pilot poppet
Sleeve
Main poppet
To tank Sleeve
Adjusting screw
From pump
Lock nut
Main poppet Chamber A
Passage B Pilot poppet
60ZV42021
1. When the oil pressure is at the set point or below
- The pressurized oil from the pump flows through the

orifice (1) of the main poppet and then into the cham-
ber A. The main poppet and sleeve are firmly
pressed by the area difference (ØD1 > Ød1, ØD2 >
Ød2) and spring force.
Also the pressurized oil in the chamber A flows
through the orifice (2) and acts on the pilot poppet.
The pilot poppet is pressed against the seat by the
spring force from the right, and the seat face is
closed.
42-25
2. When the oil pressure exceeds the set point Adjusting set pressure
- When the oil pressure in the pump port exceeds the Loosen the lock nut and adjust the pressure by the
set spring force of the pilot poppet, the pilot poppet is adjusting screw. Turn clockwise the adjusting screw to
opened, and the oil in the chamber A flows through raise the set pressure, or turn counterclockwise the
the passage B and along the sleeve and escapers to adjusting screw to lower the set pressure.
the tank port. As a result, the oil pressure in the
chamber A rapidly lowers. After adjustment, be sure to tighten the lock nut.
The main poppet is pushed to the right. Then it
opens the port to the tank port and the pressurized Set pressure
oil in the pump port escapes to the tank port. 20.6 MPa (210 kgf/cm2) (2,986 psi)
42-26
Multiple control valve overload Overload relief valve operation

relief valve (with make-up func-
tion)
(Installed on both the rod and bottom sides of the Sleeve
Passage B
bucket circuit) Orifice1 Tank
Each overload relief valve (with make-up function) is

installed between the cylinder and the control valve.
Cylinder
When the spool is in the neutral position, if external
force on the cylinder becomes too high and the oil pres- Piston
sure will be greatly increased, the overload relief valve Chamber A
returns the oil to the tank to protect the cylinders and Main poppet Pilot poppet
pipes from breakage.
Sleeve
Adjusting screw
Cylinder
Piston
Lock nut
Main poppet Orifice2 Pilot poppet
60ZV42022
1. As overload relief valve
- When the oil pressure is at the set point or below
The pressurized oil from the cylinder port is sent to

the chamber A through the orifice (1) of the piston,
and the main poppet and sleeve are pressed by the
area difference (refer to "Main relief valve") and the
spring.
Also the pressurized oil in the chamber A acts on the
pilot poppet, and the pilot poppet completely closes
the seat face by the spring force from the right.
- When the oil pressure exceeds the set point
When the oil pressure in the cylinder line rises above

the pressure set by the spring, the pilot poppet is
moved to the right and opens the port. Then the oil in
the chamber A escapes to the tank port through the
passage B and along sleeve. As a result, the oil
pressure in the chamber A rapidly lowers.
Since the pilot poppet is opened, the oil flows from
the cylinder port side through the orifice (1) of the
piston. The piston moves to the right by the pressure
difference between the cylinder port side and cham-
42-27
ber A side and the piston is pressed against the pilot Adjusting set pressure
poppet. Therefore the oil flows from the cylinder to
the chamber A through only annular clearance
between the main poppet and piston and through the
orifice (2), as a result the pressure difference
between the cylinder port side and chamber A Adjusting screw
becomes greater. The main poppet opens and the
pressurized oil in the cylinder port escapes to the
tank port.
2. As make-up valve
Lock nut
Sleeve 60ZV42023
Tank
Loosen the lock nut and adjust the pressure by the

adjusting screw. Turn clockwise the adjusting screw to
Cylinder raise the set pressure, or turn counterclockwise the
adjusting screw to lower the set pressure.
After adjustment, be sure to tighten the lock nut.
50ZV42018 Set pressure

24.5 MPa (250 kgf/cm2) (3,555 psi)
- When the overload relief valve on one side of the cyl-

inder port is actuated, the port opposite to the one in
which high pressure was produced has a greatly
reduced pressure. The sleeves is moved to the right
by the area difference between the cylinder port side
and inside of the sleeve (chamber A side), and the
oil flows from the tank port to the cylinder port. It pre-
vents a vacuum (negative pressure) in the cylinder.
42-28
Multiple control valve make-up Make-up valve operation

valve
(Installed on the rod side of the boom circuit)
Tank Chamber A
When engine speed is low and the boom is being low-
ered, if pump output is less than what is needed to fill
the boom cylinder, reduced pressure will occur in the
rod end of the cylinder.
B
A
When the cylinder pressure becomes less than tank
pressure, the make-up valves is opened.
Cylinder
Main poppet
Tank
Cylinder
60ZV42024
When the cylinder port pressure is high, due to area dif-

ference (B>A) between the cylinder port side and the
chamber A side, the main poppet is pushed leftward
and seated firmly.
When the pressure at the cylinder port side becomes

less than tank pressure, due to this area difference, the
main popper is moved to the right. Oil flows from the
tank port to the cylinder port, and this prevents a vac-
uum (negative pressure) in the cylinder.
42-29
Multiple control valve bucket spool

Bucket spool operation
1. "Bucket Roll Back" position
Overload relief valve

with make-up valve
D
B1 A1
Main relief
From pump
C valve
50ZVA42001
When the control lever is set to the "Bucket Roll Back"

position, the spool moves to the left, and the spool
shoulder (C) closes the center bypass line.
As a result, the oil from the pump opens the load check
valve (D), flows from the A1 port into the bottom side of
the bucket cylinder, and finally rolls back the bucket.
On the other hand, the oil on the rod side of the bucket
cylinder returns from the B1 port to the tank.
Under this condition, the spool is held at this position by

an electromagnetic detent until the bucket positioner is
actuated.
Force required to release the detent:

147~245 N (15~25 kgf) (33~55 lbs)
42-30
2. "Bucket Dump" position
D
B1 A1
From pump
C 50ZVA42002
When the control lever is set to the "Bucket Dump" posi-

tion, the spool moves to the right, and the spool shoul-
der (C) closes the center bypass line. As a result, the oil
from the pump opens the load check valve (D), flows
from the B1 port into the rod side of the bucket cylinder,
and finally dumps the bucket.
On the other hand, the oil on the bottom side of the

bucket cylinder returns from the A1 port to the tank.
Extremely quick dumping generates negative pressure

(or a void) on the rod side. To prevent generation of
negative pressure (or a void), the make-up valve (E) of
the overload relief valve opens so that the oil in the tank
port flows into the rod side of the cylinder.
42-31
Multiple control valve boom spool

Boom spool operation
1. "Boom Raise" position
D
B2 A2
Make-up valve
From pump Main relief valve

C
50ZVA42003
When the control lever is set to the "Boom Raise" posi-

tion, the spool moves to the left, and the spool shoulder
(C) closes the center bypass line. As a result, the oil
from the A2 port into the bottom side of the boom cylin-
der, and finally raises the boom.
On the other hand, the oil on the rod side of the boom
cylinder returns from the B2 port to the tank.
Under this condition, the spool is held at this position by

a mechanical detent.
Force required to release the detent:

147~245 N (15~25 kgf) (33~55 lbs)
42-32
2. "Boom Down" position
D
B2 A2
From pump
C
50ZVA42004
When the control lever is set to the "Boom Down" posi-

tion, the spool moves to the right, and the spool shoul-
der (C) closes the center bypass line. As a result, the oil
from the B2 port into the rod side of the boom cylinder,
and finally moves down the boom.
On the other hand, the oil on the bottom side of the

boom cylinder returns from the A2 port to the tank.
Extremely quick lowering of the boom while the engine

(pump) revolution is low generates negative pressure
(or a void) on the rod side of the cylinder. To prevent
generation of negative pressure (or a void), the
make-up valve (E) of the overload relief valve opens so
that the oil in the tank port flows into the rod side of the
cylinder.
42-33
3. "Boom Float" position
From pump
60ZV42019J
When the control lever is pushed downward beyond the

"Boom Down" position to the "Boom Float" position, the
control spool moves fully to the right.
As a result of this, all ports (i.e., pump port, tank port,

cylinder bottom end port and cylinder rod end port) are
connected to the tank port.
Therefore, the boom cylinder piston is not held by the oil

pressure force any more and can move freely up and
down by external force, which is useful for leveling
uneven ground.
42-34
Valve Control
Valve Control
B A
Down Raise
Boom operation Roll back Dump
(Forward/Rearward)
3
3
Front chassis
Floor board
1 A-A Bucket operation (Left/Right)

2
Ball joint-Detail
1. Multiple control valve 2

2. Control cable
3. Control lever
4. Ball joint
Multiple control
valve spool
B-Detail
60ZV42020J
42-35
Steering System
Steering System
Orbitrol®
Steering
cylinder
Cushion valve
To loading circuit
Priority valve
P Pump
Tank 60ZV42032
- A load sensing type steering system is employed,

designed to save energy consumed in the hydraulic
system (to raise the operational efficiency).
- When the steering wheel is turned, an amount of oil

proportional to the turning speed is sent from the
pump to the steering cylinder through the priority
valve and the Orbitrol®.
- When the steering wheel is not operated, almost all

of the hydraulic oil discharged from the pump is sup-
plied to the loading circuit.
- The priority valve detects the resistance of the

hydraulic oil passing through the Orbitrol®, namely
the speed of the steering wheel's rotation and the
amount of oil, and then distributes oil to the loading
and steering circuits.
- The cushion valve is provided to prevent shock at

the time of starting and stopping the steering wheel.
42-36
Steering System
60ZV42002E
1. Priority valve
2. Cushion valve
3. Steering cylinder
4. Orbitrol®
42-37
Priority Valve
Priority Valve
To the steering line To the loading line
CF EF
LS
To the Orbitrol®
LS port
1 To the tank
T
P
4 2 3
From the pump
Hydraulic symbols
LS CF EF
P
2 4 5 1
50ZVA42006
1. Spool Priority valve specifications

2. Relief valve
3. Adjusting screw
4. Screen Model VLE61B175B
5. Orifice Rated flow 150 L/min
Control pressure 0.7 MPa (6.9 kgf/cm2) (98 psi)
Steering relief pressure 17.2 MPa (175 kgf/cm2) (2,489 psi)
42-38
Priority Valve
Priority valve operation
Co
To loading circuit
P LS T
CF EF
Spring (2)
Chamber B
LS
Pressure chamber A T P: Pump

T: Tank
Co: Controlled orifice
Spool (1) LS: Line signal
P CF: Controlled flow
EF: Excess flow
Main steering relief valve
From pump
50ZVA42007
The priority valve functions to distribute oil discharged orifice Co). So, in the CF circuit and also in the pres-
from only one pump adequately to both steering and sure chamber A the pressure will increase.
loading circuits plus relieve excessive hydraulic pres-
sure for steering. - On the other hand, only a small amount of the pres-
sure remains in the pressure chamber B, because it
1. When the steering wheel is not operated is connected to the tank through the Orbitrol® ports
LS and T.
- Spool (1) moves right and left depending upon the
difference in the pressure between the pressure - Accordingly, when a large difference in the pressure
chambers A and B and the force of the spring (2). arises between the pressure chambers A and B, the
spool moves from the left to the right and is held in
- When the steering wheel is not operated, the oil dis- that position. Now the EF circuit is almost fully
charged from the pump flows into the Orbitrol® port P opened and the CF circuit is only slightly opened.
through the priority valve ports P and CF.
- The pressure in the steering circuit is equal to the
- When the Orbitrol® is in the neutral state, P and T spring force, namely about 0.7 MPa (6.9 kgf/cm2) (98
ports in the Orbitrol® are nearly closed (indicated by psi) regardless of the pressure in the loading circuit.
42-39
Priority Valve
2. When the steering wheel is operated
Steering wheel operated clockwise
C1
P LS T To loading circuit
CF EF
Pressure
chamber B
LS
P: Pump
T T: Tank
Pressure
chamber A Co: Controlled orifice
LS: Line signal
CF: Controlled flow
P
EF: Excess flow
From pump
50ZVA42008
- When the steering wheel is turned clockwise, the oil - So, the spool housed in the priority valve always
passage is changed in the Orbitrol® as shown below. works to keep the amount of oil discharged from the
Oil supplied to the Orbitrol® flows into the cylinder pump adequate to the speed of turning the steering
through control orifice C1 and the rotor. wheel.
- There is the following relation among the passing Flow

Angular Passing
resistance of the orifice C1 in the Orbitrol®, the angu- displacement resistance
lar displacement of the Orbitrol® spool and sleeve Large Large Medium
and the oil flow from the pump. Large Small Large
Small Large Small
- If the passing resistance is large, the difference in Small Small Medium
the pressure between the pressure chambers A and NOTE
B becomes large, thus moving the spool to the right Larger angular displacement means that the turning speed of steering
wheel is higher.
and decreasing the amount of oil supplied to the
Orbitrol®. On the contrary, if the passing resistance
is small, the spool moves to the left and increasing
the amount of oil supplied to the Orbitrol®.
42-40
Priority Valve
Relief valve operation
To Orbitrol® P port To loading circuit

P: Pump
CF EF T: Tank
Co: Controlled orifice
LS: Line signal
Pressure CF: Controlled flow
chamber B EF: Excess flow
C2
LS
From Orbitrol® LS port
Pressure
chamber A
P
3
From pump 2
50ZVA42009
- When the steering cylinder reaches the stroke end,

the pressure rises up to the set value of the relief
valve 17.2 MPa (175 kgf/cm2) (2,489 psi) in the CF
and LS circuits, and the relief valve (2) comes into
the action to relieve the high oil pressure.
- At that time there is a difference in the oil pressure

between the pressure chambers A and B. So, the
spool moves to the right and nearly blocks the flow of
the oil to the Orbitrol®.
As oil is gradually fed into the chamber B through the
orifice C2, the spool can move quickly to the right as
soon as the relief valve has opened.
- The steering main relief valve set pressure can be

adjusted by tightening or loosening the adjusting
screw (3) inside the relief valve cartridge with an
allen wrench.
Note
Actual adjustment procedure is shown in the inspection
and adjustment section of this manual.
42-41
Orbitrol®
Orbitrol®
A sensing-type Orbitrol® is used in this model in combi- Orbitrol® construction
nation with the priority valve, which regulates the oil flow
from the pump in proportion to the rotating speed of the
1. Spool 6. Centering spring
steering wheel.
2. Sleeve 7. Cross pin
3. Stator 8. Emergency check valve
4. Star 9. Inlet check valve
5. Drive shaft
Valve part
T
6
7 L
Valve part
1 9
2 R
3
4
Rotor part
60ZV42037
42-42
Orbitrol®
- The valve unit is a rotary directional selection valve, Orbitrol® specification

comprised of the spool (1) and sleeve (2). The direc-
tional selection is achieved by turning the steering
wheel, which is splined to the spool (1). Model LPAQG9D
Theoretical delivery cm3/rev 369
- When the steering wheel is not being turned, the Operation pressure MPa (kgf/cm2) (psi) 17.2 (175) (2,489)
spool (1) and sleeve (2) are maintained in the central Overload relief pressure MPa (kgf/cm2) (psi) 20.6 (210) (2,986)
position by the centering spring (6). The oil grooves
in the spool and the oil holes in the sleeve are mis-
aligned and the oil flow is completely cut off.
- As the steering wheel is turned, the oil grooves in the

spool and the oil holes in the sleeve align, the circuit
opens and oil starts flowing to the steering cylinder.
Rotor part
1 2
Oil groove
To tank
To steering cylinder
To steering cylinder
Oil hole
From priority
valve (pump)
To priority valve LS port 60ZV42038
- A kind of internal gear, when the valve opens, it func-

tions as a hydraulic motor.
- The star (4) rotation is transmitted to the valve part

by means of the connected drive shaft (5), and the
degree of valve opening is regulated depending on
how fast the steering wheel is being turned.
42-43
Orbitrol®
Orbitrol® operation
Neutral
(When the steering wheel is not being turned)
6
T
2
8
L
Oil hole
T R
6 Oil groove
7 L
1 To priority
2 9 valve
R P LS port
From priority
3 70ZV42025
valve
4 CF port
60ZV42039
5. Drive shaft
- The spool (1) and the sleeve (2) of the valve part
each have a slit into which the centering spring (6)
consisting of plate springs is set.
- When the steering wheel is not being turned, the

spool (1) and the sleeve (2) are kept in the neutral
position by means of the center spring (6).
- This model is a load-sensing, non-load reaction, nor-

mally close type Orbitrol®. That is to say that, when
the valve unit is in the central position, the oil
grooves in the spool and the oil holes in the sleeve
are misaligned so that the oil flow from the pump to
the steering cylinder is completely cut off.
- Further more, the pressure in the circuit to the prior-

ity valve LS port does not rise, due to the misalign-
ment of the sleeve and spool, and almost the entire
pump output flow is supplied to the loading circuit.
42-44
Orbitrol®
Turn
(When the steering wheel is being turned)
T
6
7 L
1
2 9
R
From priority To priority

3 valve CF port valve LS port
4
60ZV42041

6
5. Drive shaft
1
- When in the neutral position, the valve part is totally
closed and oil remains sealed inside the star, and
T the star cannot move. The sleeve (2) is directly
2 linked to the star by means of a cross pin (7) and
drive shaft (5); it is also fixed.
L
Oil hole
- When the steering wheel begins to be turned, rotary
force is applied to the spool (1), which then pushes
and compresses the centering spring (6) set in the
R
Oil groove slit; the oil groove of the spool matches the oil hole of
the sleeve, and opens the hydraulic circuit.
- The pressure in the circuit up to the priority valve LS

port also rises, increasing the volume of oil supplied
to the Orbitrol®.
65ZV42036
42-45
Orbitrol®
Orbitrol® feed-back mechanism

operation
Steering cylinder
Steering cylinder
60ZV42042
- When an angle of displacement (deviation in circum- - If the turning of the steering wheel stops, the spool
ferential direction) is generated between the spool immediately stops rotating; but, as long as there
and the sleeve through operation of the steering exists an angle of displacement between the spool
wheel, the hydraulic circuit is opened, and oil starts and the sleeve, oil continues flowing into the
flowing. Oil from the pump enters the Orbitrol® and Orbitrol®, and the star can continue rotating. Due to
turns the star; this oil flows into the steering cylinder. this rotation, the sleeve catches up with the spool,
At this time, the star rotation is transmitted to the and closes the hydraulic circuit. Finally, the centering
sleeve by the drive shaft and the cross pin. spring returns the spool and the sleeve to the neutral
position and flow of oil is completely stopped.
- As a result, the sleeve starts rotating slightly behind
the spool as if to follow its rotation. This way the
spool can continue rotating, allowing the steering
wheel to be turned and the machine to be turned.
42-46
Orbitrol®
Steering speed and flow rate con- Hydraulic pump oil amount and
trol steering force
- When there is plenty of oil flowing from the pump,
Low steering speed High steering speed the force required to turn the steering wheel need
only overcome the sliding resistance of the sleeve or
star, so the steering wheel turns very smoothly.
1
- When the amount of oil from the pump is small, the
3
Small Large
displacement angle of the spool and sleeve reaches
displacement
angle
displacement
angle 2 a maximum point; even if the hydraulic circuit is wide
open, the flow of oil from the pump to the star is
small, so the star turns slowly.
- For this reason, the spool rotates faster than the star,
and the displacement angle reaches a maximum
point, and the spool turns the star by means of the
cross pin and drive shaft. At that time, the star works
as a hydraulic pump, and the steering wheel is
70ZV42028 harder to turn.
1. Spool
2. Sleeve
3. Centering spring
- For this steering mechanism, the flow rate must be

regulated depending on the speed at which the
steering wheel is turned.
- For the Orbitrol®, the flow rate is regulated by chang-

ing the displacement angle of the spool (1) and
sleeve (2). In other words, while the steering wheel
is being turned, the sleeve (2) chases the spool (1) in
rotation, trying to close the hydraulic circuit.
- As steering speed increases, the amount of delay

(displacement angle) of the sleeve (2) increases,
and the flow rate rises.
42-47
Orbitrol®
Orbit rotor operation principle

Drive shaft (0 rotation) Drive shaft (1/14 rotation) Drive shaft (1/7 rotation)
Star center Star (rotation)
Locus of star center Stator (fixed)

1 1 1
7 2 7 2 7 2
6 3
6 3 6 3
5 4 5 4 5 4
7 2
6 3
5 4
:Flow of high-pressure oil
:Flow of low-pressure oil 60ZV42043
- Inside the star there is a stator with 7 internal gears - The star makes a 1/6 turn per rotation of the star,
that is fixed to the housing and a 6-tooth star that is pushing out oil equivalent to 7 chambers. When the
engaged with the stator. star rotates once, oil equivalent to 42 chambers (7
chambers x 6 turns) is pushed out.
- Half of the chamber formed by the stator and the star
is connected to the high-pressure side and the other - For the motor, it has 6 times larger torque or a 1/6
half to the low-pressure side. reduction effect.
When high-pressure oil flows into the chamber, the
star is forced to turn in the direction that will expand
the area of the chamber (by means of pressure dif-
ference).
- Out of this turning movement, rotation alone is taken

out by the drive shaft to turn the sleeve by means of
the cross pin.
- With this rotation, and at the same time due to the

relationship of the position between the sleeve port
and the housing port, the position of oil flowing into
the star part is gradually delayed in sequence.
42-48
Orbitrol®
Auxiliary valves
2
D
L R
1
D
A
LS
4
D
3
T P
1. Overload relief valve (section D-D)
2. Make-up valve (section C-C)
A-A
3. Emergency check valve
4. Inlet check valve (#4)
C
C
C
C
60ZV42044
®
The Orbitrol housing contains 2 overload relief valves,
2 make-up valves, 1 inlet check valve, and 1 emergency
check valve.
42-49
Orbitrol®
Overload relief valve and make-up valve When the steering wheel is not being turned, the oil
between the Orbitrol® and the cylinder is sealed in.
If the external force is applied to the steering cylinder

Cylinder port under this condition, the high pressure would be created
Tank port in the circuit, and the pressurized oil might cause a rup-
tured pipe or cylinder, a bent piston rod, or some other
problem, unless the oil is allowed to escape.
The overload relief valve directs this pressurized oil to

the tank. (Relief pressure setting = 20.6 MPa (210 kgf/
Check ball Adjusting screw cm2) (2,986 psi)
The set pressure of the overload relief valve can be

adjusted by turning the adjusting screw.
When the overload relief valve opens and causes the oil
in the cylinder to escape to the tank, the pressure in the
External force
opposite section of the cylinder (the rod end of the cylin-
der in the figure) becomes negative. When that hap-
pens, the make-up valve opens and directs the oil from
Overload Make-up valve the tank into the cylinder, cancelling the suction pres-
relief valve sure in the cylinder.
Note
Unless the Orbitrol® is removed, it is impossible to
Orbitrol® adjust the overload relief valve.
Check ball
Tank port
Cylinder port
60ZV42045
42-50
Orbitrol®
Emergency check valve

In the event that the pump fails to supply oil to the steer-
ing system, this valve functions so that the steering
wheel can still be turned. Normally, the check ball is
pressed to the extreme left by oil introduced through the
pump port, blocking the tank port.
T When the steering wheel is turned while no oil is sup-

Tank port
L plied from the pump due to engine failure or the like, the
Orbitrol® serves as a pump, suctioning oil through the
Emergency tank port and sending it to the steering system. Thus,
check valve
R the steering wheel can be turned even through no oil is
Pump port being supplied from the regular pump.
Inlet
check valve
Inlet check valve

When the steering wheel is turned and the cylinder
reaches its stroke end, the relief valve in the priority
valve is actuated. Normally, when the steering wheel is
released under this condition, the hydraulic circuit would
return to neutral, and oil under high pressure might
remain in the circuit. If the steering wheel is turned
slowly in the same direction again, the high oil pressure
remaining in the circuit would flow back through the
pump port. As a result, oil from the Orbitrol® would turn
LS
Inlet the steering wheel in the direction opposite to that in
check valve which it is being turned. (Note, however, that this phe-
nomenon would not occur if the steering wheel was
T P
being turned in the opposite direction.)
Emergency To prevent this reverse flow of oil, the inlet check valve
check valve
is installed between the priority valve and the Orbitrol®.
60ZV42046
42-51
Cushion Valve
Cushion Valve
To steering cylinder L port To steering cylinder R port To steering cylinder L port To steering cylinder R port
B A
3
Section B-B
B A
From steering From steering

cylinder L port cylinder R port
2
Section A-A
4 1
2
1. Main spool L R
2. Pilot poppet
3. Check valve
4. Plug
5. Orifice
13 5
60ZV42047
42-52
Cushion Valve
Cushion valve specifications Cushion valve operation

Model VKLF3B - When the pressure surges exceeding 1.2 MPa (12.2
Pilot poppet opening pressure 1.2 MPa (12.2 kgf/cm 2) (173 psi) kgf/cm2) (173 psi) occur between the Orbitrol® and
Main spool opening pressure 0.4 MPa (4.2 kgf/cm 2) (60 psi) the steering cylinder, the pilot poppet (2) opens.
Check valve opening pressure 0.03 MPa (0.3 kgf/cm 2) (4.3 psi)
- The pressure which opened the pilot poppet passes
This valve is provided between the Orbitrol and the ® through the passageway in the center of the main
steering cylinder to prevent the pressure surges in the spool (1), opens the check valve (3) and passes on
circuits from causing shocks to the machine when turn- the opposite cylinder port.
ing of the steering wheel starts and stops.
- However, when the pressure more than 0.4 MPa
Note (4.2 kgf/cm2) (60 psi) acts in the main spool spring
"Pressure surge" refers to an instantaneous, abnormally chamber, the main spool moves, closing off the oil
high pressure. path to the pilot poppet and check valve. The pres-
sure in the spring chamber then rises slowly due to
the orifice (5) between the main spool spring cham-
ber and the cylinder port. Consequently, only the
surge pressure escapes to the opposite cylinder
port. When the pressure is normal, this path is cut off
by the main spool so that R port and L port are never
connected.
43-1
50ZV Check & Adjustment Hydraulic Group

Hydraulic Group
43-2
Loading/Steering Circuit Relief Valve
Loading circuit relief valve setting Measurement instruments

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

(for loading line with 3 m (10 ft.) hose and steering line
Unexpected movement of the machine may cause an with 1.5 m (4 ft.) hose)
Therefore, to provide repair service with the engine Note
running, be sure to observe the following items : For safety, route the gauge to an area where it may be
- Park the machine on level ground. safely read by the person doing the test.
moving.
- Determine the signals between the service man. Gauge port
areas.
Gauge port location Port size
- Under the machine Main relief
(1), (2)
- Around the engine pressure
Rc (PT) 1/8
- In front of or behind the machine Overload relief
(1), (2)
pressure
CAUTION
Be careful, you may get burned if the high pressure
oil spouts out. To prevent such an accident, be sure
to release the residual pressure from the pipe, and
the plug from the pressure measurement port.
CAUTION
Do not touch the fan or V-belt of the engine or a high-
temperature section if the engine is running. An acci-
dent resulting in injury may occur.
Be sure to stop the engine before you open the side
cover of the engine room. Keep all guards in place.
engine is stopped.
43-3
Standard measurement value MPa Measuring loading circuit main relief pres-
(kgf/cm2) (psi) sure
Loading line main relief pressure 20.6±0.5 1. Unload the bucket.

(at maximum speed) (210±5) (2,986±71)
2. Lower the boom to the lowest limit.
Loading line overload relief pressure 24.5±0.5
(at idling speed) (250±5) (3,555±71)
3. Attach the pressure gauge 30 MPa (300 kgf/cm2)
Steering line main relief pressure 17.2±0.5 (5,000 psi) to the connector port (2).
(at maximum speed) (175±5) (2,489±71)
Steering line overload relief pressure 20.6±0.7 4. Apply the parking brake.
(at idling speed) (210±7) (2,986±100)
5. Move the bucket control lever to the roll back posi-
tion. Hold the lever at that position.
Hydraulic oil temp
50~80ºC (120~180ºF)
6. Increase the engine speed to the maximum, and
measure and record the pressure using the pres-
Reference
sure gauge.
Releasing residual pressure from tank and pipes
Adjusting main relief pressure
Keep the bottom surface of the bucket horizontal,
and stop the engine when the bucket is approxi-
adjusting screw.
mately 30 cm (1 ft.) above the ground.
Turn clockwise the adjusting screw to raise the set pres-
Tilt down the bucket until it comes in contact with
sure, or turn counterclockwise the adjusting screw to
the ground. Place the bucket control lever in the
lower the set pressure.
roll back position, and then lower the boom.
To release the residual pressure, pull the hydraulic IMPORTANT

tank cap knob and turn the tank cap counter clock-
At the completion of check and adjustment of main
wise.
relief valve pressure, be sure to tighten the lock nut.
43-4
Bucket cylinder Measuring loading circuit overload relief

pressure
1. Attach the pressure gauge to the port

((2) for the bottom side or (1) for the rod side).
2. Adjust the main relief valve pressure to 25.5 MPa

(260 kgf/cm2) (3,697 psi) + 1/4 additional turn, so
the pressure is above the overload relief pressure.
(2)
Bucket cylinder bottom side
(1)
1. Lower the boom to the lowest limit.
60ZV43001
2. Move the bucket control lever to the roll back posi-
tion.
Multiple control valve
3. Keep the engine speed at low idle.
4. Hold the bucket control lever at the roll back posi-

tion and record the pressure.
Overload relief Bucket cylinder rod side

valve
1. Keep the boom horizontal.

Main relief valve
2. Move the bucket control lever to the dump position,
hold and then measure and record the pressure.
Adjusting overload relief pressure

60ZV43002

Main relief valve adjusting screw.
Turn clockwise the adjusting screw to raise the set pres-

sure, or turn counterclockwise the adjusting screw to
Lock nut lower the set pressure.
IMPORTANT
At the completion of check and adjustment of over-
load relief valve pressure, be sure to reset the main
relief valve to the original condition.
Adjusting screw
60ZV43004
43-5
Overload relief valve
Lock nut
Adjusting screw
60ZV43005
43-6
Steering circuit relief valve setting Measurement instruments

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

(for loading line with 3 m (10 ft.) hose and steering line
Unexpected movement of the machine may cause an with 1.5 m (4 ft.) hose)
Therefore, to provide repair service with the engine Note
running, be sure to observe the following items : For safety, route the gauge to an area where it may be
- Park the machine on level ground. safely read by the person doing the test.
moving.
- Determine the signals between the service man. Gauge port
areas.
Gauge port location Port size
- Under the machine Main relief
- Around the engine pressure
(1), (2) Rc (PT) 1/8
- In front of or behind the machine Overload relief
pressure
CAUTION
Be careful, you may get burned if the high pressure
oil spouts out. To prevent such an accident, be sure Standard measurement value MPa
to release the residual pressure from the pipe, and (kgf/cm2) (psi)
the plug from the pressure measurement port.
Steering line main relief pressure 17.2±0.5
(at maximum speed) (175±5) (2,489±71)
CAUTION Steering line overload relief pressure 20.6±0.7

(at idling speed) (210±7) (2,986±100)
Do not touch the fan or V-belt of the engine or a high-
temperature section if the engine is running. An acci-
dent resulting in injury may occur. Hydraulic oil temp : 50~80ºC (120~180ºF)
Be sure to stop the engine before you open the side
cover of the engine room. Keep all guards in place. Reference
engine is stopped. Releasing residual pressure from tank and pipes
Keep the bottom surface of the bucket horizontal,

and stop the engine when the bucket is approxi-
mately 30 cm (1 ft.) above the ground.
Tilt down the bucket until it comes in contact with

the ground. Place the bucket control lever in the
roll back position, and then lower the boom.
To release the residual pressure, pull the hydraulic

tank cap knob and turn the tank cap counter clock-
wise.
43-7
Measuring steering circuit main relief pres- Adjusting steering line main pressure
sure
(1)
1. Attach the pressure gauge to the gauge port ((1) or
(2)).
(2)
2. In case the pressure gauge is installed to (1), steer

the machine to the left until the front and rear chas-
sis contact each other.
Continue to hold the steering wheel fully turned.
3. Increase the engine speed to high idle, and mea-

sure and record the pressure.
Steering cylinder
60ZV43007
Priority valve
Main relief valve
(3) (4)
Relief valve
60ZV43011
The pressure is adjusted by the main relief valve on the

priority valve.
Remove the hose nipple (3) and adjust the pressure by

the adjusting screw (4).
Turn clockwise the adjusting screw to raise the steering

line main pressure.
43-8
Measuring steering circuit overload relief Adjusting overload relief pressure

pressure
Orbitrol®
1. Attach the pressure gauge to the port ((1) for the Pump port
left turn, (2) for the right turn).
2. Adjust the main relief valve pressure to 22.6 MPa

(230 kgf/cm2) (3,270 psi), so the pressure is above
the overload relief pressure.
3. Steer the machine until the front and rear chassis

contact each other. Continue to hold the steering
wheel fully turned.
4. Keep the engine speed at low idle, and measure

and record the pressure.
Raise the engine speed to 1,000 min-1 if fail to do. (6)
(5)
(7)
60ZV43009
The pressure is adjusted by the overload relief valve

((5) for the left turn, (6) for the right turn).
Adjust the pressure by turning the plug (7) with the

hexagon wrench (3/16"). Turn clockwise the plug to
raise the set pressure.
Note
Unless the Orbitrol® is removed from the cab floor, it is
impossible to adjust the overload relief valve.
IMPORTANT
At the completion of check and adjustment of over-
load relief valve pressure, be sure to reset the main
relief valve to the original condition.
43-9
Valve Control
Valve Control
Left Right
Dump
Forward Rearward
back
Roll N
Down
Raise
78 78
Float
N
78 78 78
Standard screw 30 Ball joint

engagement length 16
(Min. 6 mm)
11
A-Detail
Boom operation Bucket operation
Raise
Down
Float
N
8 8 8 Control cable
B Control cable
Boom 12
Multiple Standard screw
Dump
back
engagement length
Roll
control valve N
spool 8 8 (Max. 13.5 mm
Bucket
Min. 5 mm)
12
B-Detail
60ZV43010J
43-10
Hydraulic Cylinder
Hydraulic Cylinder
Cylinder natural drift Measurement procedure
1. Unload the bucket.

WARNING
Standing under the boom or bucket during service 2. Keep the boom and bucket horizontal.
work is dangerous. An accident resulting in injury or
death may be caused. 3. Set the parking brake to the "ON" position.
To prevent such an accident, be sure to lock the
boom and bucket control levers in the cab, securely 4. Lock the boom and bucket control lever using the
support the boom, and remove the starter key. safety lock.
In addition, hang a "DO NOT OPERATE!" tag on the
steering wheel. 5. Stop the engine.
6. Attach vinyl tape to the cylinder rod at a point

100~150 mm (4~6 in) away from the cylinder head
cover.
7. Measure the accurate distance from the cylinder
- Scale head cover to the vinyl tape. This is distance "A"
150~300 mm (1 ft.) mm (in). Measure the distance again 5 minutes
later. This is distance "B" mm (in).
- Stop watch
Cylinder drift (mm/min) A – B (mm) (in)
- Black vinyl "electrician's" type = --------------
(in/min) 5 (min)
Note
Warm-up the hydraulic oil before measuring cylinder
drift.

(mm/min) (in/min)
Boom cylinder 3 (1/8) or less

Bucket cylinder 2 (5/64) or less
43-11
Hydraulic Cylinder
Reference
Vinyl tape
Scale
70ZV43012
Drift rate depends on the viscosity of the hydraulic oil

and its temperature. In other words, high temperature of
the hydraulic oil reduces the viscosity. Reduction in oil
viscosity increases oil leakage through the seals, and
increases the drift rate. Cold thick oil reduces the drift
rate.
IMPORTANT
At the completion of measurement, if the vinyl tape
used for measurement is not removed from the cylin-
der rod, the tape may be caught by the rod seal. The
tape will cause oil leakage from the rod seal. To pre-
vent oil leakage, be sure to remove the vinyl tape.
43-12
MEMO
52-1
50ZV Function & Structure Brake Group

Brake Group
52-2
Brake Units Layout
Brake Units Layout

The brake system is the all-hydraulic type, and has two The service brake is the wet disc type. The parking
independent systems consisting of the front system and brake is the internal expansion drum type.
the rear system for enhancing safety.
2
3
4
50ZVA52002
1. Hydraulic servo master cylinder

2. Service brake (front)
3. Service brake (rear)
4. Parking brake
52-3
Brake Circuit
Brake Circuit
T/M control valve

1
T/C line filter
T/C pump
Front axle Rear axle
50ZVA52001
1. Hydraulic servo master

2. Brake oil reservoir
3. Service brake
52-4
Hydraulic Servo Master Cylinder

Hydraulic servo master uses oil supplied from the It increases hydraulic oil pressure in the master cylinder
torque converter pump as operation force for master in proportion to the force on the brake pedal.
cylinder hydraulic oil pressure.
11
From T/C pump To T/M C/V From brake
13 oil reservoir
12
27
27 From brake
oil reservoir
4
23 To front brake 22 21 To rear brake
3
piston chamber piston chamber
5 2 24 25
8
9 10 26
1 6 7 Drain port
Hydraulic servo section Master cylinder section
27
1
12
Drain port 21
View A
60ZV52006J
Hydraulic servo section Master cylinder section

1. Body 11. Relief valve 21. Body
2. Spool 12. Plug 22. Primary piston
3. C-ring 13. Set screw 23. Secondary piston
4. Oil seal 14. — 24. Reaction piston
5. Dust cover 15. — 25. Rod
6. Cylinder cover 16. — 26. Spring
7. Power piston 17. — 27. Connector
8. Connector 18. —
9. Spring 19. —
10. Rod 20. —
52-5
Hydraulic servo master cylinder

specifications
Servo operating oil flow amount L/min (ºC) 30 (50)
Primary piston 20.5
Piston stroke mm
Secondary piston 19.5
Primary 23.4
Displacement cm3
Secondary 22.1
Relief pressure MPa (kgf/cm2) 2.84 (29)
Performance diagram
Oil pressure in master cylinder MPa (kgf/cm2)
3.92 Oil flow amount at 30 L/min

(40) Operation at full load
2.84 +0.20
- 0.49
(29 +2
-5 )
Oil flow amount at 0 L/min
+0.49
0.91 - 0.10
(9.3 +5
-1 )
0
[196] 355.1 43.6 916
+21.7 (20) (36.2 4.4) (93.5)
121.3 - 43.6
(12.4 +2.2
- 4.4 )
Force on pedal N (kgf)
60ZV52014J
52-6
Hydraulic servo master cylinder

operation
From T/C pump To T/C C/V

Release port
11 From brake
E oil reservoir
2
To front brake To rear brake
Push rod
G 23 F 25 C 22
24 D
6 9 8 B 10 26
A 7
50ZVA52003
No braking (when the brake is released) Braking
When the brake pedal is released from the applied posi- When the brake pedal is depressed, spool (2) moves to
tion, spool (2), power piston (7) and connector (8) are the right. It reduces the clearance at the notch (E)
moved back to cylinder cover (6) side by spring (9). between the spool (2) and power piston (7). The built-up
pressure in the chamber A becomes larger than the
Primary piston (22) and secondary piston (23) are also pressure in the chamber B.
moved back to the initial position by spring (26). The
chambers C and D are connected to the brake oil reser- Consequently power piston (7) moves to the right and
voir through the release port. Oil in the chamber C and also connector (8) and secondary piston (23) move to
D returns through the release port to the brake oil reser- the right. It builds up pressure in the chamber C. The
voir, releasing the brake. Oil from T/C pump flows into pressure in the chamber C pushes primary piston (22)
the chamber A and flows out from the chamber B to T/C to the right and it builds up pressure in the chamber D.
C/V through the notch (E) between spool (2) and power The pressure in the chamber C and D is transferred to
piston (7). the brake piston chamber in the axle housing, applying
the brake.
52-7
When the brake is in the hold (balanced) Braking in case of pump failure
position
If the engine and thus the hydraulic pump stop,
When the brake pedal is depressed with a certain force depressing the pedal moves the spool (2) and the con-
and held there, the pressure is created in the chamber nector (8) of the hydraulic servo master to the right,
A and C like at the time of brake application. which in turn moves the secondary piston (23) and pri-
mary piston (22) of the master cylinder, creating pres-
The pressure in the chamber C transfers to the chamber sure in proportion to the force on the pedal, and thereby
G through the passage F. It pushes reduction piston applying the brake.
(24) to the left. This reaction force moves rod (10) and
spool (2) to the left and it transfers to the brake pedal
through the push rod. Because of that rod (10) and
spool (2) move to the left, the notch E between spool (2)
and power piston (7) becomes larger and the pressure
in the chamber B decreases. When the pressure in the
chamber B decreases, power piston (7) moves to the
right and the pressure in the chamber B is increased.
The above steps are performed repeatedly to maintain

the pressure in the chamber C and D to keep the brake
applied.
When the pedal is depressed a second time
If the brake is not effective enough when the pedal is

depressed first time, the pedal may be additionally
depressed. In this case, by the quick return of the pedal,
power piston (7), secondary piston (23) and primary pis-
ton (22) move back to the initial position, and negative
pressure is momentarily created in the chambers C and
D. By this negative pressure, before oil returns from the
brake piston chamber, the chambers C and D are
replenished with oil from the brake oil reservoir. Addi-
tional depression of the pedal makes the replenished oil
to supply to the brake piston chamber, applying the
brake.
Braking in case of one brake system failing
If either the front or rear brake piping has become faulty,

the normal side of the master cylinder, which is divided
into two sections, works to apply the brake after the pis-
ton on the faulty side has moved through its entire
stroke. Note, however, that in this case, the pedal needs
to be moved through an increased stroke and the brak-
ing force is reduced by half.
52-8
Service Brake
Service Brake
Service brake operation
Differential gear
assembly
10 6 1 7 5 4 3
When stepping on the brake pedal, the brake oil from
the differential gear housing oil inlet enters the brake
piston chamber and presses the brake piston (3) to the
left. Then the brake piston presses the steel plate (4)
against the friction plate (5).
Since the friction plate (5) rotating with the sun gear (6)
is placed between the brake retainer (7) and the steel
plate (4), it makes the rotation speed of the sun gear
decrease or makes it stop.
12
11
2 9 8
60ZV52010
1. Axle housing
2. Internal gear
3. Brake piston
4. Steel plate
5. Friction plate
6. Sun gear
7. Brake retainer
8. O-ring (for brake piston inner)
9. O-ring (for brake piston outer)
10. Spider
11. Planetary gear
12. Pin
The service brake is an enclosed wet-type single-plate

hydraulic brake, and is incorporated in the axle housing.
This type of service brake ensures good braking power

and protects the brakes from mud or sand.
52-9
Service Brake
Service brake friction plate
8.5 0.15 mm (0.335 0.006 in)
7 0.15 mm (0.276 0.006 in)
1
0.4 mm (0.016 in)
or more
1 + 0.3
0
1 (0.039 + 0.012
0 in)
2
278 (10.945 in)

2
5.7 0.3
(0.224 0.012 in)
Detailed drawing of groove
60ZV52015
1. Plate
2. Lining
The friction plate has linings (paper material) on the

contact faces on both sides.
Service brake steel plate
6 0- 0.2 mm
0
(0.236 - 0.008 in)
282 (11.102 in)
210 (8.268 in)
170 (6.693 in)
60ZV52016
52-10
Service Brake
Brake circuit air bleeding proce- 1. Connect a vinyl tube to the air bleeder nipple of the
hydraulic servo master.
dure
IMPORTANT
Cap Air bleeder nipple
Do not use vegetable oil or DOT 3 brake fluid for the
brake. The seals between the hydraulic servo master
and the brake piston may be deteriorated or dam-
aged. Be sure to use mineral oil or Mobil Delvac 1 for
the brake.
2. Each time when pressing down the brake pedal,

slightly loosen the nut of the bleeder nipple to
slightly discharge brake oil. Close bleeder prior to
release of brake pedal.
60ZV52012
3. Repeat the above procedure until no air is in the
brake oil. At the completion of air bleeding, close
the air bleeder nipple.
WARNING : Air bleeder nipple of hydraulic
Unexpected movement of the machine may cause a servo master: 10.8 N-m (1.1 kgf-m) (8 lb-ft)
severe accident. To prevent such an accident, take
the following safety measures when performing air Note
bleeding with the engine running. During air bleeding, enough oil should be in the brake
- Park the machine on level ground. oil tank. Be sure to check the oil level of the brake oil
- Apply the parking brake. tank frequently, and add oil into the tank.
- Block the tires with chocks to prevent wheels from
moving.
- Determine the signals between the persons related
to the work.
- When raising the boom, install a safety support
under the boom.
- Apply the articulate stopper.
52-11
Service Brake
1. Feed brake oil (class CD, SAE 5W or Mobil Delvac

1 engine oil) into the brake oil tank.
Vinyl tube IMPORTANT

Do not use vegetable oil or DOT 3 brake fluid for the
brake. The seals between the hydraulic servo master
and the brake piston may be deteriorated or dam-
aged. Be sure to use mineral oil or Mobil Delvac 1 for
the brake.
2. Each time when pressing down the brake pedal,

Air bleeder nipple
slightly loosen the nut of the bleeder nipple to
slightly discharge brake oil.
Oil can 3. Repeat the above procedure until no air is in the

65ZA5220 brake oil. At the completion of air bleeding, close
the air bleeder nipple. Repeat this procedure at the
Connect a vinyl tube to the air bleeder nipple of the axle other axle housing.
housing, and place an oil can to catch the oil. : Air bleeder nipple of axle housing:
25 N-m (2.6 kgf-m) (19 lb-ft)
Vinyl tube length
1.2~1.3 m (4~4.5 ft.) Note
During air bleeding, enough oil should be in the brake
Outer dia. of nipple oil tank. Be sure to check the oil level of the brake oil
about 8 mm (5/16 in) tank frequently, and add oil into the tank.
60ZV52011
52-12
Parking Brake
Parking Brake
Mounting
face
ar
ge
fo rum
d
ar
in d
rw
n of
tio n
ta tio
ro irec
D
X X
60ZA5218
1. Backing plate 8. Return spring

2. Brake shoe assembly 9. Adjuster
3. Brake lever 10. Adjuster spring
4. Strut 11. Brake shoe hold-down spring
5. Brake lever pin 12. Shoe hold-down pin
6. Wave washer 13. Stop plate
7. U-retainer 14. Brake cable
52-13
Brake Control
Brake Control
Service brake linkage
1
2
8
B B
A A
9 4
8 7
3 A-A
2
4
9
5
6
5
B-B
60ZV52013
1. Brake pedal 6. Arm Because the brake pedal (1) is operated together with
2. Inching pedal 7. Arm the inching pedal (2), the stop lamp switch (5) is actu-
3. Hydraulic servo master 8. Pillow block ated and the stop lamp lights up.
4. Inching switch 9. Ball joint
5. Stop lamp switch When only brake pedal (1) is depressed the moment the
brake is applied, stop lamp switch (5) is actuated and
When the inching pedal (2) is depressed with the clutch the stop lamp lights up. No forward/reverse clutches
cut-off (declutch) select switch ON, inching switch (4) is disengaged even the clutch cut-off (declutch) select
actuated, the forward/reverse clutches are disengaged, switch is ON.
and the brake is applied simultaneously.
52-14
Brake Control
Parking brake linkage
1 5
4 6
Turn buckle
3
4
5
Parking brake Limit switch installation part

60ZV52014
1. Parking brake lever

2. Turn buckle
3. Limit switch (for parking brake)
4. Control cable
5. Rod
6. Lock nut
When the parking brake lever (1) is pulled, the parking

brake is applied and the limit switch (3) is actuated.
The signal is sent to the transmission controller, and the

forward/reverse clutches are disengaged.
52-15
Brake Oil Reservoir
Brake Oil Reservoir

Slit (+ shaped) on diaphragm
MAX capacity 352 cm3

MAX
31 Float
MIN
Alarm oil level Alarm float level
48 40
Level sensor
65ZA5216
Operation of level switch Brake oil reservoir specifications

When the brake oil level drops, the float drops all
together. When the brake oil level is high, the float is Max. 352 cm3
Tank capacity
above the level sensor switch. Therefore the level sen- Min. 287 cm3
sor switch is open and no power current flows. Level switch Float position ON 31 mm from MAX
operation point Oil level ON 39 mm from MAX
When the brake oil level is below the set point, the level
sensor switch is closed and the alarm is turned on.
Note
- When installing the cap, tighten it until the cap stops
turning.
: 3.4 N-m (2.5 lb-ft)
- Securely insert the level sensor.
- Fill the brake oil to the MAX level.
52-16
MEMO
53-1
50ZV Check & Adjustment Brake Group

Brake Group
53-2
Hydraulic Servo Master
Hydraulic servo master perfor-

mance inspection
Oil pressure in master cylinder MPa (kgf/cm2)

3.92 Oil flow amount at 30 L/min
(40) Operation at full load
2.84 +0.20
- 0.49
(29 +2
-5 )
Oil flow amount at 0 L/min
+0.49
0.91 - 0.10
(9.3 +5
-1 )
To front brake To rear
(A) brake 0
(B) [196] 355.1 43.6 916
+21.7 (20) (36.2 4.4) (93.5)
121.3 - 43.6
(12.4 +2.2
- 4.4 )
Force on pedal N (kgf)

50ZVA53001
WARNING
60ZV53001J
accident resulting in injury or death. Therefore, to
provide repair service with the engine running, be
Air bleeder
sure to observe the following items.
nipple - Park the machine on level ground.
moving.
- Determine the signals between the service man.
areas.
- Under the machine
- Around the engine
65ZA5217 - In front of or behind the machine
Note
A
Before inspecting the performance of the hydraulic
servo master, it is necessary to confirm that the trans-
mission oil pressure is between 1.3~1.6 MPa (13~16
kgf/cm2) (185~228 psi).
Gauge for oil pressure

15
0
Pressure gauge
5 MPa (50 kgf/cm2) (1,000 psi)
Brake pedal assembly

60ZV53001
53-3
Pressure measuring port
- Checking at hydraulic servo master side:
Remove the pipe from A (Front brake) and B (Rear

brake), and then install the pressure gauge.
Port size
M12 x 1
- Checking at axle side:
Remove the air bleeder nipple on the axle housing,

and then install the pressure gauge to the bleeder
position.
Air bleeder port size

7/16 -20 UNF
: 25 N-m (2.6 kgf-m) (18 lb-ft)
Measuring procedure
When the brake pedal is gradually pressed at A point,

the oil pressure should raise smoothly in line with the
performance diagram.
Cause of abnormal measurement value and solu-

tion.
Possible cause Solution

Servo master cylinder piston seal defective Repair or replacement
53-4
Service Brake
Service Brake
Service brake performance check Method 2
If no test course available as described "Method 1",

Method 1 carry out the following method.
WARNING IMPORTANT
Separate the test course by using rope etc. and keep The following method is easy and simple, however it
persons away from the test course. In addition, post is not an accurate way, because the braking force
persons in several positions near the course to warn and rim-pull may vary on each machine. Confirm
others and avoid an accident while checking the ser- engine & transmission performance via using a stall
vice brake performance. test. See page 03-3.
Reconfirm the brake performance by the method 1 as
soon as possible.
Condition
WARNING
1. Test course Unexpected movement of the machine may cause an
Level, straight, dry and the paved ground. accident resulting in injury or death.
Before starting brake performance check, be sure to
2. Run the machine and depress the brake pedal at observe the following items:
20 km/h (13 mph). - Place the machine on level ground.
Measure and record the braking distance. - Check that there is enough clearance for brake
performance check around the machine.
- During performance check, prohibit any person to
walking near the machine.
1. Lower the boom to the lowest limit, and roll back
Braking distance the bucket fully until the bucket contacts to the
5 m (5 1/2 yd) or shorter stopper.
Possible causes of extremely long braking distance 2. Release the parking brake lever to the "OFF" posi-
tion.
Hydraulic servo master defective Check and repair 3. Set the T/M (transmission) cut-off switch to OFF,
Friction plate wear Check and repair and then depress the brake pedal all the way to the
Improperly adjusted service brake linkage Check and adjustment floor.
Note 4. Set the shift lever to 2nd reverse speed.

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

Hydraulic servo master defective Check and repair
Friction plate wear Check and repair
Improperly adjusted service brake linkage Check and adjustment
53-5
Service Brake
Service brake friction plate wear

measurement WARNING
Unexpected movement of the machine may cause a
severe accident. To prevent such an accident, take
the following safety measures when performing air
bleeding with the engine running.
Large end
Small end
End (1) End (2)
- Stop the engine.
- Block the tires with chocks to prevent the wheel
from moving.
Diameter:4.4 mm (0.17 in) - Determine the signals between the persons related
Diameter:7.4 mm
(0.3 in) to this work for engine starting to prevent an acci-
dent.
- When moving up the boom, install a safety column
60ZA5211 under the boom.
- Apply the articulate stopper.
Measuring procedure*
1 Remove the drain plug (5) and drain gear oil.

: Gear oil: 20 L (5.3 gal)/axle
While applying the service brake, insert the gauge

through the drain port. Check the clearance (A). If the
gauge does not turn, the friction plate is worn beyond
2 3 specification and the plate needs to be replaced with a
new one. Check at all four points.
Wear limit (A)

4 A 7.4 mm (0.3 in)
*Normally this procedure is done during oil change

5 65ZV53003
every 2,000 hours.
- Gauge part number 33240-20030

1. Friction plate
2. Brake piston
3. Brake retainer CAUTION
4. Steel plate At the completion of checking wear of service brake
5. Drain plug friction plate, be sure to fill the oil to the specified oil
level.
Gear oil 20 L (5.3 gal)/axle
53-6
Parking Brake
Parking Brake
Parking brake performance check Method 2
If no test course available as described "Method 1",

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

limit switch.
3. Place the shift lever to the 3rd reverse position.
No movement on 1/5 slope.
4. Gradually increase the engine speed. The machine
Possible cause of machine moving during brake should not move at the maximum speed.
performance check

IMPORTANT
Clearance between brake drum and shoe If the machine begins to move with the parking brake
Clearance adjustment
too large applied, the brake shoes are burnt or misadjusted.
Improperly adjusted parking brake cable Check and adjustment At the completion of parking brake test, be sure to
connect the connector of electrical line to the limit
Note switch again.
The brake performance check condition and standard
measurement value are based on the law and the regu- Possible cause Solution
lation in Japan. Clearance between brake drum and shoe
When checking the service brake performance, follow Clearance adjustment
too large
the law and/or local regulation in your country, state, or Improperly adjusted parking brake cable Check and adjustment
province.
53-7
Parking Brake
Parking brake clearance adjust- Adjustment procedure

ment
Position of
adjusting screw
Drum rotational Brake shoe

direction for running expansion direction
forward/reverse
Brake shoe expansion direction
Adjusting
screw
Screw
driver
50ZV53001
For replacement of shoe assembly refer to Section 54.
Rivet Brake shoe

WARNING
A
Unexpected movement of the machine may cause
serious injury or death. Adjusting parking brake clear- Brake lining
ance requires the parking brake to be released. So,
to prevent accidental movement, observe the follow- Lining thickness A : 5.0 mm (0.20 in) 50ZV53002
ing items:
- Park the machine on level ground. 1. To rotate the brake drum during adjustment, lift the
- Block the tires with chocks to prevent the wheels front and rear wheels on one side (or both sides)
from moving. using safety jacks, cribbing, etc..
- Place the bucket to the ground.
- Stop the engine, and then remove the starter key. 2. Turn the inspection hole of the brake drum approxi-
Place "DO NOT OPERATE!" tag on the steering mately 15º clockwise from the vertical position as
wheel. shown in the figure.
- Prohibit any person from walking into the danger- After that, use a screw driver or brake tool to turn
ous area. the adjusting screw to adjust the clearance.
Turn the adjusting screw counterclockwise (down)
If the machine moved during parking brake performance to expand the brake shoes until the linings come in
check, the clearance between the brake drum and the contact with the brake drum.
lining is too large. After that, turn the adjusting screw 8 notches clock-
wise (up). The clearance will be adjusted to 0.2
mm. (0.008 in)
Adjustment range
0.15~0.25 mm (0.006~0.010 in)
3. After the adjustment, check the performance of the

parking brake by referring to "Parking brake perfor-
mance check".
53-8
Parking Brake
Brake lining abrasion check
Shoe Rivet
B Abrasion limit
Lining
Wear limit B : 0.8 mm (0.03 in)
80ZV53004
12 rivets are inserted to fix the lining to the brake shoe.

If the distance from the lining to the rivet head "B" is 0.8
mm (0.03 in) or less at one of the 12 rivet areas, replace
the shoe assembly.
53-9
Brake Control
Brake Control
Adjusting brake pedal and switch Adjusting right brake pedal
When the brake pedal is released

WARNING
Entering the articulation area of the machine body
while the engine is running may cause severe acci-
dents. 1
Make sure to stop the engine, pull out the starter key,
and attach a "DO NOT OPERATE!" tag to the cab
before entering the articulation area.
3
Brake pedal assembly
50ZV53003
1. Loosen the locknut (3). Adjust the height from

the floor to the tip of the pedal to be 218+0- 5 mm
(8.58+0
- 0.197 in) by the adjusting bolt (2).
mm
48º
0
-5
218
5 60ZV53008J
2. Temporarily adjust the right brake pedal rod (4) and

elbow joint (5).
Note
The elbow joint (5) std. thread engagement to the rod
(4) is minimum 9 mm (0.354 in).
53-10
Brake Control
Adjusting left brake pedal

Std. thread engagement
Min: 9 mm
16.5 mm
5 Brake pedal
Std. thread engagement
4
Min: 11 mm
9
16 mm 15 mm
6 Inching pedal
7 5 Hydraulic servo
8 master
10 10
6
115 mm 8
60ZV53009J
9 14
13
3. The distance between hydraulic servo master (6)
and elbow joint (7) is to be fixed temporarily to 115 D
15
mm (4.528 in).
C
Note
The hydraulic servo master (6) and elbow joint (7) std.
12
thread engagement to the rod (8) is minimum 11 mm
(0.43 in) respectively.
50ZV53006
4. After the above adjustment, confirm that there is a
play of 0.5~1.5 mm (0.02 in~0.06 in) to the direction
of hydraulic servo master shaft (6) at elbow joint The linkage must be adjusted with rod (14) so that the
(7), and secure it with the lock nut (9)(10). rod and elbow joint assembly (comprised of items 14 &
15) drive C block on bellcrank (12) to push against lever
IMPORTANT D on the right side bellcrank (13).
There must be some slack in the brake pedal linkage

to keep the brake from being lightly applied, and
IMPORTANT
burning friction material, or warping brake discs. Do not make the adjustment too long. It will result in
brake component damage, and may require exten-
sive repairs from accidental application of brakes.
WARNING
Unexpected movement of machine may cause seri-
ous injury or death. When adjusting the brake linkage
while operating the engine, observe the following
items to prevent an accident:
- Block the tires with chocks to prevent the wheels
from moving.
- Determine the signals between the persons related
to this work for engine starting to prevent an acci-
dent.
53-11
Brake Control
Adjusting switch Parking brake cable adjustment

Adjusting inching switch
Inching pedal 1
Std. mounting
distance 29.5
6 in)
(1.1
Inching switch
3
4
50ZV53007 6
Adjust the inching switch so that the inching switch actu-

ates at the brake pedal angle 45º.
Std. mounting distance

29.5 mm (1.16 in)
Switch insertion movement

7 mm (0.276 in) Parking brake
Adjusting stop light switch 50ZV53009
Brake pedal
WARNING
Unexpected movement of the machine may cause
serious injury or death. Adjusting parking brake clear-
ance requires the parking brake to be released. So,
to prevent accidental movement, observe the follow-
ing items:
Std. mounting 24 - Park the machine on level ground.
distance (0.945 in) - Block the tires with chocks to prevent the wheels
from moving.
Stop lamp switch
- Place the bucket to the ground.
- Stop the engine, and then remove the starter key.
50ZV53008
Place "DO NOT OPERATE!" tag on the steering
wheel.
Install the stop light switch so that the mounting dis- - Prohibit any person from walking into a dangerous
tance is 24.0 mm (0.945 in). At this position, check that area.
another 1~2 mm (0.039~0.079 in) still remains as a
clearance allowance for the stop light switch.
Switch insertion movement

3.5 mm (0.138 in)
53-12
Brake Control
Adjusting control cable Adjusting limit switch
Lock nut
Turn buckle
(1 27
in)
Plate
in)
6
.0
Rod
5
.1
(0
(1 27
in)
13
6
.0
Lock nut Stopper
Std. thread engagement Plate

in)
Min:7 mm(0.276 in)

5
.1
(0
13
Turn buckle
50ZV53010
Limit switch
A
1. Before adjusting the control cable, adjust the clear- Limit switch
ance between the parking brake lining and drum.
50ZV53011
2. Loosen the lock nuts for the turnbuckle.

1. Install the limit switch (3) temporarily.
3. Lower lever (1) until the stopper of the rod hits limit
switch installation plate. 2. Release the parking brake lever (1).
4. Adjust the control cable by turning the turnbuckle. 3. Fix the limit switch (3) to the bracket so that the
Turning the turnbuckle clockwise makes the control mounting distance (A) is 2.3 mm (0.09 in).
cable shorter.
When adjusting the control cable, do not make the
control cable too tight.
(This causes the parking brake to drag.)
62-1
50ZV Function & Structure Electrical Group

Electrical Group
62-2
How to Use Electrical Wiring Diagram
How to Use Electrical Wiring Diagram

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

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

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

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

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

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

grams. For this method, a symbol is attached to each Checking the other connector terminal where F704 RL
connector and connector terminal in order to easily (item (3)) is connected:
locate the other terminal where the other end of the
cable is connected. 1. F704
Shows that the terminal is connected to the 4th ter-
Example 1 minal of the F7 connector.
Symbol under (or above) connector, such as F6: Check the description in the 4th terminal of the F7
Shows the address of the connector. connector (F704), it shows that the F704 terminal is
connected to H128. This means that the 4th termi-
Example 2 nal of the F7 connector is connected to the 28th ter-
Symbol at the multi-terminal connector, such as 1 and minal of the H1 connector.
10: 2. RL
Shows the terminal number and the numbering direc- Shows the color of the wire "RL" represents that the
tion. insulation color is red, and "L" represents a blue
stripe is on the red insulation.
62-3
Electrical Cable Color Codes
Electrical Cable Color Codes
Color of
stripe Y G Sb Br L W R B O Lg P Gy V
Color of (yellow) (green) (sky blue) (brown) (blue) (white) (red) (black) (orange) (light green) (pink) (grey) (violet)
insulation
Y (yellow) Y YG YSb YBr YL YW YR YB YO YGy YV
G (green) GY G GL GW GR GB GO
Sb (sky blue) SbY SbG Sb SbW SbR SbO SbLg SbP
Br (brown) BrY BrG Br BrL BrW BrR BrB
L (blue) LY LG LBr L LW LR LB LO LLg LP
W (white) WY WG WL W WR WB WO WP WV
R (red) RY RG RBr RL RW R RB RO RLg RGy
B (black) BY BG BL BW BR B BO BLg BP BV
O (orange) OY OG OSb OL OW OR OB O
Lg (light green) LgY LgG LgSb LgBr LgL LgW LgR LgB Lg
P (pink) PG PL PW PB P
Gy (grey) GyY GyG GyL GyW GyR GyB GyO Gy
V (violet) V
Insulation color
Stripe color
70ZV62001
62-4
Electrical Circuit Symbols
Electrical Circuit Symbols
Name Symbol Name Symbol
Direct current Motor M
Alternating current Equipment
Conductor (General) Fuses
Branching connection Lamp
Conductors (Connected) Rectifiers
Conductors
Mechanical coupling
(Not connected)
Relay contact
Terminal
("a" contact)
Relay contact
Ground
("b" contact)
Resistance or Resistor Switch
Variable resistance or Variable Pressure switch or

resistor Temperature switch
Inductance or Electromagnetic Negative -positive-

coil negative (NPN) transistor
Positive -negative-
Battery or Direct voltage source
positive (PNP) transistor
62-5
Sensor Mount
Sensor Mount
Engine water
temperature sensor
Air cleaner
indicator
Transmission oil
temperature
switch
Transmission oil
temperature
switch
Speed sensor 50ZV62001E

62-6
Fuse
Fuse
The following fuses are provided to protect electrical cir- Fuse box
cuits.
For chassis
Fusible link
30 A x 1, 50 A x 1, 70 A x 1, Fuse
Fuse No. capacity Protective circuit
(A)
Fuse box 1 20A LIGHTING HEAD LIGHT
15 fuses x 2 (for chassis and cab) 2 15A R. WORK LIGHT 20A
BOOM KICKOUT
(For installation positions, refer to "Electrical Equipment 3 10A
BUCKET POSITIONER
Layout".) BACK LAMP SPARE
4 15A STOP LAMP
TURN SIGNAL
CAUTION 5 10A SPARE 15A
Possible burn hazard. Before replacing a fuse, be 6 15A FUEL VALVE
SPARE
sure to turn off the starter switch. 7 10A SPARE
8 15A SPARE 10A
9 15A SPARE
IMPORTANT 4WAY FLASHER SPARE
10 15A
Replace a fuse with the same capacity. HORN
If a fuse blows immediately after replacement, the 11 10A MONITOR 5A
electric system is defective. Locate the defective part, 12 15A WORK LIGHT
SPARE
and then repair it. 13 5A FUEL RELAY
14 5A NEUTRAL RELAY
15 5A BATTERY RELAY
For cab
Fuse
Fuse No. capacity Protective circuit
(A)
16 5A FL. WIPER
17 5A FR. WIPER 20A
18 5A R. WIPER
SPARE
19 10A F. WIPER
20 10A CIGAR LIGHTER 15A
21 15A SPARE
SPARE
22 3A RADIO
23 10A SPARE 10A
24 10A SPARE
SPARE
25 20A AIRCON (OPTION)
26 5A SPARE 5A
SPARE
28 10A SPARE
30 20A SPARE
62-7
Fuse
Fusible link Problems caused by fused fusible link
Fuse Problem (symptom)

Fusible link damaged During engine operation During engine stop
Cover
Fuse - Engine will be stopped. - All the electrical circuit
element - All the power for all will not function.
30A
electrical circuit will be - Engine can not be
OFF. started.
- Horn [and opt. flasher] - The same conditions
will operate. as "During engine oper-
- All the others will not ation" but engine can
70A operate and the be started and stopped.
machine can not be
operated.
- Engine can be stopped.
- The machine can be - The same conditions
operated but the batter- as "During engine oper-
Box for fusible link Fusible link 50A ies can not be charged ation".
70ZV62010
and the batteries will be
discharged soon.
12V 12V
[W5]
30A
W
W5
BATTERY
1.25
R1 BR WR F15 WR WL
B AC
BW R2 C 5A [WV]
G1.25
BATTERY
F14
5A
WR1.25 RELAY
G1.25
STARTER
70A
F11
B C
MAGNETIC
[R5]
S/W
BW5
RL1.25 [WG]
NEUTRAL
SWITCH
(Lg) (WG) VOLTAGE
F11 RELAY
CHARGE LAMP
R5X6 WL1.25
R2
ALTERNATOR
15 R
50A B
E
15
FUEL VALVE
F6 W2 FR BW2
WB F13 15A
FR
5A WB
HEATER
BW RELAY
15 15
AIR HEATER
(BG)
B ACC’ PREHEAT LAMP

WR
TO BACK
E 50ZV62002E
Fusible link location LAMP SWITCH
The fusible link is located in the box as shown in the

above figures. If excessive current flows through the
starter switch or the electric line downstream of the
starter switch due to shortcircuit, the fuse element will
be blown to protect the circuit. The condition of the fuse
element can be seen through the transparent cover.
Determine the cause before replacing the fusible link.
For replacement of a fusible link, remove 2 bolts and

pull it up.
62-8
Engine Start Circuit
Engine start circuit diagram
Starter switch
B BR ACC R1 R2 C
Preheat
Off Fusible link
Battery (24 V)
On
Start 30A
Fuel solenoid
F13
5A
F11 F15
Monitor lamp Battery
10A 5A relay F6 15A
Fuel solenoid relay
70A
Diode unit
Starter motor
From alternator B
F14
5A
Heater
Magnetic S/W
relay
Air heater
Neutral switch
Preheat lamp
Voltage relay
neutral current
Alternator
Alternator
1 2 3
Neutral
switch R N F
50ZV62003E
62-9
Neutral starter
To prevent the machine from unexpected movement at
engine start up, the machine is so designed that the
engine can start only while the shift lever is in the neu-
tral (N) position.
Shift lever neutral (N) position
When the shift lever is in the neutral (N) position, the

neutral switch is ON.
When the starter switch is turned to the START position,

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

power is not supplied to the neutral relay coil, and the
main contact is OFF. As a result, the starting current
from the starter switch does not flow in the magnetic
switch, and the engine does not start.
62-10
Starter switch
OFF
35º 30º
Preheat Run
35º
Start
B
C
C
AC
BR
R1
R2
Connection table
B BR ACC R1 R2 C
W3 W5 Preheat
Off
BW R1 BR WRx2
On
B ACC WBx2
R2 Start
BG C G
To neutral switch
To battery relay,
To heater relay
monitor lamp
From battery
To fuel relay
BW WR WR G W
BG WB WB W
50ZV62020a
Off Preheat
Enables insertion and removal of the starter key. Preheats the intake air to ensure smooth starting in cold
All the electrical circuits (except the horn and hazard weather.
flasher [OPT.]) will be turned off. Setting the fuel sole-
noid to this position activates the engine stopper that
stops the engine.
On
Supplies power to the charge, lamp, monitor and fuel
solenoid circuits.
Start
Starts the engine.
62-11
Battery relay Battery relay operation
Starter switch
From AC B
charge
Terminals for coil circuit Battery relay
Moving contact
energizing current (B)
(4 mm) Main contacts
To main (E)
circuit
Battery
BR
Terminals for
main current Suppression
Coil for energizing (8 mm) diode 65ZV62028a
95ZV62017
Battery relay
When the starter switch is placed to the ON position or
Rated voltage DC 24 V
the start position, the battery relay is turned on. When
the starter switch is set to the off position, the alternator Minimum operating voltage 20 V or less
stops generating power, and the battery relay is auto- Release voltage 9 V or less
matically turned off so that the electrical circuits will not
function. When current flows from the starter switch terminal AC,
the coil will be energized, and the moving contact will
If the battery relay was not used, a large amount of cur- lower to close the main contact. As a result, current will
rent would be directly sent through the starter switch flow from the battery to the main circuit.
when it is turned on. However, use of the battery relay
reduces the amount of current because this relay needs
only a small amount of current to energize it.
62-12
Alternator R terminal wire Diode unit
12V 12V
30A
(2) BATTERY
R1 BR F15 WR WL
B AC
R2 C 5A [WV] WV:To battery relay
WV
BATTERY
(3) (1) WR:To starter switch terminal ACC (VIA F15)
WL: To alternator
F14
5A
RELAY WR WL
Heater From
B
E
F11
Voltage relay
Back lamp switch
relay Charge Surge alternator

circuit suppression R terminal
diode Diode storage section
50ZV62006E 50ZVA62008
Engine motion-active circuit (1) The diode unit is incorporated in the milky white connec-
tor near the battery relay. It is provided for the following
When the starter switch is turned OFF, the battery relay purpose.
is automatically turned OFF since the command current
from the starter switch terminal AC stops flowing and 1. Diode (2)
the coil is demagnetized. Then the charging circuit from This diode is provided to prevent the roundabout
the alternator is shut down. current from the alternator to the engine stop motor
relay.
However the alternator is still generating power and the
load dump surge may be generated. This may damage 2. Diode (3)
the related circuits and equipment. In order to prevent This diode is provided to prevent the roundabout
this trouble, this circuit (1) is provided to hold the battery current from the starter switch AC to the alternator
relay in the "ON" position. R terminal.
62-13
Neutral switch Neutral switch specifications
1 2 3
Neutral
switch R N F
(A) (B)
60ZV62023E
Rated load 24V2A (MAX)

60ZV62004E Actuating force 20~29 N (2~3 kgf)
0
When not actuated (A) 17.73 -0.6 mm
Dimensions 0
When actuated (B) 16.6 -0.7 mm
The neutral switch prevents the starter motor from oper-
ating when the shift lever is not in the neutral position.
This is to eliminate the danger of the machine moving Note
away if the engine is started with the forward or reverse The neutral switch and back-up lamp switch are identi-
clutch engaged. cal.
Neutral switch operation
The neutral switch is mounted on the top of the trans-

mission forward and reverse spool. The contacts are
closed and current can flow only when the shift lever is
in the neutral position. The contacts are open and no
current can flow when the shift lever is in any other posi-
tions.
62-14
Magnet switch
Rating 24V x 200A

M C
C C’
M’
M’ C’
70ZV62019
Note
The illustrations show the de-energized condition.
When the neutral relay is magnetized, electric current

flows from the battery to the magnetic switch through
the starter switch C. It magnetizes the magnetic switch.
On the other hand since the battery relay is already ON

at this time, electric current flows from the battery to the
starter motor C terminal through the battery relay and
the magnetic switch, engaging the starter motor to start
engine.
62-15
Voltage relay
Blue
K70V2J62005
Voltage relay
Contact point closed 6V
Contact point open 8V
Note
The illustrations show the de-energized condition.
Once the engine is started, the alternator starts generat-

ing electric power.
When electric current is supplied from the alternator R

terminal to the voltage relay, the voltage relay is magne-
tized and is turned OFF.
Consequently the magnetic switch turns OFF and no

electric current flows to the starter motor C terminal, dis-
engaging the starter motor.
62-16
Power Generating/Charging Circuit

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

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

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

initial excitation
Adjusted
voltage
operation
For
battery relay
operation
Starter
Load circuit operation
switch
Battery charge
<Load>
For rotor coil Battery

initial excitation 70ZV62021
The power generating/charging device and the charging

circuit consisting of an alternator, regulator, battery, etc.
generate and supply the power required to all electrical
units of the machine.
62-17
Alternator generation theory To generate power in an alternator, a magnetic rotor is

rotated via the slip ring, generating a current in the static
stator coil outside. Initially, when N and S of the rotor
Generated current Diode rotate in the sense indicated by the arrow, a current
C
Regulator
flows in the direction shown by the arrow in the conduc-
D
tors C and C' which are wound on the stator.
Battery
This current flows through the diode D into the batteries.
However, the current attempts to flow in the opposite
C’ Slip ring direction during the subsequent half revolution of the
Stator Stator coil rotor, but the characteristics of the diode D prevent a
Rotor
current from flowing in this direction, so that no current
Diagram of the theory of the alternator flows in the direction of the broken arrow in the figure.
Consequently, the current flow to the battery is in only
one direction ie.direct current.
Diode
Battery
Stator coil
Rotor
Slip ring
Brush
N
Slip ring Rotor
Theory of the Rotor 50ZV62014

62-18
Engine Stop Circuit
Engine Stop Circuit
Fuel solenoid Fuel solenoid specification
Voltage DC 24 V
Fuel
solenoid Resistance 36 Ω (22ºC)
Min. operation voltage 18 V
Fuel pump 50ZV62015
When the starter switch is turned to "ON", the fuel sole-

noid relay is turned to "ON" and electric current is sup-
plied to the fuel solenoid
The fuel solenoid is energized and the fuel supply circuit

in the fuel pump is opened.
When the starter switch is turned to "OFF", no electric

current is supplied to both fuel solenoid relay and fuel
solenoid and then the fuel supply circuit is closed.
Fuel solenoid relay
1 2
WB
B
1
2
5
BW
5 3
Chassis side
Elec. circuit coupler
50ZV62016
Rating DC 24 V Coil resistance 250 Ω

Operation voltage 20 V or less Contact point A
62-19
Instrument Panel and Switch
Instrument panel
1 14 16 4 15 2 17 3 8 9
10
20 19
22
11
21 12
13
18 6 7 5
50ZV62004E
1. Speedometer 12. Air cleaner clogging warning lamp

2. Engine coolant temperature gauge 13. Charge warning lamp
3. Fuel gauge 14. Turn signal indicator lamp (left)
4. Parking brake indicator lamp 15. Turn signal indicator lamp (right)
5. Transmission cut off selection indicator lamp 16. High beam indicator lamp
6. Working light indicator lamp (rear) 17. Hour meter
7. Preheat indicator lamp 18. Ride control selector indicator lamp (option)
8. Brake oil warning lamp 19. Working light switch (rear)
9. Engine oil pressure warning lamp 20. Transmission cut-off selector switch (Declutch)
10. Bulb check switch 21. Ride control switch (option)
11. Transmission oil temperature warning lamp 22. Engine water temperature warning lamp
62-20
Instrument panel rear surface
CN4
CN1 CN3
1 4 L11 L13 29 48
L12
8P L20 12P 16P
L1 58 57
5 8 L14 L10 35 56
Hour L10 L10
L2 meter
L10 L15 S
L21
L3
L16 E V
L4 S S
L17 L10
L5 E V E V
Fuel gauge Engine water temperature Speedometer
L18
sensor
L6 L10 L10
L19
L7
CN2
L8 9 18 L22 L23 L24 L25 L26 L27
20P
L9 19 28
Layout of connector pins (Instrument panel side)
CN1(8P) CN2(20P) CN3(12P/16P) CN4(2P)
1 2 3 4 9 10 11 12 13 14 15 16 17 18 29 30 31 32 33 34 41 42 43 44 46 47 48
58 57
5 6 7 8 19 20 22 23 24 25 26 27 28 35 36 37 38 39 40 49 50 53 54 55 56
60ZV62059
Pin Lamp Pin Lamp Pin Lamp

Signal Signal Signal
No. No. No. No. No. No.
1 — L9 21 — — 41 — L20
2 Charge lamp L7 22 Fuel gauge (sensor) — 42 — L16
3 Air cleaner clogging alarm L6 23 — — 43 Speedometer (+) —
4 T/M oil temperature alarm L5 24 — — 44 Speedometer (–) —
5 Engine water temp. alarm L4 25 — — 45 — —
6 Engine oil pressure alarm L3 26 — — 46 Transmission cut-off lamp (Declutch) L17
7 Brake alarm L2 27 — — 47 Preheating lamp L19
8 — L1 28 GND (–) — 48 Work lamp L18
9 +24 V power supply — 29 +24 V power supply — 49 — L14
10 — L22 30 — — 50 GND (–) —
11 Ride control (optional) L23 31 — — 51 — —
12 — L25 32 — — 52 — —
13 — L24 33 — — 53 High-beam lamp L12
14 — L26 34 Neutral L21 54 Turn signal (left) lamp L13
15 — L27 35 — — 55 Turn signal (right) lamp L11
16 Engine water temperature (sensor) — 36 — — 56 — —
17 — — 37 — — 57 Hour meter (–) —
18 — — 38 — — 58 Hour meter (+) —
19 Instrument panel illumination L10 39 — —
20 — L8 40 Parking brake lamp L15
62-21
Gauge circuit
Controller
Grounding S Power supply

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

K90ZV62016
Sensors respectively detect the temperature and fuel

level, and then convert them into electric signals. The
signals are transmitted to the corresponding gauges
that indicate the transmitted values.
Note
If a gauge is removed from the panel, the resistance
between the terminals will differ from the standard value
shown in the table.
Gauge Engine water temperature Fuel level
97ºC 100ºC
103ºC
35ºC
Indication
White Red White
Resistance
120~125 115~120
between S and E (Ω)
Resistance
120~125 115~120
between S and V (Ω)
Resistance
170~190 165~170
between E and V (Ω)
62-22
Temperature sensor (For T/C oil temperature)

(For engine water temperature)
Flat terminal
Thermister
Terminal
95ZV62066
Temperature of 60 80 100 120 Thermal lead switch

detection part (ºC) [140ºF] [176ºF] [212ºF] [248ºF] K60V2J62016
Resistance (Ω)
between terminal 56.3 29.5 16.5 10
and body Set temperature 122ºC
115ºC or lower
OFF temperature (When lowering
Operation temperature)
temperature 122±3ºC
ON temperature (When rising
temperature)
Max. Amp. 0.5 A
Resistance value Below 0.15 Ω (Contact ON)
62-23
Fuel level sensor
1.4 (0.055 in)

3 (0.12 in)
Terminal
48.5 (1.909 in)
Terminal
(ground)
(88.5 (3.484 in))
FULL
167.5 (6.594 in)
3/4
(233.5 (9.193 in))
286.5 (11.280 in)
1/2 Resistance wire
Contact
1/4
Float arm
Float Float arm

EMPTY
50ZV62019
The sending unit float arm in the fuel tank moves by the
fuel level movement in the tank. The contact installed on
the float arm axis also moves by contacting the resis-
tance wire. The contact position is fixed, based on the
Fuel gauge
F11 float position and the fuel level.
When the fuel level becomes low, the resistance value
10A rises accordingly.
The position of the fuel gauge pointer is decided by this
Sending unit resistance value, and the fuel gauge shows the fuel
amount left in the tank.
E
Sending unit circuit Float position FULL 3/4 1/2 1/4 EMPTY
60ZV62052 Resistance (Ω) (10 +1.0
- 0.5 ) (19) 32±3 (49.5) 80 +12
-2
Note
Figure in ( ) is for the reference resistance.
62-24
Monitoring system
If a problem of a unit is detected while the engine is run-
ning, a monitor lamp lights to inform the operator.
The buzzer also sounds for some problems.
The bulb check switch is provided to check whether the

monitor lamps are normal (not burn out).
11 13 7 12 1 2
Bulb check switch
3
4
5
6
14 9 10 8
50ZV62005E
62-25
Items to be monitored and operation condi-

tion
Monitor lamp
No. Item to be monitored Operation condition Buzzer Lamp test Remarks
Lighting Symbol
color
39 mm (1.54 in) from oil level MAX or less

1 Brake oil level
for more than 3 seconds
(red)
While engine running

2 Engine oil pressure 0.03+0.02
0 MPa (0.3+0.2 2
0 kgf/cm )
(red) (4.3+2.8
0 ±2 psi) or less for more than
2 seconds
101±2ºC or more
3 Engine water temperature (214±4ºF or more) —
(red) for more than 2 seconds
Torque converter oil 120±5ºC or more

4 (transmission) (248±9ºF or more) —
temperature (red) for more than 2 seconds
Filter resistance: 635±58 mmAq or more

5 Clogged air cleaner —
(25 inches H2O) for more than 2 seconds
(red)
6 Charging condition Defective charge system —

(red)
62-26
Operation monitor lamps
Monitor lamp
No. Monitor item Lighting condition Remarks
Lighting Symbol
color
When parking brake lever is pulled

7 Parking Red
(switch is set to ON)
When transmission cut off switch is set

8 Transmission cut off Green For declutch
to ON
When working light (rear) switch is set

9 Working light Green
to ON
When starter switch is in the PREHEAT

10 Preheat Yellow
position
Turn signal indicator

11 Green When turn signal lever (left) is actuated
(left)
Turn signal indicator When turn signal lever (right) is

12 Green
(right) actuated
13 High beam Blue When head lamp is set to high beam
14 Ride control Green When ride control switch is set to ON (OPT)
Caution on storage of individual instrument panel
Pointer axis
IMPORTANT Gauge pointer
Axis hole
When storing the instrument panel individually, make Main body
sure that the panel face (transparent face) faces frame
upward.
If the panel face faces below the vertical direction, the
damper oil may leak from meter pointer axis holes.
Damper
oil Magnet
Meter
70ZV62039
62-27
Transmission Electrical Circuit
Transmission cut off (Declutch) When cut off select switch (1) is OFF
switch Even when declutch/brake pedal is depressed and the
inching switch (3) is actuated, the solenoid valve in the
transmission control valve does not operate and the
clutch is not disengaged.
1 When cut off select switch (1) is ON

(Declutch select light (2) is lit)
When declutch/brake pedal is depressed, the inching

switch (3) is actuated, and the solenoid valve in the con-
trol valve is energized, closing the clutch oil circuit and
disengaging the clutch.
2
60ZV62007E
Solenoid valve
Control valve Transmission

60ZV62008E
60ZV62009E
62-28
Inching switch Solenoid valve
COM NC
NO
60ZV62011E
COM NO NC 60ZV62038
Solenoid valve specification
Rated load DC30V5A Rated voltage DC 24 V

Current 0.78 A
Resistance Approx. 31 Ω
Clutch cut-off circuit
Solenoid valve operation table

Clutch cut-off
Inching switch switch Parking lever
Parking Running
position
Parking switch ON OFF
Forward/reverse Declutch select

— OFF ON
clutch switch
Inching switch — — OFF ON
Transmission De-ener- De-ener-
Solenoid valve Energized Energized
solenoid valve gized gized
Clutch Neutral — — Neutral
Cut-off valve
Clutch oil pressure
Torque converter
Hyd. line pump
Elec. line
60ZV62010E
62-29
Electrical Detent Circuit

Bucket detent
Connector Detent holding plate
Rod
Proximity switch Bucket cylinder

Magnet coil
Multiple control valve detent section Detent activated
50ZVA62007 Sensor
This circuit is comprised of a detent holding plate

directly connected to a spool and an electromagnetic
detent coil.
Detent released
The coil is located on the tilt side for "raise" purposes.
60ZV62027J
Bucket positioner
After dumping, if the control lever is set to the "rollback"

position, the control lever will be held at that position
until the bucket is tilted to the set angle. This is because
the detent magnet in the multiple control valve is ener-
gized so that the holding plate connected to the spool is
held by magnetic force. When the bucket is positioned
at the set angle, the rod will retract from the proximity
switch. The proximity switch, therefore, is turned off,
and the coil of the multiple control valve is de-energized
and demagnetized. The control lever is automatically
returned to the neutral position by the spring. As a
result, the bucket is set to the selected digging angle
automatically.
Boom kick-out unit (optional)
While the boom is being raised, the control lever is held

at the "raise" position. When the boom is raised to the
set height, the boom kick-out unit automatically returns
the control lever to the "neutral" position. The detent
function and the units are the same as those of the
bucket positioner.
62-30
Proximity switch
Proximity switch +24V

LED
Switch Br 1
main B 2
Multiple control valve
circuit L detent coil
3
+24V
Detection part
Operation indicator lamp (LED)
1(Br)
Detected View Z
object
3(L) 2(B)
5±2 mm 85ZV62015
Adjust the clearance between the sensor and the

adjusting plate to 5±2 mm. In this condition, the opera-
tion indicator lamp (LED) is on, and the circuit between
the switches (2) – (3) is on.
Bucket detent specification
Voltage DC 24 V
Power 4 W or less (at 24 V)
Release force 147~245 N (15~25 kgf) (33~35 lbs)
62-31
Diode Unit Circuit
Diode Unit Circuit
Diode unit
Diode unit location (Relay unit)

60ZV62012E
The uni-directional property of the IC diodes (rectifiers

on the printed circuit board is used to light the warning
lamps and sound the buzzer, operate the solenoid and
to carry out the bulb check.
(Diodes allow current to flow in the direction, but not in
the reverse direction.)
Diode inspection
A B C D
E I
F G
60ZV62013E
If any problem occurs, the conductivity of each of the Do not use a high-voltage insulation resistance tester
individual diodes must be inspected with a circuit tester. for these checks.
The diodes should conduct in the positive direction only.
If any diode conducts in both positive and negative
directions or does not conduct in either direction, the
diode is defective.
62-32
Diode Unit Circuit
Specifications
DIODE UNIT DIODE UNIT

A (GREEN) A (WHITE) H
B C D E F G H i B C E F G D i
A B C D A B C D
E F G H i E F G H i
6 10 6 10
GyL LgL SbW LgBr SbY
A301 A302 A512 E802 A307
G604 G605 C902 G606
YR Gy SbY LgR Gy
A107 A306 A307 B802 A306
G603 G606 G512 G603
5 (GREEN) 1 5 1
D5 D6
Wiring diagram
60ZV62024E
Peak inverse voltage 100 V

Rectified current 1A
Surge current 50 A
Operating temperature range -30~75ºC
62-33
Diode Unit Circuit
Electrical connection diagram
AC E
PARKING LAMP PARKING BRAKE SWITCH

F11
10A INCHING SbW TRANSMISSION

SOLENOID CUT-OFF
INCHING
SELECTOR SWITCH
AC SWITCH
LgR (DECLUTCH)
LgW
(LgY)
T/M CUT OFF
i
H D
LgBr
BUZZER G
F
E
C
A B
(Lg)
DIODE UNIT (WHITE)
BRAKE
SbY
ENGINE OIL PRESSURE

Gy
AIR CLEANER
LgL
TRANSMISSION OIL TEMPERATURE

GyL
YR
B A LAMP BULB CHECK SWITCH
C
D
E
F
G E
H
i
DIODE UNIT (GREEN)
60ZV62014E
62-34
Stop Light Switch Circuit
Stop Light Switch Circuit

Specifications
Stop light switch Stop light Current 2.2 A
Contact B
F4
15A
E
Elec. diagram
60ZV62015E
Brake pedal
Stop light
switch
60ZV62016E
(Stop light switch, Parking switch)

60ZV62017E
When the brake pedal is depressed and the brake is

applied, the stop light switch is immediately actuated,
lighting up the stop light.
62-35
Parking Switch
Parking Switch
(Identical with stop light switch)
Parking brake E
Parking lamp switch
F11
10A
Inching solenoid
Elec. diagram
60ZV62018E
Parking
brake lever
Parking switch
60ZV62019E
When the parking brake lever is pulled and the parking

brake is applied, the parking switch is immediately actu-
ated, disengaging the clutch.
62-36
Back-up Light Switch Circuit
Back-up Light Switch Circuit
Back-up light switch Back-up light

F15
5A
Elec. diagram
60ZV62020E
When the spool installed above the transmission for-

ward/reverse spool is moved to the reverse position, the
switch contacts are closed, causing the back-up light to
light up.
(The switch is identical to the neutral switch. For

detailed information, refer to "Neutral switch".)
62-37
Horn Circuit
Horn Circuit
Horn switch
(GL)
F10 GW
15A G
Horn relay Horn
E
Elec. diagram
60ZV62021E
When the horn switch is pressed, the horn relay coil is

energized, closing the movable contacts, thereby ener-
gizing and sounding the horn.
Horn relay
1 2
3 4
Elec. diagram
Body black
60ZV62022E
The horn relay prevents voltage drop across wires and

protects the horn switch.
Voltage 24 V
Resistance 320 Ω
62-38
Diode
Diode
Symbols Open circuit, failed in open position.
Snap!
+24V
Switch
+ Solenoid
[Anode] [Cathode]
Surge voltage
(forward direction) Diode

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

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

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

Diode ment, electrical connection diagrams should be referred
to first, to determine and repair the cause. If a diode is
Current flows through the diode with smaller resistance. provided in the electrical equipment, the diode should
The solenoid is not energized. be checked for damage.
95ZV62074
62-39
Diode
Diode check method Caution for diode check method

Continuity check mode
When checking the continuity by continuity check mode

of volt-ohm-ammeter, only in case that the resistance is
Coil
about 300 Ω or smaller, the continuity is detected.
If the continuity check mode of volt-ohm-ammeter is

+
used to check the continuity of diode with 500 ~ 600 Ω,
no continuity is detected both ways.
+
Analog type tester Use a volt-ohm-ammeter with diode mode for checking
diode continuity.
95ZV62129
12V 12V
Diode check mode
30A
ECM Battery
(1)
R1 BR F15 WR (2) (3) WP
B AC
R2 C 5A
(2)(3): Diode unit
Suppression diode
F14
F13
5A
5A
R1
Charge From
circuit alternator
R terminal
B Neutral
relay
115V2E62005
Forward check
Continuity is detected in the status shown in the figure.
Normal Continuity is not detected when tester terminals are con-
nected in opposite way.
Continuity is not detected in either way Disconnection
Abnormal
Continuity is detected in either way Short-circuit
Note
When the circuit tester is the digital (number indication)
type, exchange the positions of the terminals of the
tester during the check. Some solenoid coils contain
diodes inside the solenoid coil pack.
Backward check
85V2E62036
Forward check Backward check Judgment

Continuity (voltage value) Over level Normal
Over level Over level Open circuit
0 volt 0 volt Short-circuit
62-40
Diode
Resistance check mode
Analog type tester
R1>0 R2=
0 0
Forward check Backward check
Digital type tester
R1>0 R2=
R1
Forward check Backward check
Forward check Backward check Judgment

R Ω (0<R<∞) ∞Ω Normal
∞Ω ∞Ω Open circuit
0Ω 0Ω Short-circuit
62-41
Diode
Surge voltage and surge suppres- Fig. 3

sion diodes
Fig. 1 Surge suppression
diode
Electromagnetic field
forms when switch closes. Coil
Current direction
Coil
Voltage
Battery
Current
Switch or
Current [A]
Voltage [V]
transistor
Time [sec] 65ZV62041
Load When the surge voltage was generated, it causes to

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

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

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

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

tronic parts. (See connection diagram.)
62-42
MEMO
63-1
50ZV Check & Adjustment Electrical Group

Electrical Group
63-2
Cautions Regarding Electric Circuit Check
Disconnecting or reinstalling con-

nector
Inserting waterproof round connector

80ZV63006
Removing square connector

80ZV63003
80ZV63007
1. Before disconnecting or reinstalling the connector,

Removing waterproof round connector be sure to turn the power off (turn the starter switch
80ZV63004
to OFF).
2. To disconnect a connector, firmly grab the connec-

tor, and press and hold the stopper claw. While
holding down the claw, pull out the connector in the
straight direction. Do not pull the electric cable or
wires. They may be damaged. Do not twist the con-
nector or the female terminal cover may be dam-
aged to cause poor contact.
3. When reconnecting, insert it until the stopper claw

clicks.
If the connector is not completely connected, it may
cause poor contact.
Inserting square connector
80ZV63005
63-3
Note
In corrosive environments (such as salt air, phosphate
plants, or fertilizers) the square type connectors will
require special coatings to prevent or minimize electrical
problems. Use only an approved sealant like Dow Corn-
ing 738 or Loctite "Ultra Blue".
Other silicone sealants may contain acetic acid which
may corrode the wiring.
(Hint: If the silicon has a vinegar type odor it has acetic
acid and should not be used.)
Use only a very small amount of di-electric grease if
needed.
63-4
How to attach the probes of the

circuit tester
How to attach the probes of the circuit tester

to the square connector.
80ZV63008
How to attach the probes of the circuit tester

to the waterproof round connector. 80ZV63009
When checking the conductivity or the voltage, follow

the procedure below:
1. Square connector
Insert the probes for the tester to the wire side of

the connector. Do not insert the probes into the
open side of the connector. The damaged connec-
tor may cause poor contact.
2. Waterproof round connector
For the waterproof round connector, do not attach

the probes of the tester to the wire side because
the wire side is waterproofed. Attach the probes to
the open connector side. Do not force the probes
into the female side. The damaged connector may
cause poor contact.
63-5
Electrical Circuit Check
Transmission control circuit Be sure engine is off before checking.

check Push the manual operation knob to the ON position by
hand, and then check that the spool operates smoothly.
If machine does not move forward/reverse, the inching If it does not move smoothly, judge that the valve is
solenoid may not be operating properly. sticking.
<Step 1> Checking solenoid valve <Solution>
- Measuring coil resistance If the coil is disconnected or the valve is sticking,

replace the defective unit as an assembly.
Disconnect the connector from the solenoid valve,
and then measure the coil resistance using a tester. <Step 2> Checking diode
Note that a diode is incorporated in the coil.
Check the continuity of the parking brake switch,
Coil resistance Judgment replace the switch if the abnormality is found.
Approx. 31 Ω Normal
∞Ω Abnormal Continuity Judgment
Continuity is detected when the
switch is ON.
Normal
No continuity is detected when the
switch is OFF.
Abnormal
switch is OFF.
Check the continuity of the inching switch, replace the

switch if the abnormality is found.
Manual
Continuity Judgment
operation
knob Continuity is detected when the
switch is ON.
Normal
+ No continuity is detected when the
switch is OFF.
Abnormal
switch is OFF.
<Step 3> Checking cable

+ 60ZV63001E
Check the cable between the solenoid valve and the
parking switch and/or the inching switch in order.
- Check valve for sticking
If wire has short circuit, replace it.
WARNING
accident resulting in injury or death. Be sure to
observe the following items before starting work.
- Place the machine on level ground, and lower the
bucket onto the ground.
- Block the tires with chocks to prevent them from
moving.
63-6
Bucket positioner electrical cir- <Step 3> Checking detent magnet solenoid
cuit check
Detection part Connector Detent holding plate

Operation indicator lamp (LED) 1(Br)
Detected View Z
object
3(L) 2(B)
Proximity switch
Magnet coil
+24V Multiple control valve detent section
LED Br 1
Switch Coil for detent
main. B 2 inside 50ZVA62007
circuit L pilot valve
3
+24V
90ZV63009
Check the continuity between coupler pins for the multi-
ple control valve detent magnet solenoid.
Though the clearance between the proximity switch and
the rod (detecting element) is 5±2 mm (0.197±0.079 in), If wire breakage is detected, repair it.
the operation indicator lamp (LED) is not lit, judge that
the proximity switch is defective, or the cable at the Detent coil specification
chassis side is disconnected or a wire broken.
<Step 1> Checking proximity switch Resistance 141 Ω
Supply +24 V to pin 1 (Br) and pin 2 (B), and connect

the ground to pin 3 (L).
If the operation indicator lamp (LED) does not light,

judge that the proximity switch is defective.
<Solution>
Replace the proximity switch.
<Step 2> Checking cable at chassis side
Check the cable from the proximity switch to the multi-

ple control valve detent magnet solenoid in order. If wire
disconnection is found, repair it.
63-7
Diode unit circuit check
Diode unit Diode unit
A
Green A
White H
B C D E F G H i B C E F G D i
A B C D A B C D
E F G H i E F G H i
Connection diagram
A B C D
Green
E I
F G
+
(Analog type meter) K60V2J63001
Check the continuity between terminal (A) and terminal

(B)~(I) for the green diode unit (between (A) and
(B)~(G), between (H) and (D)~(I) for the white diode
unit.)
Continuity is detected in the status shown in the figure.

Normal Continuity is not detected when tester terminals are con-
nected in opposite way.
Continuity is not detected in either way Disconnection
Abnormal
Continuity is detected in either way Short-circuit
Note
When the circuit tester is the digital (number indication)
type, exchange the positions of the terminals of the
tester during the check.
63-8
Gauge circuit electrical circuit Engine water temperature

check
Temperature of 60 80 100 106
detection area (ºC) (140ºF) (176ºF) (212ºF) (223ºF)
Resistance
between terminal 56.3 29.5 16.5 10
INSTRUMENT PANEL and body (Ω)
+ ES DD WTM
(+) FM GND
11 20
Fuel level sensor
RB YBr B
B206 G608 Ground
Lg O O YB
C106 B601 B602 G609
Fuel level 10 1 Fuel level E 1/2 F
A4
E/G water temp.
Resistance between
G6 80 32 10
two terminals (Ω)
FUEL LEVEL
E/G WATER SENSOR
TEMP.
SENSOR <Step 2> Checking gauge
G608
Controller
B
YBr
YB
G609 1 2
L9 L0 Grounding S Power supply

24V
E V 15V
60ZV63002E
Viewed from rear surface of instrument panel

The sensors detect the fuel level and engine water tem- K90ZV62016
perature and then convert them into electric signals.

The electric signals are then fed to the respective Remove the instrument panel, and then disconnect the
gauges and indicated on the gauges. If a gauge indi- connector from the panel. Measure the resistance
cates wrong values, either the sensor, gauge or wiring between the screw terminals on the rear surface of the
will be defective. Determine the defective unit by using panel. Judge whether the resistance value is accept-
the following procedure. able.
<Step 1> Checking sensor signal Note

When the ground of the gauge is defective such as con-
Disconnect the connector A4 from the instrument panel, tact failure and/or derailment, the pointer scales out.
or disconnect the connector from the corresponding Before replacing the gauge, check the ground circuit.
sensor. Measure the resistance between the sensor sig-
nal terminal and the ground terminal. If the measure-
ment value is acceptable compared with the standard
value shown below, the sensor is not defective. If the
measurement value is abnormal, check the wire in addi-
tion to the sensor because the cable may be defective
(corroded, broken, or high resistance).
63-9
Gauge Engine water temperature Fuel level
97ºC 100ºC
103ºC
35ºC
Indication
White Red White
Resistance
120~125 115~120
between S and E (Ω)
Resistance
120~125 115~120
between S and V (Ω)
Resistance
170~190 165~170
between E and V (Ω)
Instrument panel (back side view)
CN4
CN1 CN3
1 4 L11 L13 29 48
L12
8P L20 12P 16P
L1 58 57
5 8 L14 L10 35 56
Hour L10 L10
L2 meter
L10 L15 S
L21
L3
L16 E V
L4 S S
L17 L10
L5 E V E V
Fuel gauge Engine water temperature L18
sensor Speedometer
L6 L10 L10
L19
L7
CN2
L8 9 18 L22 L23 L24 L25 L26 L27
20P
L9 19 28
60ZV63016
63-10
MEMO
72-1
50ZV Function & Structure Operator Station Group

Operator Station Group
72-2
Cabin (OPT)
Cabin (OPT)
4
6
A A
B
D
D
3
B
1
2
5 5
C
C
8
B-B A-A
Strip seal
Glass Glass
1. Door (left side)
2. Door (right side)
3. Front wiper Catch
4. Window washer jet nozzle
5. Rear view mirror Outside chassis
6. Rear view mirror Washer
7. Duct (outside air suction port) D-D
8. Door stopper
Duct Strip seal
C-C
60ZV72001J
72-3
Cabin (OPT)
Cabin connection diagram
ACC’ E
Wiper motor
F19 OR
M F Wiper
10A
Wiper switch
S2 S3
WASH B
Sint S1
5 3
1
Washer motor Intermittent 6
2
wiper relay
PB
M 4
Wiper motor
F18 OL
M R Wiper
5A
E S1 S2
B
WASH
Washer motor
PL Wiper switch
M
F12 RG1.25 (RGy) To working

R2
light PL
15A
Cabin
RLg working light
Cabin
working light
F20 O
Cigarette
10A lighter
F16 (WBr)
Radio
3A
Night illumination (RB)
G
F10 Room lamp
ACC’ E
Cabin
50ZVA72010
72-4
Cabin (OPT)
Wiper motor
Front
(Y)
(R) 2
(R) 10
11 (W) (L)
6
1
5
4
3 (A)
Ro
tati
ng
dire
c tion
(A) can be adjusted between 55º ~ 110º

60ZV72004J
1. Wiper motor
2. Link assembly
3. Washer C
4. Nut Circuit breaker
5. Cap
6. Nut C
7. Bolt
8. Crank arm assembly
9. Spring washer
10. Nut
11. Connector
24V
Wiper motor (front) specifications
Circuit diagram
Locked rotor current < 16 A
= 60ZV72005J
Wiping angle 52º
72-5
Cabin (OPT)
Rear (OPT)
Wiping angle 91º±3º Automatic
stop position
1 (L) (LR)
(B) (LW)
3 4 5
2
Cabin 6
Pantagraph arm 60ZV72006J
1. Wiper motor
2. Washer Circuit breaker Motor
3. Packing B
4. Nut
5. Cap
6. Nut
7. Connector
LR LW L
Wiper motor (rear) specifications
+1 S +
Nominal torque 12 N-m (1.2 kgf-m) OFF

Rated voltage DC 24 V 24V
ON
Rotating speed Load: Speed 38±5 min-1
0.6 N-m (0.6 kgf-m) Current 2 A or less Circuit diagram Switch
Rotating speed Speed 40±5 min-1
No load Current 1 A or less 60ZV72007J
Starting voltage 16 V or less

Locked rotor current 7 A or less
72-6
Operator Seat
Operator Seat
Seat assembly
2
2
ke
g stro
l i ni n
Rec
3
1
4
8
4
1
6 7
5
10 9
11
A-Detail
50ZVA72001
1. Cushion assembly Reclining seat adjustment

2. Back assembly
3. Arm rest Lift reclining adjuster lever (5) up and hold, select back
4. Reclining adjuster assembly (2) angle, release adjuster lever (5).
5. Reclining adjuster lever
6. Slide adjuster
7. Slide adjuster lever
8. Seat bracket
9. Hinge bracket
10. Bushing
11. Screw
72-7
Operator Seat
Suspension assembly
2
11 5
4
19
Suspension stroke
16
7
40
40
6
3
1
2
4 20 6
19 11
18
17
Section A-A
Section B-B
11 View P
7
13 14 10 3 9 14 15
15
12
3 8 9 5 Detail-10
Hook (7) Detail
60ZV72010J
Suspension adjustment
1. Lower body 11. Adjusting knob
2. Upper body 12. Bearing
Sit on the seat and turn adjusting knob (11) to adjust
3. Main arm 13. Spring pin
seat height.
4. Sub arm 14. Castle nut
5. Spring 15. Sprit pin
- Clockwise to raise seat
6. Sock absorber 16. Rubber stopper
7. Hook assembly 17. Bolt
- Counter-clockwise to lower seat
8. Shaft 18. Nut
9. Spring pin 19. Shaft
10. Adjuster bolt 20. Nut
72-8
Air Conditioner (OPT)
Air conditioner mount

Filter
Air duct
Air conditioner cover
Air damper
Air conditioner
Air duct assembly
Air duct assembly
60ZV72011J
Air conditioner specifications Heater performance
Heat radiation quantity 5.9±0.59 kw (5,100±510 kcal/h)

Cooler performance
Air quantity 450±45 m3/h
Cooling capacity 4.7±0.47 kw (4,000±400 kcal/h) Blower revolution 3,650 min-1
Air quantity 550±55 m3/h Power consumption 215 W
Rated voltage 24 V Rated voltage 24 V
Motor revolution 3,400 min-1 (Difference in temperature: 65ºC, water flow rate: 6 L/min)
Power Motor 225 W

consumption Magnet 40 W or less
72-9
Air conditioner line
6 3
s s.
p re
w
Lo
H ig
hp
1 res
s.
Ho t
wa t
er
4
2
5
urn
r re t
a te
tw
Ho 50ZV72001J
1. Air conditioner unit

2. Condenser unit
3. Compressor
4. Cooler hose
5. Water hose
6. Air damper unit
7. Receiver dryer
72-10
Air conditioner structure

Air conditioner unit
2 4
5
11
14
13
8 15
10
12
A
Air damper
unit side
60ZV72013J
1. Cooling unit case (lower) 9. Expansion valve

2. Cooling unit case (upper) 10. Water valve
3. Heater case 11. Blower resistor
4. Blower motor 12. Air mix damper (A)
5. Fan 13. Air mix damper (B)
6. Blower motor 14. Thermistor assembly
7. Evaporator 15. Water valve selection servo motor
8. Heater radiator
72-11
Air damper unit
A
Air conditioner
unit side
60ZV72014J
1. Unit case (lower)

2. Unit case (upper)
3. Inside/outside air selection damper
4. Inside/outside air selection servo motor
5. Air filter cover
6. Air filter (upper)
7. Air filter (side)
72-12
Air duct unit
60ZV72015J
1. Air duct 3. Catch

2. Air filter (primary) 4. Gasket
Compressor (with magnetic clutch)
2
1
60ZV72016J
1. Compressor
2. Magnetic clutch
72-13
Condenser unit
2 4
3
1
60ZV72017J
1. Condenser core
2. Condenser fan motor
3. Fan
4. Fan shroud
5. Motor resistor
6. Wire harness
72-14
Control unit
Control amplifier
Control panel 50ZVA72002
Control panel
Push type switch
A/C
OFF LO HI
50ZVA72003
72-15
Function of cooling mechanism contain some minor gas fractions, it is routed into the
receiver drier. There it dries the refrigerant by use of a
material we term a "desiccant", which means drying
Principle of cooling
agent. A down tube in the receiver drier is submerged
into the heavier liquid that is now at the bottom of the
Expansion
receiver drier. This tube will permit passage of only the
Indoor valve heavier liquid that is at the bottom of the receiver drier.
Expansion Condenser
Then the high-pressure liquid passes through the ther-
Evaporator
mal expansion valve that provides a restriction or throt-
Evaporation Releases
Condensation heat to the tles the flow of refrigerant. This restriction reduces the
outside. pressure of the liquid refrigerant thus reducing its boiling
Deprives heat
Compression Refrigerant point. The expansion valve also meters the amount of
of the adjacent
area.
refrigerant to the evaporator, by modulating the valve
from wide open to closed, which varies with the heat
Compressor
load. The expansion valve separates the high-pressure
Basic cooling cycle side from the low-pressure side.
97ZV72029
The refrigerant is now at the evaporator. Temperatures

in the evaporator are cold enough to cause the ambient
Function and operation of air conditioning sys- air to cool when blown through it. This causes conden-
tem sation to happen. The fan-charged air that rushes
through the evaporator is now going to shed its humid-
Very often, things are much simpler than they may ity. This humidity, or condensed water, is routed through
appear. This is also the case with an air conditioning some tubing to be discharged to the outside of the cab
system. Gas when compressed often heats as a result as waste water that falls to the ground. The refrigerant
of molecular compression, and when decompressed it is now on its way back to the compressor. It is still under
cools. Some gases are more prone to heat or cool to a pressure when compared to the atmospheric air pres-
greater degree when undergoing these changes than sure. However, because it is drawn along by the refrig-
are others. We use these natural laws to make an air erant compressor suction, we now say that is in the
conditioning system work. Another factor to take into suction side (low-pressure side) of the circuit.
consideration is that we enhance the natural effects of
hot and cold in these refrigerants by manipulating the
gas temperature while it is undergoing the heating or
cooling process.
Note
HFC 134A is a very effective "vehicle" to carry away
heat.
Explanation of function of air conditioning unit.
As an example of manipulating refrigerant tempera-

tures, imagine that you can very quickly make the refrig-
erant intensely hot. This is done by use of a
compressor, as we just mentioned in paragraph one.
If you course the heated refrigerant that just came from

the compressor through a condenser that will cool it
while it is very hot and in a compressed gaseous state,
you will make it shed some of its heat that it gained in
the compression process. This refrigerant then is con-
verted into a liquid at this point, while still in the con-
denser. This is why it is called the condenser, as it has
condensed the gas into a liquid. As a liquid that may still
72-16
Refrigerant
A liquid object which circulates inside cooling circuit and

transmits heat is called "refrigerant". The refrigerant
changes repeatedly its state, from "liquid --> gas --> liq-
uid --> gas ...", and carries heat from the low tempera-
ture side (inside the cab) to the high temperature side
(outside the cab) while changing its status.
There are many types of refrigerants. This air condi-

tioner adopts refrigerant R134a which does not contain
chlorine and does not destroy the ozone layer.
IMPORTANT
Make sure to use the specified refrigerant (R134a). If
any other refrigerant is used, following problems may
occur:
- The air does not become cool enough.
- The equipment may be damaged.
And never mix R134a with any other refrigerant.
Chemical formula CH2FCF3

Molecular weight 102.03
Boiling point -26.19ºC (-15ºF)
Critical temperature 101.14ºC (214ºF)
4.1 MPa (41.45 kgf/cm2)
Critical pressure
(595 psi)
Critical density 511 kg/m3 (0.073 lbs)
Density of saturated liquid
1,206 kg/m3 (595 psi)
(at 25ºC/77ºF)
Specific volume of saturated vapor
0.0310 m3/kg
(at 25ºC or 77ºF)
197.54 KJ/kg (186 BTU)
Latent heat of evaporation (at 0ºC/32ºF)
(47.19 kcal/kg)
Combustibility Noncombustible
Ozone decomposition modulus 0
72-17
Refrigerant characteristics Generally, fluid (which is the generic name for com-
pressed / condensed non-gas liquid) has following prop-
erties.
100
(212)
1. When the temperature of gas at a certain pressure

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

When evaporated, the refrigerant absorbs the heat of
evaporation from the air inside the cab.
Accordingly, in order to cool down the air inside the cab

to approximately 25ºC (77ºF), the refrigerant should
change (be evaporated) from liquid into gas at a tem-
perature lower than 25ºC (77ºF). From the figure, it can
be seen that the refrigerant R134a can sufficiently cool
down the air inside the cab at a pressure above the
atmospheric pressure. (If used refrigerant requires a
pressure below the atmospheric pressure to cool down
the air to the necessary temperature, air enters into the
circuit and the ability of the cooler is diminished.)
In the process at which the vaporized refrigerant is con-

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

can be liquefied at the pressure of 785 kPa (8.0 kgf/
cm2G) (114 psi) or more.
72-18
Cooling circuit The figure on the left shows the cooling circuit of the air
conditioner.
In this circuit diagram, the area which cools down the air
inside the cab is the evaporator. The cooling circuit uti-
lizes the fact that the refrigerant absorbs heat (latent
heat of evaporation) from the adjacent area when evap-
orated, and cools down the air inside the cab. The area
Inside cab where the refrigerant is evaporated is the evaporator.
Pressure bulb
The "cooling" effect can be obtained only when the air to
be cooled down is continuously fed to the area around
the evaporator by the blower fan and the liquid refriger-
Evaporator Expansion valve
ant (wet evaporation refrigerant with low degree of dry-
Blower ness) is supplied into the evaporator.
Inside engine room

For example, in order to cool down the air to 15ºC
(59ºF), the refrigerant can absorb the latent heat of
evaporation from the air only when it is evaporated at a
Compressor Cooling fan temperature lower than 15ºC (59ºF). It can be seen from
the figure in the previous page that the pressure of the
Pressure switch
refrigerant inside the evaporator should be 353 kPa (3.6
kgf/cm2G) (51 psi) or less to realize it. And in order to
Receiver dryer keep sufficient cooling effect, the supplied refrigerant
quantity should be adjusted so that the refrigerant sup-
Condenser plied to the evaporator is completely evaporated inside
the evaporator into dry vapor or gas.
Structure of cooling circuit
Accordingly, the cooling circuit should be constructed to
85V2U72003
reduce the pressure inside the evaporator and supply
proper quantity of refrigerant into the evaporator so that
the evaporator can cool down the air sufficiently.
The supplied refrigerant quantity is adjusted by the

expansion valve. The pressure inside the evaporator is
kept at a low value by the closing action of the expan-
sion valve and the suction action of the compressor.
The compressor works as a pump which circulates the
refrigerant. The refrigerant in the dry vapor status
returns into liquid by the compression action of the com-
pressor and heat change (heat radiation) of the con-
denser, which acts to change the state of the gas to
liquid.
72-19
Air conditioner function of compo-

nents
Control unit
Control amplifier
Control panel 50ZVA72002
It consists of the control panel and the control amplifier.
Control panel
Ventilation mode Air conditioner operation lamp Air conditioner Air intake control switch
selection lamp switch
Ventilation mode
selection switch
A/C
Ventilation temp. Blower operation lamp
Indication lamp
OFF LO HI
Temperature control switch OFF switch Blower switch

50ZVA72004
72-20
Name and function of each part on control panel
Switch Switch Name Function
OFF OFF switch - Turn OFF blower fan and air conditioner.
Ventilation switch Face - This selects ventilation Face and lights indication lamp.
Ventilation switch Face/Foot - This selects ventilation Face/Foot and lights indication lamp.
Ventilation switch Foot - This selects ventilation Foot and lights indication lamp.
Ventilation switch Def/Foot - This selects ventilation Def/Foot and lights indication lamp.
Ventilation switch Def - This selects ventilation Def and lights indication lamp.
LO
Blower switch LO - This changes blower fan to LO and lights indication lamp.
Blower switch Me1 - This changes blower fan to Me1 and lights indication lamp.
Blower switch Me2 - This changes blower fan to Me2 and lights indication lamp.
HI
Blower switch HI - This changes blower fan to HI and lights indication lamp.
- It turns air conditioner ON and lights indication lamp.

A/C
Air conditioner switch
(Only in the case that the blower switch is ON)
Inside air circulation selection switch - It changes to inside air circulation and lights indication lamp.
Outside air introduction selection switch - It changes to outside air introduction and lights indication lamp.
- Every time [ ] (Blue) switch is pushed ventilation temperature lowers and

more green lights.
Temperature control switch
- Every time [ ] (Red) switch is pushed ventilation temperature rises and more
red lights.
- When the starter switch is ON, operation mode starts at the same mode just
Starter switch Starter switch
before the starter switch is OFF.
72-21
Control amplifier
The control amplifier controls each servomotor and

relay in accordance with manipulation of the switches
on the control panel.
Control name Switch Function

- When the operator turns ON the starter switch, the control amplifier detects the
inside/outside air selection servo motor stop position and water valve selection
servo motor stop position, starts control from each mode selected just before
Pre control Starter switch
the operator turned OFF the starter switch, and turns ON the indicator lamps in
accordance with the selected mode. However, the control amplifier starts to
control the blower fan from the Me mode.
- The control amplifier turns OFF the blower fan and air conditioner (compressor)
OFF control OFF switch
when the operator turns ON the OFF switch.
- The control amplifier controls the blower fan relay to change over the air quan-
Blower control Blower switch
tity when the operator manipulates the blower switch.
- The control amplifier controls the compressor clutch relay and condenser fan
relay to start the air conditioning function when the operator turns ON the air
conditioner switch.
Air conditioner - The control amplifier detects the air blow temperature using a thermister while
Air conditioner switch
control the air conditioner is operating, temporarily turns OFF the compressor to pre-
vent freezing of the evaporator when the air blow temperature becomes 3ºC or
less, and turns ON the air conditioner again when the air blow temperature
returns to 4ºC or more.
- The control amplifier controls the inside/outside air selection servo motor to
Air inlet control Inside/outside air selector switch change over the air inlet when the operator manipulates the inside/outside air
selector switch.
- The control amplifier controls the water valve selection servo motor, and con-
Air outlet trols the waver valve position and air mixing damper opening/closing position to
temperature Air outlet temperature control switch change the temperature at the air outlet when the operator manipulates the air
control outlet temperature control switch. In addition, the control amplifier detects the
water valve position, and controls the indicator lamp lighting pattern.
- The control amplifier issues buzzer sound instantaneously when it receives the
Buzzer control Each switch
switch ON signal.
Troubleshooting the control unit
Item Symptom Cause Action

- Wire is broken in power supply, or fuses are blown
Every indicator lamp does not turn
off. Repair/replacement
ON.
Indicator lamps do not - Something is wrong inside control unit.
turn ON. - Wire is broken in indicator lamps.
Some indicator lamps do not turn
- Operation switches are defective. Repair/replacement
ON (, or they remain ON).
- Something is wrong inside control unit.
Blower fan does not change its - Blower switch is defective.
Blower malfunctions. Repair/replacement
speed (or does not rotate at all). - Something is wrong inside control unit.
Control unit cannot Control unit cannot change over air - Air outlet selector switch is defective.
Repair/replacement
change over air outlet. outlet. - Something is wrong inside air outlet selection duct.
Compressor malfunc- - Air conditioner switch is defective.
Compressor does not turn ON. Repair/replacement
tions. - Something is wrong inside control unit.
Air quantity is small, and pressure is
Frost is formed. - Something is wrong inside control unit. Repair/replacement
low.
Control unit cannot
Control unit cannot change over - Inside/outside air selector switch is defective.
change over inside air Repair/replacement
inside air and outside air. - Something is wrong inside control unit.
and outside air.
Control unit cannot con-
Air mixing damper does not operate. - Air outlet temperature control switch is defective.
trol correctly tempera- Repair/replacement
Water valve is not opened or closed. - Something is wrong inside control unit.
ture at air outlet.
Control unit does not Control unit does not issue buzzer
- Something is wrong inside control unit. Repair/replacement
issue buzzer sound. sound.
72-22
Air conditioner unit Air mixing damper
[Maximum cooling]
Air mixing damper B
Heater radiator r
Blower motor at e
He
tor
Evaporator
dia
Ra Blower
Fan
Cold air motor
Cold air
Cold
Air mixing damper A air
[Maximum heating]
Evaporator Air mixing damper B
Air conditioner unit Cold air

r
ate
He
tor
Evaporator
dia
Ra Hot air Blower
motor
Link rod B
Supporting (between dampers
Air mixing damper B point B A and B)
Air mixing damper A Hot air
Evaporator
50ZVA72006
ate
r
Blower
He Fan motor
Link rod A During maximum cooling, the air mixing damper B is
(for water valve) completely closed, and the air mixing damper A is com-
Supporting point pletely opened. As a result, the air cooled by the evapo-
rator does not go through the heater radiator but is
blown off.
Water valve Supporting
selection point A Water valve
servo motor
Air mixing damper A
During maximum heating, the air mixing damper A is
completely closed, and the air mixing damper B is com-
pletely opened. As a result, all the air which has gone
through the evaporator goes through the heater radia-
50ZVA72005 tor, then the warmed air is blown off.
The air conditioner unit has the cooling, heating and air
blowing functions to perform conditioning of the air
inside the cabin, and consists of an evaporator which
cools down the air, a heater radiator which warms the
air and a blower motor which blows the air.
The temperature in the vent position is adjusted when

the opening/closing position of the air mixing damper is
so controlled that the cooled air while passing through
the evaporator and the warmed air while passing
through the heater radiator are mixed.
The air mixing damper is controlled by the servo motor

for air mixing assembled in the unit.
72-23
Evaporator The evaporator is an important heat exchanger which

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

adjusted by the expansion valve described next. In
order to ensure that the refrigerant quantity is accurately
Refrigerant flow inside evaporator ( ) adjusted, pressure drop of the refrigerant inside the
From expansion valve→(1) to (8) evaporator should be minimal.
→Compressor
Accordingly, reduction of pressure drop is an element to
enhance the performance of the evaporator.
97ZV72048
Troubleshooting the evaporator

Both high pressure and low pressure are low,
- Joint portion of supply area - Tightening
Gas leak and air bubbles can be seen through sight
- Cracks in evaporator main body - Repair/replacement
glass.
Blockage in circuit Both high pressure and low pressure are low. - Blockage inside - Cleaning/replacement
Blockage in fins Air quantity is small. (Filters may be clogged.) - Blockage in fins - Cleaning
- Blockage in filter
Freezing Air quantity is small, and low pressure is low. (Evaporator is not preforming - Cleaning/replacement
inadequately.)
72-24
Expansion valve (box type) Expansion valve operation
(Evaporator) Diaphragm
Evaporator
Spring
Temperature
sensing rod
Diaphragm
Temperature sensing rod
Needle valve (To compressor)

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

(High pressure) (Low pressure)
97ZV72049 97ZV72050
The expansion valve offers the following two functions. The temperature sensing rod detects the temperature of
the refrigerant which has gone through the evaporator,
1. By injecting the liquid refrigerant at high tempera- and transfers the detected temperature to the refriger-
ture and high pressure which has gone through the ant gas chamber located in the upper portion of the dia-
receiver from a small hole, the expansion valve phragm chamber.
expands dramatically the liquid refrigerant into mist
refrigerant at low temperature and low pressure. The gas pressure changes in accordance with the
detected temperature, the temperature sensing rod
2. Promptly in accordance with the vaporized status of directly connected to the diaphragm is moved, then the
the refrigerant inside the evaporator, the expansion needle valve opening is adjusted.
valve adjusts the refrigerant quantity.
In order to ensure that the evaporator offers its full - When the temperature at the exit of the evaporator is
performance, the liquid refrigerant should be kept in low or when cooling load is small, following occurs.
a state in which it deprives heat of the adjacent
area and its evaporation is always completed at the The gas pressure inside the diaphragm chamber
exit of the evaporator. becomes low, the volume decreases, the temperature
To realize this, the expansion valve automatically sensing rod moves to the right, and the needle valve is
adjusts the refrigerant quantity in accordance with closed.
fluctuation of the temperature inside the cabin
(cooling load) and fluctuation of the rotation speed - When the temperature at the exit of the evaporator is
of the compressor. high or when cooling load is great, following occurs.
The expansion valve consists of a needle valve, a
diaphragm and a temperature sensing rod. The gas pressure inside the diaphragm chamber
The temperature sensing rod detects the tempera- becomes high, the volume increases, the temperature
ture of the refrigerant which has gone through the sensing rod moves to the left, the needle valve is
evaporator, and transfers the detected temperature opened, and more quantity of refrigerant is supplied to
to the refrigerant gas chamber located in the upper the evaporator.
portion of the diaphragm chamber.
72-25
Troubleshooting the expansion valve

Blocked expansion Both high pressure and low pressure are low,
valve or defective and air bubbles cannot be seen through sight - Expansion valve - Cleaning/adjustment or replacement
adjustment (too closed) glass.
Defective adjustment Low pressure is too high, and compressor
- Expansion valve - Adjustment or replacement
(too open) head is cold.
Cooling is disabled during operation. Frosting
Freezing caused by is not detected in evaporator. Both high pres- - Replace receiver tank, evacuate air,
- Expansion valve
moisture sure and low pressure are low, and air bubbles then charge gas again.
cannot be seen through sight glass.
72-26
Heater radiator
UT
te rO
Wa
Water IN
Fin
Heater core
60ZV72027J
The heater radiator utilizes the engine cooling water as

the heat source. When going through the heater radia-
tor, the air receives heat from the heater radiator fins
and is warmed.
The hot water inside the heater radiator is forcedly cir-

culated by the engine water pump.
Troubleshooting the heater radiator

- Joint portion of supply area
Water leak Water leaks from heater core. - Repair/replacement
- Cracks in heater core main body
Blockage in circuit Air inside cabin does not become warm. - Blockage inside heater radiator - Replacement
Blockage in fins Air quantity is small. - Blockage in fins - Cleaning
72-27
Water valve
Valve lever
[Operating angle]
Closed
72
OUT
Opened
Valve lever
IN
60ZV72028J
The water valve installed on the inlet side of the heater

radiator changes the valve lever opening position in
accordance with manipulation of the air outlet tempera-
ture control switch on the control panel, and controls the
flow rate of hot water flowing in the heater radiator.
Troubleshooting the water valve

- Water valve
No water valve closed
Insufficient cooling capacity - Insufficient connection between - Repair/replacement
completely
valve lever and link
- Joint portion of supply area
Water leak Water leaks. - Repair/replacement
- Cracks in water valve main body
Blockage in circuit Air inside cabin does not become warm. - Blockage inside heater radiator - Repair/replacement
72-28
Air mixing servo motor
COOL
Stop position
set at delivery
Spa
re
HOT
Servo motor
Circuit diagram
50ZVA72007
This servo motor operates in accordance with manipula- Air mix servo motor specifications
tion of the switches on the control panel. The servo
motor rotates only while the control amplifier applies the Voltage DC 24 V
power between the terminals A and B. The servo motor Load torque 0.3 N-m (3 kg-cm)
rotates in the normal direction or reverse direction in Rotating speed 5 min-1
accordance with the direction of the power applied Current 75 mA
between the terminals A and B. Terminal A HOT side
Voltage application terminal
Terminal B COOL side
While the servo motor rotates, the moving contact slides
in the resistor area on the fixed plate. When the
detected position (electric potential) of the moving con-
tact (which is connected to the control lever) becomes
equivalent to the indication on the control panel, the
power to the servo motor turns OFF. As the result, the
servo motor stops.
Troubleshooting the servo motor

Servo motor does not - Air conditioner unit does not change over mode - Motor
- Repair/replacement
rotate normally. from cooling to heating (or from heating to cooling). - Control unit
- Indicator lamps of temperature setting switches do
- Fixed plate
Contact is contacting not light in accordance with preset pattern.
- Moving contact - Repair/replacement
poorly. - Servo motor does not stop in accordance with pre-
- Control unit
set pattern.
72-29
Ventilation selection duct The ventilation selection duct changes the ventilation to
Face, Face/Foot, Foot, Def/Foot and Def. It is controlled
by the ventilation mode selection switch on the control
To Face panel.
When the ventilation mode selection switch is pushed,

links are moved by the servo motor and finally the
dampers are moved to change the ventilation.
To Def
Foot
From air conditioner unit
60ZV72031J
Face
Link
Face • Def Def

damper
Foot
Link
Ventilation selection
servo motor
Foot damper
60ZV72032J
72-30
Ventilation selection servo motor
Spare
Spare Spare
Voltage
between
C and E
Stop position
Servo motor
FACE Operating angle DEF

Circuit diagram
Potentiometer output relationship drawing - initial value
50ZVA72008
This servo motor operates in accordance with manipula- Ventilation selection servo motor specifications
tion of the switches on the control panel. The servo
motor rotates only while the control amplifier applies the Voltage DC 24 V
power between the terminals A and B. The servo motor Load torque 0.3 N-m (3 kg-cm)
rotates in the normal direction or reverse direction in Rotating speed 10 min-1
accordance with the direction of the power applied Current 75 mA
between the terminals A and B. Terminal A Face side
Voltage application terminal
Terminal B Def side
While the servo motor rotates, the moving contact slides
in the resistor area on the fixed plate. When the
detected position (electric potential) of the moving con-
tact (which is connected to the control lever) becomes
equivalent to the indication on the control panel, the
power supplied to the servo motor turns OFF. As the
result, the servo motor stops.

Motor is locked - Motor
- Servo motor does not rotate. - Repair/replacement
(disabled). - Control unit
- Indicator lamps of temperature setting switches do
- Fixed plate
Contact is contacting not light in accordance with preset pattern.
- Moving contact - Repair/replacement
poorly. - Servo motor does not stop in accordance with pre-
- Control unit
set pattern.
72-31
Blower motor assembly Blower motor assembly specifications
Voltage DC 24 V
Fan Blower motor
Number of rotations of motor 3,100 min-1
Power consumption 225 W±10 %
Fan outer diameter ø150
Air
Air
97ZV72053
The blower motor assembly consists of a DC motor and

a fan, and blows air.
Troubleshooting the blower motor

- Blower motor
Blower motor operation is defective. Air is not blown at all. - Repair/replacement
- Control unit
Blower resistor
Me1 Hi
Resistor Lo Me2
0.4 Ω 0.4 Ω 1.2 Ω 2.8 Ω
Fuse Fuse
Hi Me2 Me1 Lo
60ZV72037J
It is a resistor to change air flow amount from blower

motor.
Troubleshooting the blower resistor

- Blower resistor
Blower resistor disconnected. No air blown amount change. - Replacement
- Control unit
- Blower motor
Blower motor operation is defective. No air blown. - Repair/replacement
- Control unit
72-32
Thermistor Evaporator Heater radiator Blower
Appearance of thermistor
8,000
7,000
6,000
Resistance (Ω)
5,000
4,000 Thermistor
3,000
30A Fuse
2,000
20A Fuse
1,000
Compressor
0 clutch relay
10 5 0 5 10 15 20 25 30
Temperature (ºC)
Characteristics curve between temperature
and resistance of thermistor 97ZV72055
Control amplifier Compressor
To battery relay
Temp. clutch
sensor
The thermistor, a kind of semi-conductor, offers the circuit
3C ON
OFF
characteristics as shown in the curve on the above. 4C
When the temperature becomes high, its resistance Thermistor

becomes small. When the temperature becomes low, its 60ZV72039J
resistance becomes large.
The thermistor mounted on the blowoff port side of the

evaporator detects the temperature of the air cooled by
the evaporator, and transmits it as a signal to the control
amplifier.
If the air at the vent is 3ºC or less, the control amplifier

turns off the compressor clutch relay. If the air at the
blowoff port becomes 4ºC or more, the control amplifier
turns on the compressor clutch relay again to restart
cooling.
Because the air temperature at the vent is detected and

the compressor clutch relay is turned on and off accord-
ingly, freezing of the evaporator is prevented.
Troubleshooting the thermistor

Cable in thermistor is broken. Compressor clutch does not work.
- Thermistor - Replacement
Thermistor is short-circuited. Air is not blown.
72-33
Air filters and air damper box [Outside air introduction mode]
Inside air inlet

The air damper box changes over the air inlet between on top face
the modes outside air introduction and inside air circula-
tion.
When the operator manipulates the inside/outside air

selector switch on the control panel, the servo motor
inside the air damper box changes over the inside/out-
Inside/outside
side air selection damper. air selection damper
The air filter for outside air is provided on the outside air Air outlet
introduction side, and the air filers for inside air are pro-
vided on the top face and side of the inside air circula-
tion side to remove dusts from the air.
Outside air inlet Inside air inlet
on side (closed)
Air damper box 60ZV72042J
Inside air A [Inside air circulation mode]

Air conditioner unit Inside air inlet
on top face
Inside air
Inside/outside
air selection damper
Outside air
60ZV72040J
Air outlet
Inside/outside air selection servo motor

Outside air inlet Inside air inlet
(closed) on side
Inside air side
60ZV72043J
The inside/outside air selection servo motor changes

over the inside/outside air selection damper to the
Control lever Damper inside air side or outside air side by way of a link and
lever.
Outside air side

View A
60ZV72041J
72-34
Inside/outside air selection servo motor
a Spare
(FRS)
MRFB
(REC)
Outside air MRFA
introduction Servo motor
position
Circuit diagram
Inside air
circulation
position
50ZVA72009
This servo motor operates in accordance with manipula- Inside/outside air selection servo motor specifica-
tion of the switches on the control panel. The servo tions
motor rotates only while the control amplifier applies the
power between the terminals A and B. The servo motor Voltage DC 24 V
rotates in the normal direction or reverse direction in Load torque 0.1 N-m (1 kg-cm)
accordance with the direction of the power applied Rotating speed 20 min-1
between the terminals A and B. Current 75 mA
Outside air introduction
Terminal A
Voltage application mode side
terminal Inside air circulation
Terminal B
mode side

Servo motor does not change over
mode from inside air circulation to
- Motor
Servo motor does not rotate normally. outside air introduction (or from out- - Repair/replacement
- Control unit
side air introduction to inside air cir-
culation).
72-35
Air filters Air filters for inside air
Air filter for outside air
Air filter on side
Catch
Air duct
Air filter
Stopper
60ZV72046J
This air filter removes dusts from the introduced outside

air. Turn the catch clockwise and remove the air duct,
Air damper box Air filters on top face
and then remove the air filter.
60ZV72047J
These air filters remove dusts from the circulated inside

air. (The inside air goes through the air filters on the top
face while the air conditioner unit introduces the outside
air.) Remove the stopper. Remove two air filters toward
you from the top face, and remove one air filter upward
from the side.
Air filters specifications
Air filter Air filters for inside air

Item
for outside air Top (two) Side (one)
Filtration area 12,811 cm2 2,670 cm2 4,005 cm2
Ventilation
3 mmAq or less 8 mmAq or less
resistance
Cleaning
98% or more 65% or more
efficiency
Troubleshooting the air filters

Blockage Air quantity is small. - Air filter - Cleaning/replacement
72-36
Compressor and magnetic clutch Compressor specifications

Compressor
Piston
Discharge valve
Discharge valve
Pressure relief valve

Service valve
Low press. side

Swash plate
charging valve
Suction valve
Shaft seal Suction valve
Diagonal plate
Suction/compression action 97ZV72061
O-ring
Piston Model 10PA15C

Cylinder diameter ø29.5
Stroke 22.7 mm
Number of cylinders 10
Cylinder capacity 155.3 cm3
Cylinder
Maximum allowable number of rotations 4,000 min-1
Valve Lubricating oil ND-OIL8
Shaft Lubricating oil quantity 180 cm3
Magnetic clutch assembly
60ZV72048J
The compressor is driven by the V belt from the engine

by way of the magnetic clutch. The compressor sucks
and compresses the gaseous refrigerant at low temper-
ature and low pressure which deprived heat of the air
inside the cabin in the evaporator and was vaporized to
make the gaseous refrigerant be at high temperature
and high pressure, then feeds it to the circuit on the high
pressure side again. Five pairs of pistons (with ten cylin-
ders) reciprocate in the same direction with the shaft in
accordance with rotations of the shaft.
Accordingly, when one piston of a pair is in the com-

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

tained in the gaseous refrigerant and the oil splashed by
the diagonal plate.
Accordingly, if the refrigerant quantity decreases, the

compressor is seized by oil shortage. To prevent sei-
zure, a pressure switch is provided in the circuit so that
the power supplied to the magnetic clutch is shut down
and the compressor is protected when the refrigerant
quantity decreases.
72-37
Magnetic clutch Magnet clutch specifications
Model L50T
S
Voltage DC 24 V
Pulled
Power consumption 40 W
force
Stator Drive belt V-ribbed belt (six ribs)
Switch Air gap 0.5±0.15 mm
Iron piece
(rotor)
Power
supply
Magnetic
force
N
Principle of magnetic clutch 97ZV72062
The magnetic clutch controls mechanical connection

between the engine and the compressor. When the
engine is rotating and the air conditioner ON/OFF
switch is ON, if the temperature inside the cabin
reaches or exceeds the temperature set by the temper-
ature setting switches, the magnetic clutch stops or
drives the compressor.
Suction face Pulley

Stator coil
Hub Rotor Stator

Ball bearing
Magnet clutch
97ZV72063
The hub of the magnetic clutch is fitted onto the shaft of

the compressor. While the compressor is not driven, the
hub is separated from the rotor and only the pulley is
rotating. When the air conditioner switch is set to ON,
the current flows in the stator coil, the stator works as a
magnet and engages the hub, then the compressor
rotates together with the pulley.
When the current applied on the stator coil is set to

OFF, the hub is not immediately separated but rotates
together with the pulley because the pulley has residual
magnetism. Accordingly, clearance is provided between
the hub and pulley so that they are not in close contact
with each other during disengagement. This clearance
is called air gap.
72-38
Troubleshooting the compressor and magnetic

clutch

- Compressor temperature is abnormally high.
- High pressure is abnormally low, and low
pressure is abnormally high.
Suction or exhaust valve is - Air bubbles cannot be seen through sight - Suction or exhaust valve - Repair/replacement
damaged. * glass.
- Abnormal sounds are made while clutch is
turned on.
Clutch draw voltage is low. - Stator coil - Replacement
- Wiring on main body - Repair
Power is not supplied to
- Control amplifier - Replacement
stator coil.
- Pressure switch - Replacement
- Compressor does not rotate.
Gap between hub and rotor (Air in cab does not become cool enough.) - Magnetic clutch - Replacement
is large.
Compressor main body is
defective - Shaft, piston - Repair/replacement
(seized, etc.).
Clutch bearing is damaged. - Clutch bearing - Replacement
Contact or slippage caused
- Abnormal sounds are made while clutch is
by too small gap between - Magnetic clutch - Replacement
turned off.
hub and rotor.
V belt is slack. - V belt - Adjustment/replacement
Compressor main body is - Internal compressor trou-
- Abnormal sounds are made while clutch is - Repair/replacement
defective. ble
turned on.
V belt is slack. - V belt - Adjustment/replacement
* This can be the result of "liquid charging". Do not liquid charge as a compressor cannot compress liquid; this will damage it.
72-39
Condenser unit Condenser
The condenser consisting of tubes and fins cools down

the gaseous refrigerant at high temperature and high
pressure (70ºC, 1,618 kPa (16.5 kgf/cm2)) sent from the
compressor, and change it into liquid refrigerant during
passing tubes.
Condenser fan motor
The condenser fan motor used to cool down the con-

denser is mounted on the condenser together with a fan
Condenser unit shroud.
60ZV72050J
Condenser specifications
Voltage DC 24 V
Power consumption 132 W x 2 %
Air quantity 1,100 m3/Hr x 2
IN Tube Number of rotations of motor 2,400 min-1
Resistor
The resistor controls rotation of the condenser fan

motor in two steps in accordance with a command given
OUT
Fin by the fan control pressure switch (medium pressure
switch).
Resistor
Resistor specifications
Resistance 2.8 Ω
Fan
Condenser
fan motor
Fan shroud 60ZV72051J
Each condenser unit consists of a condenser, a con-

denser fan motor and a resistor. Two condenser units
are arranged in series with the piping.
The condenser units cool down the gaseous refrigerant

at high temperature and high pressure sent from the
compressor, and change it into liquid refrigerant.
72-40
Troubleshooting the condenser unit

Heat radiation quantity is
- Blockage or crushed fins - Clean or replace condenser
insufficient due to blockage*. Both high pressure and low pressure are
abnormally high, and air does not become
Rotation of condenser fan cool enough. - Fan motor - Repair or replace motor
motor is defective.
High pressure is abnormally high, low pres-
sure is abnormally low, and air does not
Blockage / condenser airflow - Internal to condenser fins - Clean or replace condenser
become cool enough.
Air bubbles can be seen through sight glass.
Both high pressure and low pressure are
- Leaks at joints - Tightening
Gas leak abnormally low, and air bubbles can be seen
- Cracks in main body - Repair or replacement
through sight glass.
* It is important to check the fan blades also as these can become bent or packed with dirt, making them ineffective.
72-41
Receiver dryer Desiccant
If moisture is present inside the cooling circuit, the com-

pressor valve and oil may deteriorate, metal parts within
the circuit may corrode, or moisture may be frozen
Refrigerant inlet inside expansion valve which may clog the circuit. To
Refrigerant outlet prevent such failure, synthetic zeolite (drying agent) is
positioned inside the air conditioner and acts as a desic-
cant suitable to the circuit so that it absorbs moisture
entering the circuit during installation or refrigerant
charging.
When the expansion valve is often frozen by moisture

(icing), the desiccating agent does not have enough
absorption ability. When this happens, the receiver must
Desiccant Strainer
be replaced.
Desiccant specifications
Capacity 550 cm3

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

compressor changes and the proper refrigerant quantity
in the cooling circuit fluctuates in accordance with fluc-
tuation of the number of revolution of the engine.
The receiver tank receives such fluctuation. When the

cooling circuit does not require much refrigerant, the
receiver stores temporarily excess refrigerant. When the
cooling circuit requires much refrigerant, the receiver
tank supplies refrigerant from its receiver tube to the cir-
cuit.
In addition, the receiver tank stores a reserve of refriger-

ant in order to take balance of charging of the refriger-
ant and respond to any minute leaks of the refrigerant
caused by permeation through rubber hoses.
72-42
Strainers
If dusts enter the circuit, the expansion valve may be

clogged, the compressor may be damaged, and the
cooling function may be deteriorated.
Strainers are provided to prevent dusts from flowing

with in the refrigerant.
The strainers cannot be cleaned. When they are consid-

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

- At first, air in cab will cool down, but after a
Icing - Desiccating agent in receiver - Replacement of receiver dryer
short time no longer will cool properly.
- High pressure is excessively high, low pres-
Blockage in strainers sure is excessively low, and air does not - Blockage in strainers - Replacement of receiver dryer
become cool enough*.
*A means to test this is to check the temperature between the inlet and outlet of receiver dryer. If it drops more than it should the dryer is
plugging and should be replaced.
72-43
Sight glass Pressure switches
Sight glass Terminal
Contact area
Pressure switch High press.

side charging
valve
Tube accessory
60ZV72054J 97ZV72067
This sight glass is installed on the receiver joint located The pressure switch detects the pressure on the high
on the top of the receiver dryer. Only through this sight pressure side of the cooling circuit, and stops the com-
glass, the refrigerant quantity inside the circuit can be pressor when detecting any abnormality so that damage
visually checked. of the equipment in the cooling circuit can be prevented.
There are three types of pressure switches, high pres-

sure type, medium pressure type and low pressure
type, which function as shown in the table below.
Switching pressure Switch operation Causes of abnormal

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

A
When pressure between com- 2,550 3,136
pressor and expansion valve (26) (32) Heat radiation of condenser
High
becomes abnormally high, this ON C D is insufficient due to clogging
pressure
switch shuts down power sup- in condenser or defective
switch
plied to compressor magnetic rotation of condenser fan.
clutch to protect circuit. OFF B
Check conductivity
between A and B.
When detecting fluctuation of

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

pressor and expansion valve 226
becomes abnormally low due (2.3)
to refrigerant leak, this switch ON
Low Check conductivity between A and B
shuts down power supplied to Refrigerant leak from a part
pressure in pressure switch coupler shown
compressor magnetic clutch to of circuit.
switch above.
prevent seizure of compressor OFF
caused by insufficient com- 196
pressor oil which decreased (2.0)
together with refrigerant.
72-44
Troubleshooting the pressure switch

- Condenser fan motor does not change its speed - Medium pressure
Insufficient cooling - Replacement
(to high speed). switch
- Even when abnormal high pressure (3,136 kPa (32 kgf/cm2))
occurs, compressor does not turn off. - High or low pres-
Gas leak - Replacement
- Even when gas (refrigerant) has run short, compressor does sure switch*
not turn off.
*If abnormal high pressure occurs while the high pressure switch is nonconforming, the equipment in the cooling circuit may be damaged.
The pressure relief valve releases the refrigerant to the atmosphere in order to prevent damages of the equipment.
Pressure relief valve
Flow rate
(L/min)
113
Gas discharge route while valve

is operating
97ZV72071
This valve mounted on the high pressure side of the

compressor service valve releases the refrigerant to the
Pressure atmosphere when abnormal high pressure occurs.
28.1 35.0 42.4 (kgf/cm2 )
2,756 3,430 4,158 (kPa)
IMPORTANT
Characteristics drawing of When the refrigerant quantity inside the cooling cir-
relief valve operation cuit is correct, the pressure switch always remains
97ZV72069
ON even if the compressor is stopped because the
refrigerant pressure is approximately 588 kPa (6.0
kgf/cm2) as far as the outside air temperature is
Service valve Pressure relief valve around 25ºC.
When the outside air temperature becomes 0ºC or
less, the pressure switch for low pressure detection
turns off even if the refrigerant quantity is proper
because the refrigerant pressure becomes 196 kPa
Low press. (2.0 kgf/cm2) or less. As a result, the compressor
side charging does not work.
valve It means that the pressure switch for low pressure
detection functions also as a thermostat which
detects the outside air temperature.
60ZV72053J
72-45
Relay A Relay B
97ZV72072 97ZV72099
Relay A specifications Relay B specifications
Rated voltage DC 24 V Rated voltage DC 24 V

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

- Blower motor does not rotate at all. - Blower motor main
- Blower motor remains rotating. relay
- Blower motor does not rotate at high speed. - Blower motor Hi
- Blower motor remains rotating at high speed. relay
- Blower motor does not rotate at medium speed Me2. - Blower motor Me2
- Blower motor speed does not change from Me2 to Me1. relay
- Blower motor does not rotate at medium speed Me1. - Blower motor Me1
Coil wire is broken. - Blower motor speed does not change from Me1 to low speed. relay
- Replacement
Contact is melted down.
- Both condenser fans do not rotate.
- Condenser fan relay
- Both condenser fans remain rotating.
- When condenser fan is at high pressure, it does not rotate at
high speed. - Condenser fan relay
- When condenser fan is at low pressure, it remains rotating at 1
high speed.
- Compressor magnetic clutch does not turn on. - Compressor clutch
- Compressor magnetic clutch remains ON. relay
72-46
Refrigerant hose
WARNING
Burst hazard
These hoses operate at high pressure for HVAC sys-
Outer layer tems and must not be replaced with substandard
hoses.
Reinforcing layer
Use only OEM replacement hoses or hoses of the
same rating as OEM replacement hoses.
Mouth ring
Inner layer
Intermediate layer
97ZV72073
White line and "R134a" indication
97ZV72074
As shown in the figure on the above, the refrigerant

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

"R134a" is indicated on this hose as shown in the figure
on the right.
IMPORTANT
Never use any other hose or any other refrigerant.
Otherwise, refrigerant may leak.
72-47
Charge of refrigerant
WARNING
WARNING Serious accidents may occur during storage and
transportation of a service can.
Serious accidents may occur in the refrigerant charg- Observe the following contents.
ing work. - A service can accommodates high pressure gas in
Observe the following contents. the saturated liquid status. If the temperature rises,
- Only trained or experienced specialists having suf- the pressure may increase drastically and the can
ficient knowledge on the contents of the work may burst. Keep the temperature of the service
should be allowed to perform the refrigerant charg- can at 40ºC (104ºF) or less.
ing work. Make sure to keep the can away from hot objects
- If the refrigerant comes into contact with your eyes, or fire.
you may lose your eyesight. Make sure to wear - During storage, make sure to avoid direct sunlight,
protective goggles. and store the can in a dark and cool place.
- The refrigerant in the liquid status is at low temper- - Inside the closed cab (including trunk), the air tem-
ature (approximately -30ºC (-22ºF)). If it splashes perature may rise considerably due to solar heat,
on your skin, you may suffer from frostbite. Pay etc., and may become dangerously temperature
close attention when handling it. even in winter if the closed cab is exposed to direct
- If the refrigerant (Refrigerant R134a) touches a hot sunlight. Never put the can inside the cab.
object (approximately +400ºC or more), it decom- - If the service can suffer from flaws, dents and
poses and generates harmful substances. deformations, its strength deteriorates. Never hit or
Never release the refrigerant in a room where ven- drop it. And never throw or drop a package of cans
tilation is bad and there is a hot object or a fire while loading or unloading it.
(such as in the presence of a stove). - Keep the can away from the reach of children.
- In order to protect the environment, do not release
the gaseous refrigerant to the atmosphere.
IMPORTANT
CAUTION - It is prohibited by law to reuse service cans. Never
reuse them.
Serious accidents may occur during the refrigerant - Pay close attention so that air and dusts do not
charging work. enter into the cooling circuit.
Observe the following contents. - Never charge the refrigerant excessively.
- When warming a service can to charge the refrig- - The air conditioner is so designed as to be used
erant, make sure to open the low pressure valves with Refrigerant R134a. Never charge any other
of the service can and the gauge manifold, then refrigerant such as Freon R12.
warm it with hot water of 40ºC (104ºF) or less (tem- - If the compressor oil (ND-OIL 8) adheres to the
perature at which you feel warm when putting your painting face or the resin area, the painting may
hand into it). peel off or the resin may be damaged. If so, wipe it
Never warm the can with boiling water or overheat off soon.
it with open fire. If the can is treated in such a way, - Tighten the piping at the specified torque.
it may burst.
- When charging the refrigerant after having started
the engine, never open the high pressure (Hi)
valve. If it is opened, the high pressure gas may
flow in the reverse direction, and the service can
and the hose may burst.
72-48
Work procedure Charging procedure
The refrigerant charging process is mainly divided into 1. Charge the system with the required amount of gas
"refrigerant evacuation procedure" and "gas charging by weight, and check for leaks by letting the HVAC
procedure" as shown below. system sit static and permit pressure to equalize.
2. Check the system pressure in comparison to the
ambient temperature. If acceptable, go to next step
Refrigerant evacuation procedure (3).
3. Turn on the engine, run at 1,200~1,500 rpm.
The "refrigerant evacuation process"* eliminates mois- 4. Turn on the HVAC air condition system, making
ture present inside the cooling circuit. If the moisture sure that the heat is off and A/C is set with fan on
remains inside the circuit, it may cause varied problems high.
even if its quantity is extremely small: The moisture may 5. Let the HVAC system run on coldest setting until all
freeze inside the expansion valve during operation, and parts are cold saturated; this should take about 30
may block the circuit or generate oxidation. To prevent minutes or more.
such problems, the refrigerant containing air inside the 6. Check the temperature that is coming from the
cooling circuit should be evacuated, and the moisture vents of the HVAC system inside the cab. Check
inside the circuit should be boiled and evaporated so the performance in the operating pressure and tem-
that all moisture is eliminated before pure refrigerant is perature chart.
recharged into the circuit. 7. Either remove or install more refrigerant depending
upon the findings.
*May be referred to as "air evacuation procedure" since it contains air
which also contains water that can cause system damage as noted.
Observe the work procedure and cautions shown
below, and charge the refrigerant correctly.
Gas charging procedure
The system should operate within about 5% of the
The "gas charging procedure" charges the refrigerant parameters. Be sure that the condenser is clear, evapo-
as gas into the circuit while in a vacuum state. The gas rator is clean and the fans are all working as they should
charging process not only affects the cooling ability of with good airflow in the system.
the air conditioner but also affects the system compo-
nent life.* Note
If the inside of the cab become cold during the charging
If the refrigerant is charged too quickly or in a liquid process, the compressor magnetic clutch turns off and
state, pressure inside the circuit may become extremely system charging is disabled.
high and the cooling ability may deteriorate. If the refrig-
erant charging volume is too low, the lubricating oil for When charging, completely open the cab doors.
the compressor may not circulate smoothly and com-
pressor pistons may seize and lock up the compressor. This will keep the system from turning off and on.
Because the gas charging process involves high pres-

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

tions, and charge the refrigerant correctly.
*Note
Liquid charging destroys a compressor. Never permit
entry of liquid refrigerant.
72-49
Charging procedure chart
Start evacuation.
20~30 min -750 mmHg (-30" Hg) or less

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

(air entry)
When gage indicates a normal value
Charge refrigerant gas. Charge gaseous refrigerant until gauge pressure

reaches 98 kPa (1 kgf/cm2) (14 psi). Check for leaks.
Check for gas leak.

Gas Note
charging A full charge should be about 2±0.1 lbs (900±50 g) of
process
refrigerant.
Charge refrigerant.
As a general guideline, with engine off and HVAC

system static, the pressure in the system should be
Check for gas leak. about 85 psi (588 kPa) (6.0 kgf/cm2) with the pres-
sure has equalized between the low and high pres-
sure side.
Performance test
95ZVE72042
72-50
Refrigerant charging tools Charging hose and quick connectors

Recovery and recycling unit
Gauge manifold*
Low pressure
charging hose High pressure
(blue) charging hose
95ZV72024
(red)
Quick connector
(Lo)
It is against Federal Regulations* in the United States to
release refrigerant to atmosphere. A recovery and recy-
cling unit must be used to capture the refrigerant so as
not to release it into the atmosphere.
Center charging hose
(green or yellow)
*Refer to section 609 of the clean air act at www.epa.gov.
Quick connector
(Hi)
It is used for the following;
1. Recover the refrigerant. 97ZV72077

2. Filter the refrigerant.
3. Measure the refrigerant weight.
These different colored hoses are used to evacuate the
4. Remove trapped non compressible gases (air).
air and charge the gas. (The colors may be different
5. Measure the refrigerant to install in system by
depending on the manufacturer.)
weight.
6. Measure the pressure of the refrigerant in system.
Red hose
7. Measure ambient temperature.
Connects the high pressure valve of the gauge manifold
8. View bubbles in system if there are any.
and the high pressure charging valve (with "H" mark on
its cap) of compressor outlet hose.
Read and understand the Operation Manual for the
recovery and recycling machine.
Blue hose
Connects the low pressure valve of the gauge manifold
IMPORTANT and the low pressure charging valve (with "L" mark on
Only use a vacuum pump if the system is already its cap) of the compressor inlet hose.
open to atmosphere and refrigerant has completely
left the system. Green or yellow hose
Connects the center valve of the gauge manifold and
the vacuum pump (or the service can valve).
*Gauge manifold may be used with vacuum pump or recovery unit.

72-51
Leak detector Gauge manifold
Many recovery and recycling units are equipped with a

gauge manifold, which is very similar to the gauge man-
ifolds that were used for earlier application refrigerant
handling systems.
Typically, the low pressure side hose color is blue, the

charging hose color is yellow (may be light green), and
the high pressure side hose color is red.
These are generally integrated into the recovery and

recling unit.
85V2U72007
Low pressure High pressure
gauge gauge
A leak detector find areas where refrigerant traces are
leaking and sounds an alarm to alert the technician of
areas of leakage.
Gauge manifold
Low pressure
valve High pressure
valve
Low pressure
charging hose Center valve High pressure
mounting nipple Center charging charging hose
hose mounting mounting nipple
nipple 97ZV72078
It is used to evacuate the air and charge the gas, and

equipped with a high pressure gauge, a low pressure
gage, plus valves and hose mounting nipples as shown
in the figure on the above.
Some gauge manifolds are equipped with sight glasses.

These are used to check for bubbles in the refrigerant.
Excessive flow of bubbles may indicate:

1. Low pressure.
2. Leak to atmosphere (air ingestion) when in vac-
uum.
3. Boiling action, perhaps due to pressure changes.
72-52
Cautions on handling of quick connector and Precautions

charging valve
When discharging the refrigerant, use a quick connec- Quick connector

tor.
1. Connecting the quick connector.
Screwdriver, etc.
Sleeve "Click" sound (OK)
Valve pin
(A)
Spring
Charging valve Charging valve
97ZV72082
97ZV72080
IMPORTANT
Slide the sleeve upward, push the quick connector If you push the valve pin with a considerable force
against the charging valve, press and hold securely [294 kPa (3 kgf/cm2) (43 psi)] with a screwdriver, etc.,
part (A) until a click is heard, then slide the sleeve the spring may come off and the refrigerant may leak.
downward. Never do this.
IMPORTANT
- Push quick connector against charging valve verti-
cally.
- If refrigerant remains inside the charging hose, the
quick connector may not be easily connected.
2. Disconnecting the quick connector
(A)
(B)
97ZV72081
While pressing and holding the part (A) of the quick

connector, slide sleeve upward to disconnect quick
connector.
72-53
Refrigerant charging procedure Valve setting

Lo Hi
Air evacuation work
Closed Closed
High pressure valve
WARNING
If hoses are connected incorrectly, serious accidents Low pressure valve
may occur.
Observe the following.
(red)
- Never confuse connection of hose to the high pres-
(blue)
sure side and the low pressure side of the gauge
(green)
manifold.
(Hi)
Recovery and recycling unit
(Lo)
Charging valve
on high pressure
side (located on
receiver dryer)
Vacuum pump shown
Compressor (stopped)
A refrigerant recycle and recovery unit
may be used.
95ZVE72045
With system "OFF";

(a) Close both the high pressure (Hi) valve and the low
pressure (Lo) valve of the gauge manifold.
95ZV72024
(b) Connect the charging hose.

It is against Federal Regulations* in the United States to
release refrigerant to atmosphere. A recovery and recy- Red hose
cling unit must be used to capture the refrigerant so as To be connected between the high pressure (Hi)
not to release it into the atmosphere. valve of the gauge manifold and the high pressure
charging valve.
*Refer to section 609 of the clean air act at www.epa.gov.
Blue hose
1. Connecting the gauge manifold To be connected between the low pressure (Lo)
valve of the gauge manifold and the low pressure
CAUTION charging valve of the compressor.
Close both low and high pressure valve, as seen in Yellow or green hose
"a" below. To be connected between center valve of gauge
manifold and recovery unit (equipped with vacuum
pump).
IMPORTANT
Connect quick connectors to both the high pressure
and low pressure sides before starting air evacuation.
The check valve of a quick connector cannot hold
vacuum status. If a side of quick connector is not con-
nected, a vacuum condition cannot take place.
72-54
2a. Evacuating the system with a vacuum pump 2b. Evacuating the system with a recycling and recove-
ry unit.
When pulling a vacuum with a vacuum pump on a sys-
tem that has been open due to replacing major compo-
nents.
Valve setting
After air evacuation Valve setting
Lo Hi for 30 minutes Lo Hi
OpenedOpened Closed Closed
High pressure valve
Low pressure valve

95ZV72024
(red)
(blue)
Each manufacture of recycling and recovery units pro-
(green) vide operating instructions for their units. Read, under-
stand and closely follow operating instructions as
provided.
(Hi)
(Lo)
Charging valve
on high
pressure side
Vacuum pump (operating)

Compressor (stopped) (stopped)
95ZVE72046
(a) Open both the high pressure (High) valve and the
low pressure (Low) valve of the gauge manifold.
(b) Turn on the switch of the vacuum pump, and evac-

uate until the degree of vacuum becomes -750 mm
Hg (-30" Hg) for about 20~30 minutes.
(c) After finishing evacuation, close both the high pres-

sure valve and the low pressure valve of the gauge
manifold. Then, turn off the switch of the vacuum
pump.
IMPORTANT
If you stop the vacuum pump before closing each
valve of the gauge manifold, refrigerant from vacuum
unit and tank is released to the atmosphere. It is
important to first close both high and low side valves.
72-55
3. Checking for leaks after vacuum has been drawn Refrigerant charging process
This section describes a static charging procedure with

Valve setting Leave for 10 minutes or more
as per EPA regulations
the engine in "OFF" and compressor not turning.
Lo Hi
Pointer of low
Closed Closed pressure gauge Do not run engine until high and low pressures are
moves toward "0".
Low pressure gauge equal so that no damage is done to the compressor.
0
0 The illustrations below show use of a gauge manifold
assembly. This is not the preferred method in the USA
due to EPA regulations against purging refrigerant to
Moves atmosphere. Use of a recovery and recycle unit is best.
toward "0". Carefully follow instructions with recovery unit.
Tighten connection areas
of piping.
97ZV72085
Valve setting
Lo Hi
After a vacuum has been pulled on system; Closed Closed
Leave the circuit for 5 minutes or more with H and L

valves of gauge manifold closed. Then, make sure that Open the
service can-
the needle of each gauge does not move. ister valve.
Red
Blue (low) (high)
If the needle of the gauge moves toward "0", a leak has
occurred somewhere in the circuit. Tighten the connec-
tion areas of the piping, evacuate the system again, Service
Charging hose canister
then make sure that there is no leaks. R134a
(green or yellow) 97ZV72086
IMPORTANT
Make sure to tighten the connection areas of the pip-
IMPORTANT
ing at a specified tightening torque. Never purge or vent refrigerant to atmosphere. (EPA)
For the tightening torque, refer to the volume "Mainte-
nance Standard".
72-56
1. Charging the refrigerant from the high pressure

Valve setting After 1~1.5 service Valve setting side with the engine in the "OFF“ position.
Lo Hi cans are charged Lo Hi
OpenedOpened Closed Closed
(a) After evacuation, disconnect the charging hose
(green or yellow) of gauge manifold from vacuum
pump, and connect it to the service canister.
High pressure valve
(b) Purging air from lines

Low pressure
valve Open the service canister valve very slightly with
low and high pressure manifold valves closed.
(red) Open both high and low side valves so that lines
are charged. Connect lines to HVAC system. A
small amount of trapped air will escape from the
(blue)
lines, as air is discharged by the refrigerant pres-
(green) (Hi)
sure. EPA says that release of this tiny bit of air that
is very small is ok.
(Lo)
Charging valve
on high pressure
(c) WITH ENGINE "OFF"; Open tank canister valve
side and charge the gaseous refrigerant until gauge
pressure read 98 kPa (1 kgf/cm2) (14 psi). (This
should take about one to one and half one lb ser-
Compressor
(stopped) vice cans. If using scale, add one to one and a half
Service can valve lbs.)
(opened charge
R134a closed)
95ZVE72052 (d) After charging, close the low and high pressure
valves of the gauge manifold and the service can
valve.
WARNING
If the refrigerant were changed from the high pres- 2. Check for gas leak with a leak detector
sure side, the refrigerant would flow in reverse direc-
tion and the can and the hose may be burst if you Check for gas leak in the circuit using a leak tester,
start the engine and operate the compressor. Never etc. If a leak is detected, repair leak as required. If
start the engine in this condition. located at connections, tighten the connection area.
IMPORTANT
IMPORTANT
Make sure to tighten the connection areas of the pip-
If you charge refrigerant with refrigerant canister ing at a specified tightening torque.
placed upside down liquid will exit canister, refrig- For the tightening torque, refer to the volume "Mainte-
erantis sucked into the compressor in a liquid state. nance Standard". Do not overtighten or it will worsen.
This will damage the compressor. Charge only with
refrigerant gas.
72-57
3. Charging the refrigerant - low pressure side - e/g (c) Start the engine, and increase the number of rota-
"ON". tions to approximately 1,500 min-1(rpm).
Charge the refrigerant (d) On the control panel, set the fan speed to high and
Valve setting until air bubbles seen Valve setting set the air flow volume to maximum cold, and set
through the sight glass
Lo Hi disappear. Lo Hi the vent port temperature switches to the coldest
Opened Closed Closed Closed
status.
(e) Open the low pressure valve of the gauge manifold

High pressure valve
and service canister valve to charge the refrigerant.
When air bubbles seen through the sight glass of
Low pressure the receiver dryer disappear, charge the refrigerant
valve further more by 150~250 g.
(red)
IMPORTANT
When replacing service canister while charging
refrigerant, connect the line as described earlier so
(blue) (green) (Hi)
as to not have air in the line.
(Lo)
Charging valve (f) After charging, close the low pressure valve of the
on high pressure gage manifold and the service can valve. Then,
side stop the engine.
Compressor Refrigerant quantity to be charged (guideline)

(On-load)
Service can valve
900±50 g (2.0±0.1 lb)
(opened charge
R134a closed) Refrigerant
Sight glass situation
95ZVE72052 quantity
Gas bubbles are few.
(When the number of rpm’s of the
Proper engine is gradually increased from the
idle status to 1,500 min-1, gas bubbles
Sight glass disappear.)
Gas bubbles are not seen in the flow at

all. System is over-pressurized.
Too much (In this case, both the high pressure
Receiver joint and the low pressure are high, and the
cooling ability is deteriorated.)
Many gas bubbles are seen in the flow.

Receiver dryer Insufficient
(Gas bubbles visibly seen constantly.)
97ZV72066
(a) Make sure that the high and low pressure valves of
the gauge manifold and service canister valve are
closed.
(b) If the inside of the cab becomes cold during the

charging process, the compressor magnetic clutch
turns off and system charging is disabled.
When charging, completely open the cab doors.
This will keep the system from turning off and on.
72-58
4. Guidelines to determine quantities of refrigerant 5. Disconnecting the gauge manifold

charge
Use the following table to determine the refrigerant

charge quantity.
Item Criteria
(A)
Doors Completely open
Temperature control switches Maximum cooling
Blower speed High
Inside/outside air selection Inside air
(B)
Number of rotations of engine 1,500 min-1

Air conditioner switch ON
1,862 kPa (19 kgf/cm2) (270 psi)
Pressure on high pressure side 97ZV72081
or less
After inspecting the refrigerant charge, disconnect

IMPORTANT the charging hose from the high and low pressure
- If outside air temperature is high (40ºC/104ºF or charging valves using the following procedure.
more) or if the pressure on the high pressure side
is 1,862 kPa (19 kgf/cm2) (270 psi) or more when (a) While pressing and holding part (A) of the quick
the judgement condition above is set, perform the connector, slide sleeve upward and disconnect the
following so that the pressure becomes 1,862 kPa quick connector.
(19 kgf/cm2) (270 psi) or less, then check the
refrigerant quantity. (b) Attach a cap to each of the high and low pressure
- Close the doors completely, and set the charging valves.
blower fan to the low speed (by pressing
the Lo switch).
- Use a shaded area or a place indoors
away from sunlight.
- If you turn on the air conditioner while the refriger-
ant quantity is extremely low, lubricant in the com-
pressor may be insufficient and a failure such as
seizure of the compressor may occur. Never do
this.
- If the refrigerant quantity is over charged, cooling
may be insufficient or the pressure inside the cir-
cuit may become abnormally high (which is dan-
gerous). Never do this.
72-59
Troubleshooting using the gauge manifold Condition

Normal status After warming up the engine, check the pressure under
the following condition.
- Doors
<Low pressure side> <High pressure side>
Completely open
215~275 kPa 1,470~1,765 kPa
(2.2~2.8 kgf/cm2) (15~18 kgf/cm2) - Inside/outside air selection
(31~40 psi) (213~255 psi)
Inside air
- Number of rotations of engine

1,500 min-1
- Temperature at suction port of air conditioner

30~35ºC (86~95ºF)
- Blower speed
High
- Temperature control switches

Maximum cooling
97ZV72091
Pressure values indicated by gauges in the normal status
A/C suction port temp. Pressure Pressure value by gauge

High pressure side 1,000~1,215 kPa (10.2~12.4 kgf/cm 2) (145~176 psi)
20~25ºC (68~77ºF)
Low pressure side 127~167 kPa (1.3~1.7 kgf/cm 2) (18~24 psi)
25~30ºC (77~86ºF)
30~35ºC (86~95ºF)
35~40ºC (95~104ºF)
72-60
When the refrigerant charge quantity is insuffi- When the refrigerant does not circulate (due to
cient clogging in the cooling circuit)
<Low pressure side> <High pressure side> <Low pressure side> <High pressure side>
49~98 kPa 686~981 kPa Negative value 490~588 kPa
(0.5~1.0 kgf/cm2) (7~10 kgf/cm2) (5~6 kgf/cm2)
(7~14 psi) (100~144 psi) (71~85 psi)
97ZV72092 97ZV72093
Symptom Cause Inspection/action point Symptom Cause Inspection/action point

- Pressure is low on - Refrigerant - Find and repair - If cooling circuit is Clogging in cool- - Inspect receiver
both low and high quantity is leaks. completely blocked, ing circuit dryer, expansion
pressure sides. insufficient. needle on low pres- valve, etc. (Temper-
- Repair leak. Add sure side indicates a ature is different
- Gas bubbles go - Gas is refrigerant. vacuum immedi- between IN and
through sight glass leaking. ately. OUT of failing part.)
continuously. - If pressure indicated
by gage is around - If cooling circuit is - After finishing work,
- Temperature of "0", detect and partially blocked, evacuate system
blown air is not cold. repair leaks, vac- needle on low pres- and recharge.
uum system and sure side slowly
recharge. indicates a vacuum.
72-61
When the moisture has entered into the cooling When the compression in compressor is defec-
circuit. tive.

392~588 kPa 686~981 kPa
Abnormal status 686~981 kPa
(4~6 kgf/cm2) (7~10 kgf/cm2)
Vacuum (7~10 kgf/cm2)
(57~85 psi) (100~144 psi)
(100~144 psi)
Normal status
215~275 kPa 1,470~1,765 kPa
(2.2~2.8 kgf/cm2) (15~18 kgf/cm2)
(31~40 psi) (213~255 psi)
97ZV72095
Symptom Cause Inspection/action point

- Pressure on low Compressor is - Review 2nd symp-
97ZV72094 pressure side is defective. tom.
unusually high, and
pressure on high - If pressure in com-
Symptom Cause Inspection/action point pressure side is pressor is low, com-
unusually low. pressor will not build
- Air conditioner oper- Expansion valve - Inspect expansion much heat due to
ates normally for a is frozen due to valve, replace if - Shortly after air con- lack of pressure.
while after startup, entry of mois- needed. ditioner turns off,
but pressure on low ture. pressure becomes - Replace compres-
pressure side indi- - Replace receiver equal between high sor.
cates a vacuum dryer. pressure side and
value later. low pressure side. - After finishing work,
- After finishing work, evacuate system
evacuate system and recharge.
completely and
recharge.
72-62
When there is too much refrigerant or cooling When air has entered into the cooling circuit
in the condenser is insufficient
<Low pressure side> <High pressure side> <Low pressure side> <High pressure side>
245~343 kPa 1,961~2,452 kPa 245~294 kPa 1,961~2,452 kPa
(2.5~3.5 kgf/cm2) (20~25 kgf/cm2) (2.5~3.0 kgf/cm2) (20~25 kgf/cm2)
(35~50 psi) (284~355 psi) (35~43 psi) (284~355 psi)
97ZV72096 97ZV72097
Symptom Cause Inspection/action point Symptom Cause Inspection/action point

- Pressure is high on - Refrigerant - Check and correct - Pressure is high on Air has entered - Refrigerant is bad.
both low pressure quantity is refrigerant charge both low pressure system.
side and high pres- too much. pressure. side and high pres-
sure side. sure side.
- Plugged or - Inspect and repair
- Even when engine bent con- condenser fins. - Low pressure pip- - Evacuate system
rpm’s (min-1) are denser fins. ing is not cold. completely.
reduced, gas bub- - Repair or replace
bles cannot be seen - Bad fan fan or fan motor - Gas bubbles go - Replace refrigerant.
at all in sight glass. motor or fan through sight glass.
blade. - Inspect and repair
- Air in cab does not evaporator fins.
become cool - Heat trans-
enough. fer does not
occur in
evaporator
has plugged
fins
72-63
When the expansion valve is opened too much

294~392 kPa 1,961~2,452 kPa
(3.0~4.0 kgf/cm2) (20~25 kgf/cm2)
(43~57 psi) (284~355 psi)
97ZV72098
Symptom Cause Inspection/action point

- Pressure is high on Expansion valve - Temperature sens-
both low pressure is defective. ing rod may be
side and high pres- sticking.
sure side.
- Inspect expansion
- Condensation forms valve. Check temp
on low pressure in and out of valve
side pipes. to determine if it is
operating correctly.
Thermal expansion valve
To and from evaporator Diaphram
Spring
Temperature sensing
Needle valve Compressor return

From receiver dryer
97ZV72049
72-64
MEMO
73-1
50ZV Check & Adjustment Operator Station Group

Operator Station Group
73-2
Air Conditioner
Air Conditioner
Adjustment of lubricating oil

quantity when components of air WARNING
conditioner are replaced In order to protect the environment, do not release
refrigerant to atmosphere when removing compo-
nents from air conditioner system. It not illegal to do
so.
IMPORTANT
- When replacing components of the air conditioner,
if the lubricant oil quantity is too small, the com-
pressor may seize. And if the lubricating oil quan-
tity is too much, the cooling ability may lessen.
Use the correct amount of compressor lube oil.
- When connecting a joint, apply compressor oil
(ND-OIL 8) on the O ring before tightening (Fig. 1).
Fig. 1
97ZV73002 - If the compressor oil (ND-OIL 18) is applied to
paint, paint may peel or otherwise be damaged. If it
gets on a painted surface, quickly wipe it off.
- Tighten the piping, etc. at the recommended
torque.
Tightening torque table
Connection Tightening torque

Pipe size or bolt size
area N-m (kgf-cm) (lb-ft)
ø8 pipe 14.7 (150) (7)
Nut type
1/2 pipe 24.5 (250) (18)
(Fig. 2)
Fig. 2
97ZV73003 5/8 pipe 34.3 (350) (25)
M6 bolt in receiver (4T) 6.9 (70) (5)

Block joint
(Fig. 3) Any M6 bolt other than
11.8 (120) (9)
above (6T)
Fig. 3 97ZV73004
73-3
Air Conditioner
When the compressor is replaced Torque values
New compressor Old compressor to be replaced

Compressor mounting bolt
29 N-m (3.0 kgf-m) (22 lb-ft)
Hose block joint on high pressure side

12 N-m (1.2 kgf-m) (9 lb-ft)
Hose block joint on low pressure side

12 N-m (1.2 kgf-m) (9 lb-ft)
Oil quantity Example

remaining (B)
inside circuit Suppose that the oil quantity (A) removed from the com-
A A pressor to be replaced is 100 cm3. See figure 1.
Fig. 1 Oil quantity remaining inside circuit (B)

97ZV73005
= 180 cm3 - (100 + 20) = 60 cm3
Remove 60 cm3 from the new compressor to avoid

To avoid overloading the circuit;
overloading the circuit.
1. Remove the oil from the removed (old) compressor,
measure and record the oil quantity. (Approxi-
mately 20 cm3 (0.7 oz) of oil cannot be removed,
and remains inside the compressor.)............. A cm3
2. The compressor can hold about 180 cm3 (6.1 oz; or

0.76 cup) of oil. Determine the system’s remaining
oil quantity using the following equation.
Oil quantity remaining inside circuit is:
= 180 cm3 - (Oil quantity A discharged; see fig. 1.
from removed compressor + 20 cm3)
3. Drain as much oil from the compressor as the

quantity remaining inside the refrigerant circuit.
When finished, mount the new compressor.
Compressor lubricating oil

ND-OIL 8 (Nihon Denso oil 8; Polyalkalene glycol
(PAG) oil)
IMPORTANT
- Oil (180 cm3; or 0.76 cup) required for the cooling
circuit is sealed inside a new compressor.
Prior to replacing the compressor, excess oil
should be drained from the new compressor.
- The compressor oil can come to absorb moisture.
Seal the compressor immediately after adjusting
the oil quantity with a plastic cap.
- Never use ester based oil. Use only PAG oil.
73-4
Air Conditioner
When the evaporator is replaced When the condenser is replaced

Condenser
IN
1
OUT
Evaporator
2 50ZVA73002
Quantity of lubricating oil lost by replacement of con-

Expansion valve
denser is approximately 40 cm3 (1.35 oz).
When replacing the condenser core, add 40 cm3 (1.35

oz) of compressor oil (ND-OIL 8) to a new condenser.
: (1): 25 N-m (2.5 kgf-m)

: (2): 15 N-m (1.5 kgf-m)
When the receiver dryer is replaced
50ZVA73001
1
Quantity of lubricating oil lost by replacement of evapo-

rator core is approximately 40 cm3 (1.35 oz). 2
Tube accessory
3
When replacing the evaporator, add 40 cm of compres-
sor oil (ND-OIL 8) to a new evaporator.
Receiver dryer
: (1): 12 N-m (1.2 kgf-m)
50ZVA73003
Quantity of lubricating oil lost by replacement of receiver

dryer is approximately 20 cm3 (0.7 oz).
The amount of oil loss by replacement of the receiver

dryer is within the allowable range, and adding oil is not
needed if this is the first replacement of the condenser
core.
At the next time the dryer is replaced and from then on,
add 20 cm3 (0.7 oz) of compressor oil (ND-OIL 8) to a
new receiver dryer.
: (1): 7 N-m (0.7 kgf-m)

: (2): 15 N-m (1.5 kgf-m)
73-5
Air Conditioner
Water valve and air mix damper Water valve adjustment

adjustment
1. Set the temperature control switch on the control
panel to the lowest temperature.
Link rod B
Supporting
(between damper
2. Confirm that the water valve is completely closed.
Air mix damper B point B Unless that the water valve is closed completely,
A and B)
remove clamp A link stopper and adjust the link rod
A position.
Evaporator
ate
r
Blower
He Fan motor
Link rod A
(for water valve)
Air mix damper B adjustment
Supporting point Heater
radiator
core 1. Confirm that the air mix damper B closes the heater
Water valve radiator core completely.
Supporting
selection
point A Water valve
servo motor 2. Remove clamp B link stopper and adjust the link
Air mix damper A
rod B position, unless that the air mix damper B
Link • damper position at lowest ventilation temperature closes the heater radiator core completely.
50ZVA73004
Air mix damper B

Clamp A
Link rod A
Water valve
Link rod B
Water valve
Clamp B
servo motor
Air mix damper A
Water valve • Air mix damper link
60ZV73003J
73-6
Air Conditioner
Adjustment of air gap (between 1. Remove the front cover of the magnetic clutch.
hub and rotor) in compressor 2. Measure dimension A between rotor end face and
magnetic clutch hub end face while magnetic clutch is "OFF".
3. Apply the battery voltage directly on the connector

of the magnetic clutch, and measure the size of B in
the same way as step 2 above. Note the difference.
Position while magnetic
clutch is OFF Reference plane Standard (normal dimension) of air gap (A - B)
0.50±0.15 mm (0.020±0.006 in)
Air gap
0.50±0.15 mm (0.020±0.006 in)
A (OFF status) If the obtained value does not agree with the crite-
Position while magnetic ria, loosen the head bolt, remove the hub, and
clutch is ON
adjust the air gap by adjusting the thickness of the
B (ON status) washer plate between the hub and the shaft.
Hub
Head bolt
Washer plate
Rotor
95ZVE73002
WARNING
Shut off the engine to do this procedure.
If you try to adjust air gap while engine is "ON", a

serious accidents would occur.
Turn starter switch "OFF", stop rotation of engine tag
out unit, pull out starter key, then start adjustment.
Use a "Do Not Start" tag on the machine when perform-

ing this work.
73-7
Air Conditioner
Compressor V-belt adjustment
Front
L.H R.H
10
1
8
3
4 6
2 7
Crank shaft center 9 8

5
50ZVA73005
1. Compressor Belt adjustment value

2. V-belt
3. Pulley
4. Lock nut
5. Adjusting bolt
6. Shaft
m
7. Bracket
8~10m
8. Bolt
9. Bolt
10. Bolt
Loosen lock nut (4) and turn adjusting bolt clockwise or

counter-clockwise to adjust the V-belt tension. After the
adjustment, tighten lock nut (4).
50ZVA73006
: Tightening torque
Bolt (4): 31.0 N-m (3.10 kgf-m)
Bolt (8) (9): 53.0 N-m (5.40 kgf-m)
Bolt (10): 27.9 N-m (2.85 kgf-m)
73-8
Air Conditioner
Parts to be replaced periodically Receiver dryer
Air filters Replacement

Once/3 years
Air filter for outside air
Cleaning WARNING
Once/2 weeks When replacing the receiver dryer, do not release the
refrigerant into the atmosphere.
However, if the operating environment is severe (with
much sand, dust, etc.) and the air filter is easily clogged,
clean it more frequently.
In cleaning, blow the compressed air of 196~294 kPa
(2~3 kgf/cm2) mainly from the inside of the filter.
Replacement
Once/year
When the air quantity is so small as to hinder air condi-

tioning even after cleaning, or when the air filter has
been cleaned 20 times, replace it.
Air filters for inside air
Cleaning
Once/1 month
However, if the air filters are easily clogged, clean them

more frequently.
In cleaning, blow the compressed air of 196~294 kPa
(2~3 kgf/cm2) mainly from the inside of the filters.
Replacement
Once/3 years
When the air quantity is so small as to hinder air condi-

tioning even after cleaning, or when the air filters have
been cleaned 6 times, replace them.
INDEX
3rd speed clutch ...............................................................32-8 Brake Oil Reservoir ........................................................ 52-15
Brake oil reservoir specifications .................................... 52-15
Brake Units Layout ........................................................... 52-2
A
Braking ............................................................................. 52-6
Accelerator pedal ..............................................................22-4
Braking in case of one brake system failing ..................... 52-7
Accumulator ....................................................................32-23
Braking in case of pump failure ........................................ 52-7
Accumulator for 1st speed clutch ....................................32-23
Bucket cylinder ............................................................... 42-17
Adjusting brake pedal and switch .....................................53-9
Bucket detent ................................................................. 62-29
Adjusting left brake pedal ...............................................53-10
Bucket positioner ............................................................ 62-29
Adjusting right brake pedal ...............................................53-9
Bucket positioner electrical circuit check .......................... 63-6
Adjusting set pressure ........................................ 42-25, 42-27
Bucket spool operation ................................................... 42-29
Adjusting shim (#5) ...........................................................13-4
Adjusting switch ..............................................................53-11
Adjusting tooth contact .....................................................23-7 C
Adjustment ........................................................................13-3 Cabin (OPT) ..................................................................... 72-2
Adjustment of air gap (between hub and rotor) Cabin connection diagram ................................................ 72-3
in compressor magnetic clutch ......................................73-6 Caution for diode check method ..................................... 62-39
Adjustment of lubricating oil quantity Cautions ......................................................................... 00-20
when components of air conditioner are replaced .........73-2 Cautions on Hydraulic Parts Replacement ....................... 42-3
Adjustment procedure .......................................................53-7 Cautions on Safety ........................................................... 03-2
Air Conditioner ..................................................................73-2 Cautions Regarding Electric Circuit Check ...................... 63-2
Air Conditioner (OPT) .......................................................72-8 Cautions regarding parts removal .................................. 00-18
Air conditioner function of components ...........................72-19 Cautions regarding reassembly ...................................... 00-18
Air conditioner line ............................................................72-9 Cautions regarding welding repair service ..................... 00-20
Air conditioner mount ........................................................72-8 Center Pin ............................................................... 12-6, 13-4
Air conditioner specifications ............................................72-8 Charge of refrigerant ...................................................... 72-47
Air conditioner structure ..................................................72-10 Check valve ...................................................................... 42-6
Air conditioner unit .............................................. 72-10, 72-22 Clutch control oil pressure curve .................................... 32-19
Air damper unit ...............................................................72-11 Clutch cut-off circuit ........................................................ 62-28
Air duct unit .....................................................................72-12 Clutch cut-off solenoid valve .......................................... 32-25
Air filters ............................................................................73-8 Clutch cut-off solenoid valve operation .......................... 32-25
Air filters and air damper box ..........................................72-33 Clutch Oil Pressure .......................................................... 33-2
Air mix damper B adjustment ............................................73-5 Clutch Pack ...................................................................... 32-6
Alternator ........................................................................62-16 Clutch specifications ......................................................... 32-8
Alternator generation theory ...........................................62-17 Compressor (with magnetic clutch) ................................ 72-12
Alternator R terminal wire ...............................................62-12 Compressor and magnetic clutch ................................... 72-36
Auxiliary valves ...............................................................42-48 Compressor V-belt adjustment ......................................... 73-7
Axle ...................................................................................23-5 Condenser unit .................................................... 72-13, 72-39
Axle Assembly ...................................................... 22-11, 92-2 Condition ................................................................. 53-4, 53-6
Axle Support ...................................................................22-12 Contact between pinion and side gear ........................... 22-15
Continuity check mode ................................................... 62-39
Control unit .......................................................... 72-14, 72-19
B
Control Valve .................................................................. 32-15
Back-up Light Switch Circuit ...........................................62-36
Control valve .................................................................. 32-17
Battery relay ....................................................................62-11
Coolant ........................................................................... 00-10
Battery relay operation ....................................................62-11
Coolant specification ...................................................... 00-10
Before shifting to 1st speed ............................................32-23
Cooling circuit ................................................................. 72-18
Before the shift lever is moved
Cushion Valve ................................................................ 42-51
(travelling or stop condition) ........................................32-20
Cushion valve operation ................................................. 42-52
Belt adjustment value .......................................................73-7
Cushion valve specifications .......................................... 42-52
Bolt tightening torque ......................................................00-13
Cylinder natural drift ....................................................... 43-10
Boom cylinder .................................................................42-16
Cylinders .......................................................................... 42-4
Boom kick-out unit (optional) ..........................................62-29
Boom spool operation .....................................................42-31
Brake Circuit ........................................................... 52-3, 92-5 D
Brake circuit air bleeding procedure ...............................52-10 Difference in gear shapes .............................................. 22-15
Brake Control ........................................................ 52-13, 53-9 Differential Gear ............................................................. 22-14
Brake lining abrasion check ..............................................53-8 Differential gear ................................................................ 23-6
Diode .............................................................................. 62-38 Fuse ..................................................................................62-6
Diode check method ...................................................... 62-39 Fuse box ...........................................................................62-6
Diode check mode ......................................................... 62-39 Fusible link ........................................................................ 62-7
Diode inspection ............................................................. 62-31
Diode unit ....................................................................... 62-12
G
Diode Unit Circuit ........................................................... 62-31
Gauge circuit ..................................................................62-21
Diode unit circuit check .................................................... 63-7
Gauge circuit electrical circuit check ................................63-8
Directional control valve ................................................... 42-6
Gauge port ...............................................................43-2, 43-6
Disconnecting or reinstalling connector ........................... 63-2
Gear arrangement ............................................................32-4
During shifting to 1st speed (A) ...................................... 32-23
Gear pump specifications .................................................32-3
During shifting to 1st speed (B) ...................................... 32-24
Dust seal .......................................................................... 12-7
H
E Hexagon bolt ..................................................................00-13
High pressure holding .....................................................32-20
Electrical Cable Color Codes ........................................... 62-3
Horn Circuit .....................................................................62-37
Electrical Circuit Check .................................................... 63-5
Horn relay .......................................................................62-37
Electrical Circuit Diagram (Cabin Air Conditioner) ......... 92-14
Hose band tightening torque .......................................... 00-17
Electrical Circuit Symbols ................................................. 62-4
How to attach the probes of the circuit tester ...................63-4
Electrical Connection Diagram ......................................... 92-8
How to Use Electrical Wiring Diagram ..............................62-2
Electrical Detent Circuit .................................................. 62-29
How to Use Manual ..........................................................00-2
Electrical Equipment Layout ........................................... 92-10
How to wind a seal tape .................................................00-19
Electrical Wiring Diagram (1/2) ........................................ 92-6
Hydraulic Circuit Diagram ...............................................32-12
Electrical Wiring Diagram (2/2) ........................................ 92-7
Hydraulic Circuit Symbols .................................................42-4
Electrical Wiring Diagram (CAB) ...................................... 92-9
Hydraulic Cylinder ...............................................42-16, 43-10
Electrical Wiring Diagram (Cabin Air Conditioner) ......... 92-15
Hydraulic cylinder specifications ..................................... 42-18
Emergency check valve ................................................. 42-50
Hydraulic lines ..................................................................42-4
Engine .............................................................................. 23-2
Hydraulic oil level check .................................................42-12
Engine / Transmission ...................................................... 22-3
Hydraulic Pump ..............................................................42-13
Engine / transmission mount ............................................ 22-3
Hydraulic pump bushing lubrication ................................42-15
Engine Start Circuit .......................................................... 62-8
Hydraulic pump oil amount and steering force ...............42-46
Engine start circuit diagram .............................................. 62-8
Hydraulic pump principle ................................................ 42-14
Engine Stop Circuit ........................................................ 62-18
Hydraulic pump specifications ........................................42-13
Hydraulic pump wear plate .............................................42-15
F Hydraulic Servo Master ....................................................53-2
Flanged hexagon bolt ..................................................... 00-16 Hydraulic Servo Master Cylinder ......................................52-4
Floor board ....................................................................... 12-5 Hydraulic servo master cylinder operation .......................52-6
Floor board mount ............................................................ 12-5 Hydraulic servo master cylinder specifications .................52-5
Flow control valve ............................................................ 42-5 Hydraulic servo master performance inspection ..............53-2
Flushing Hydraulic Circuit ................................................ 42-2 Hydraulic System Diagram .............................................32-11
Forward ............................................................................ 32-9 Hydraulic System Operation .............................................42-8
Forward 1st speed ........................................................... 32-9 Hydraulic system operation outline ...................................42-8
Forward 2nd speed .......................................................... 32-9 Hydraulic Tank ................................................................42-10
Forward 3rd speed ......................................................... 32-10 Hydraulic tank breather valve (tank cap) ........................42-11
Forward and 2nd speed clutch ......................................... 32-6 Hydraulic tank specifications .......................................... 42-12
Forward/Reverse selection ............................................ 32-14
From cooler to lubrication circuit .................................... 32-13
I
From the torque converter pump to torque converter
Inching switch ................................................................. 62-28
.................................................................................... 32-13
Initial oil feeding to clutch piston chamber ......................32-21
From torque converter to cooling circuit ......................... 32-13
Inlet check valve .............................................................42-50
Front Chassis ................................................................... 12-2
Inspection and maintenance table ....................................00-5
Front differential – Transmission ...................................... 22-9
Install position ................................................................... 23-2
Fuel control ...................................................................... 22-5
Installing bearing cover (#3) .............................................13-4
Fuel level sensor ............................................................ 62-23
Instrument panel .............................................................62-19
Fuel solenoid .................................................................. 62-18
Instrument Panel and Switch .......................................... 62-19
Fuel solenoid relay ......................................................... 62-18
Instrument panel rear surface .........................................62-20
Fuel solenoid specification ............................................. 62-18
Items to be monitored and operation condition .............. 62-25
Fuel tank .......................................................................... 12-4
Function of cooling mechanism ...................................... 72-15
Function of T.P.D ........................................................... 22-15
L Orbit rotor operation principle ......................................... 42-47
Layout of Hydraulic Units ..................................................42-9 Orbitrol® .......................................................................... 42-41
Layout of main components ..............................................00-4 Orbitrol® construction ..................................................... 42-41
Liner ..................................................................................13-2 Orbitrol® feed-back mechanism operation ..................... 42-45
Linkage Pin .......................................................................13-2 Orbitrol® operation .......................................................... 42-43
Liquid gasket and screw lock agent ................................00-18 Orbitrol® specification ..................................................... 42-42
Loading circuit relief valve setting pressures ....................43-2 Outline .............................................................................. 00-4
Loading linkage .................................................................12-2 Overload relief valve and make-up valve ....................... 42-49
Loading linkage pin ...........................................................12-3 Overload relief valve operation ....................................... 42-26
Loading System ..............................................................42-20
Loading system .................................................................42-8 P
Loading/Steering Circuit Relief Valve ...............................43-2 Parking Brake ........................................................ 52-12, 53-6
Loading/Steering Hydraulic Line .......................................92-4 Parking brake cable adjustment ..................................... 53-11
Lower center pin ...............................................................12-6 Parking brake clearance adjustment ................................ 53-7
Lubrication chart .............................................................00-11 Parking brake linkage ..................................................... 52-14
Parking brake performance check .................................... 53-6
M Parking Switch ................................................................ 62-35
Magnet switch .................................................................62-14 Parts to be replaced periodically ...................................... 73-8
Main relief valve operation ..............................................42-24 Performance diagram ....................................................... 52-5
Make-up valve operation ................................................42-28 Power flow path ................................................................ 32-2
Measurement instrument ...................................... 23-2, 43-10 Power Flow Path in the Transmission .............................. 32-9
Measurement instruments ...................................... 43-2, 43-6 Power Generating/Charging Circuit ................................ 62-16
Measurement procedure .................................................43-10 Power Line ....................................................................... 22-2
Measuring engine oil pressure ..........................................23-2 Pressure control valve ...................................................... 42-5
Measuring engine speed ..................................................23-2 Pressure increase .......................................................... 32-22
Measuring loading circuit main relief pressure .................43-3 Pressure relief valve ....................................................... 72-44
Measuring loading circuit overload relief pressure ...........43-4 Pressure switches .......................................................... 72-43
Measuring steering circuit main relief pressure ................43-7 Principle of cooling ......................................................... 72-15
Measuring steering circuit overload relief pressure ..........43-8 Priority Valve .................................................................. 42-37
Miscellaneous hydraulic symbols .....................................42-7 Priority valve operation ................................................... 42-38
Modulation Mechanism ...................................................32-19 Priority valve specifications ............................................ 42-37
Monitoring system ...........................................................62-24 Propeller Shaft ......................................................... 22-8, 23-3
Multiple Control Valve .....................................................42-21 Propeller shaft phase ....................................................... 23-3
Multiple control valve boom spool ...................................42-31 Proximity switch .............................................................. 62-30
Multiple control valve bucket spool .................................42-29 Pumps & motors ............................................................... 42-4
Multiple control valve main relief valve ...........................42-24 Purpose of flushing ........................................................... 42-2
Multiple control valve make-up valve ..............................42-28
Multiple control valve overload relief valve R
(with make-up function) ...............................................42-26 Radiator ............................................................................ 22-6
Multiple control valve specifications ................................42-23 Radiator mount ................................................................. 22-7
Rear Chassis .................................................................... 12-4
N Receiver dryer ....................................................... 72-41, 73-8
Neutral ............................................................................42-43 Reclining seat adjustment ................................................ 72-6
Neutral starter ...................................................................62-9 Recommended lubricants ................................................. 00-8
Neutral switch .................................................................62-13 Recommended mixture of antifreeze ............................. 00-10
Neutral switch operation .................................................62-13 Refrigerant ...................................................................... 72-16
Neutral switch specifications ...........................................62-13 Refrigerant characteristics .............................................. 72-17
No braking (when the brake is released) ..........................52-6 Refrigerant charging procedure ...................................... 72-53
Refrigerant charging tools .............................................. 72-50
Refrigerant hose ............................................................. 72-46
O Relay A ........................................................................... 72-45
Oil Flow ...........................................................................32-13 Relay B ........................................................................... 72-45
Oil flow in the torque converter line ................................32-13 Relief valve operation ..................................................... 42-40
Oil flow to the clutch ........................................................32-13 Resistance check mode ................................................. 62-40
Oil port layout ..................................................................32-17 Return Filter .................................................................... 42-19
Operation methods ...........................................................42-5 Return filter specifications .............................................. 42-19
Operation monitor lamps ................................................62-26 Reverse .......................................................................... 32-10
Operation of T.P.D ..........................................................22-16 Reverse 1st speed ......................................................... 32-10
Operator Seat ...................................................................72-6 Reverse 2nd and 3rd speeds ......................................... 32-10
Reverse and 1st speed clutch .......................................... 32-7 Troubleshooting using the gauge manifold .....................72-59
Rotor part ....................................................................... 42-42 Turn ................................................................................42-44
S U
Safety precautions ........................................................... 00-2 Upper center pin ...............................................................12-6
Screw lock agent application procedure ........................ 00-19
Seat assembly .................................................................. 72-6
V
Second propeller shaft alignment ..................................... 23-3
Valve Control .........................................................42-34, 43-9
Second propeller shaft assembly ..................................... 22-9
Valve location ................................................................... 32-5
Sensor Mount ................................................................... 62-5
Valve part .......................................................................42-41
Service Brake .......................................................... 52-8, 53-4
Viscous mount ..................................................................12-5
Service brake friction plate ............................................... 52-9
Voltage relay ...................................................................62-15
Service brake friction plate wear measurement ............... 53-5
Service brake linkage ..................................................... 52-13
Service brake operation ................................................... 52-8 W
Service brake performance check .................................... 53-4 Water valve adjustment ....................................................73-5
Service brake steel plate .................................................. 52-9 Water valve and air mix damper adjustment ....................73-5
Shift Lever ...................................................................... 32-14 Weight of main components ...........................................00-12
Shift lever forward/reverse (F/R) position ......................... 62-9 When shifting to 1st speed is completed ........................32-24
Shift lever neutral (N) position .......................................... 62-9 When the brake is in the hold (balanced) position ............52-7
Sight glass ...................................................................... 72-43 When the compressor is replaced ....................................73-3
Solenoid Valve ............................................................... 32-25 When the condenser is replaced ......................................73-4
Solenoid valve ................................................................ 62-28 When the evaporator is replaced ......................................73-4
Solenoid valve operation table ....................................... 62-28 When the pedal is depressed a second time ....................52-7
Solenoid valve specification ........................................... 62-28 When the shift lever is moved (1) ...................................32-21
Speed selection .............................................................. 32-14 When the shift lever is moved (2) ...................................32-22
Standard measurement value ........................ 23-2, 53-4, 53-6 Wiper motor ......................................................................72-4
Standard measurement value (mm/min)(in/min) ............ 43-10 Work procedure ..............................................................72-48
Standard measurement value MPa (kgf/cm2) (psi)
............................................................................. 43-3, 43-6
Starter switch ................................................................. 62-10
Steering circuit relief valve setting pressures ................... 43-6
Steering cylinder ............................................................ 42-17
Steering speed and flow rate control .............................. 42-46
Steering System ............................................................. 42-35
Steering system ............................................................... 42-8
Stop Light Switch Circuit ................................................ 62-34
Sub-plate ........................................................................ 32-18
Surge voltage and surge suppression diodes ................ 62-41
Suspension adjustment .................................................... 72-7
Suspension assembly ...................................................... 72-7
Symbols ........................................................................... 00-3
System diagram ............................................................. 32-16
T
Third propeller shaft assembly ....................................... 22-10
Tightening torque ............................................................. 23-4
To forward and reverse clutches .................................... 32-13
To speed clutches .......................................................... 32-13
Torque Converter ............................................................. 32-2
Torque Converter and Transmission ................................ 92-3
Torque Converter Gear Pump .......................................... 32-3
Torque Converter structure .............................................. 32-2
Torque multiplication ........................................................ 32-2
Transmission .................................................................... 32-4
Transmission – Rear differential .................................... 22-10
Transmission control circuit check ................................... 63-5
Transmission cut off (Declutch) switch ........................... 62-27
Transmission Electrical Circuit ....................................... 62-27
MEMO
Maintenance Log
Date Machine hours Service performed

Notes

50ZV (Ex F&S) A4 (93205 00151)

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50ZV (Ex F&S) A4 (93205 00151)

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Copyright:

Available Formats

93205-00151

Orbitrol® .......................................................................................................................................................... 42-41

Orbitrol® construction ................................................................................................................................ 42-41

Orbitrol® operation .................................................................................................................................... 42-43

Orbitrol® feed-back mechanism operation ................................................................................................ 42-45

50ZV General Information

How to Use Manual

- Place the machine on level and solid ground, and

- Remove the cable from the battery before starting

- Be sure to release the internal pressure before you

- Be sure to apply the articulation stopper before start-

- While supporting the bottom of the chassis using a

- When the boom or bucket is raised or when a unit is

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

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

- Just after stopping operation, be careful not to

Symbol Item Description

Shows the condition or procedure that will be useful

Shows the weight of a part or unit. The weight

Tightening Shows the tightening torque of a section that should

Shows the type of coating or adhesive and the coat-

Shows the oil or water drain port and the drain

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

Layout of main components

1. Engine assembly (Cummins 4B4·5T) 9. Radiator

Inspection and maintenance table

: First time replacement or cleaning only

Check Engine Oil Level

Check Engine Coolant Level

Check Warning Lamps

Check Exhaust Gas

Drain Water and Sediment from Fuel Filter

Check Fuel Level

Check Drive Belt

Check Air Intake System

Check Cooling Fan

Drain Water and Sediment from Fuel Tank

Replace Fuel Filter Cartridge

Clean Fuel Prefilter

Inspect Automatic Belt Tensioner Pulley

Clean Fuel Tank

Check and Adjust Valve Lash Clearance

Clean or Replace Air Cleaner Element

Clean Radiator Fins

Replace Coolant Every 2 years or 3000 hours

Check Transmission Oil Level

: First time replacement or cleaning only

Check Tire for Damage, Air and Tread Depth

Check Tire Air Pressure

Greasing (Axle support)

Check Differential Gear Oil

Greasing (3rd Propeller Shaft)

Check Tightness of Wheel Bolts

Replace Differential Gear Oil

Check Steering Wheel Operation

Check Brake Oil Level

Check Service Brake Operation

Check Parking Brake Operation

Check Service Brake Disk Wear

Overhaul Brake Master Cylinder

Check Hydraulic Oil Level

Replace Hydraulic Oil Return Filter

Replace Bucket Teeth (option)