KCM WHEEL LOADER 115ZV-2 SHOP MANUAL 93216-00462 PDF

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KCM WHEEL LOADER 115ZV-2 SHOP MANUAL 93216-00462 – PDF DOWNLOAD

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KCM WHEEL LOADER 115ZV-2 SHOP MANUAL 93216-00462 – PDF DOWNLOAD

Language :English
Pages :586
Downloadable : Yes
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KCM WHEEL LOADER 115ZV-2 SHOP MANUAL 93216-00462 – PDF DOWNLOAD

General Information
Standard Measurement Values for
Performance Check
Function & Structure
Check & Adjustment
Powered by CUMMINS QSK19 Engine
Serial No. 11C5-9001 and up

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.

• 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.

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.

TABLE OF CONTENTS:

KCM WHEEL LOADER 115ZV-2 SHOP MANUAL 93216-00462 – PDF DOWNLOAD

General Information
Standard Measurement Values for
Performance Check
Function & Structure
Check & Adjustment
Powered by CUMMINS QSK19 Engine
Serial No. 11C5-9001 and up

Foreword 2
Safety Symbols 3
CONTENTS 4
00 General Information 16
How to Use Manual 17
Safety precautions 17
Symbols 18
Outline 19
Layout of main components 19
Inspection and maintenance table 20
Recommended lubricants 23
Coolant 24
Coolant specification 24
Recommended mixture of antifreeze 24
Lubrication chart 25
Weight of main components 26
Bolt tightening torque 27
Hexagon bolt 27
Flanged hexagon bolt 30
Hose band tightening torque 31
Liquid gasket and screw lock agent 32
Cautions regarding parts removal 32
Cautions regarding reassembly 32
Screw lock agent application procedure 33
How to wind a seal tape 33
Cautions regarding welding repair service 34
03 Measurement for Performance Check 36
Cautions on Safety 37
Standard Measurement Values for Performance Check 38
12 Function & Structure Chassis Group 42
Front Chassis 43
Loading linkage 43
Loading linkage pin 45
Rear Chassis 46
Fuel tank 46
Floor board mount 47
Floor board 47
Viscous mount 47
Center Pin 48
Upper center pin 48
Lower center pin 49
Dust seal 50
13 Check & Adjustment Chassis Group 52
Linkage Pin 53
Liner 53
Bucket hinge pin section (#1) 54
How to assemble 54
Bucket link pin section (#2) 55
How to assemble 55
Adjustment 56
Center Pin 57
Adjusting shim 57
Installing bearing cover 57
Installing bearing outer ring 58
22 Function & Structure Power Group 60
Power Line 61
Engine / Transmission 62
Engine / transmission mount 62
Radiator (S/N 9001~9050) 63
Radiator mount 64
Radiator (S/N 9051~) 65
Propeller Shaft 67
First propeller shaft assembly 68
Transmission – Torque converter 68
Second propeller shaft assembly 69
Front differential – Transmission 69
Third propeller shaft assembly 70
Transmission – Rear differential 70
Axle Assembly 71
Axle Support 73
Differential Gear 75
Conventional type 75
Function of differential gear 78
Power transmission 78
Operation of differential gear 78
Straight 78
Turn 79
Limited Slip Differential (option) (S/N 9054~) 80
LSD structure 80
LSD function 81
LSD operation 81
23 Check & Adjustment Power Group 82
Engine 83
Measuring engine speed 83
Measuring engine oil pressure 83
Propeller Shaft 84
Propeller shaft phase 84
Second propeller shaft alignment 84
Propeller shaft tightening torque 85
Axle 86
Axle nut tightening procedure 86
Differential gear adjustment procedure 87
Preload adjustment 88
Bearing installation 89
Oil seal installation 89
Adjusting tooth contact 90
32 Function & Structure Torque Converter and Transmission Group 92
Torque Converter 93
Torque converter structure 94
Power flow path 94
Torque multiplication 94
Torque Converter (Lock-up) (Option) 95
Lock-up clutch structure 96
Lock-up clutch function (only forward) 96
Automatic shift (with lock-up solenoid) 97
Torque Converter Gear Pump 98
Gear pump specifications 98
Transmission 99
Clutch combination100
Planetary gear100
Shift lever position100
Downshift button operation100
Gear train and number of teeth101
Clutch specifications101
Friction plate: mm (in)102
Steel plate: mm (in)103
Clutch Pack105
Power Flow Path in the Transmission106
Forward 1st speed power flow path106
Forward 2nd speed power flow path107
Forward 3rd speed power flow path107
Forward 4th speed power flow path108
Reverse 1st speed power flow path108
Reverse 2nd speed power flow path109
Reverse 3rd speed power flow path109
Hydraulic System Diagram110
Hydraulic Circuit Diagram111
Oil Flow113
Oil flow in the torque converter line113
From torque converter gear pump to torque converter113
From torque converter to cooling circuit113
From cooler to lubrication circuit113
Oil flow in the transmission line113
From torque converter gear pump to clutch solenoid valve assembly113
From clutch solenoid valve to clutch valve assembly113
From torque converter gear pump to lock- up clutch (option)113
From accumulator to clutch valve114
Limit switch114
From direct charge valve to clutch valve114
T/C and T/M Oil Circulation115
Modulator Valve Unit116
Interior schematic (simple explanation)118
Modulation Mechanism119
Modulator valve function119
Modulator valve operation120
Control Valve Assembly122
Clutch solenoid valve assembly124
For high, low, reverse and speed clutches126
Clutch valve assembly127
Accumulator assembly128
Accumulator structure128
Direct charge valve129
Lock-up clutch solenoid valve130
33 Check & Adjustment Torque Converter and Transmission Group132
Clutch Oil Pressure and Time Lag133
Measuring clutch oil pressure133
Clutch oil pressure measurement procedure134
Time lag measurement procedure135
42 Function & Structure Hydraulic Group136
Flushing Hydraulic Circuit137
Purpose of flushing137
Cautions on Hydraulic Parts Replacement138
Hydraulic Circuit Symbols139
Hydraulic lines139
Pumps & motors139
Cylinders139
Operation methods140
Pressure control valve140
Flow control valve140
Directional control valve141
Check valve141
Miscellaneous hydraulic symbols142
Hydraulic System Operation143
Hydraulic system operation outline143
Loading system143
Steering system143
Efficient loading system144
Fan motor system144
Ride control system (OPT)144
Layout of Hydraulic Units145
Hydraulic Tank146
Hydraulic Tank (S/N 9001~9150)146
Hydraulic tank breather valve (tank cap) (S/N 9001~9150)147
Hydraulic Tank (S/N 9151~)148
Hydraulic tank breather valve (tank cap) (S/N 9151~)149
Hydraulic tank specifications150
Hydraulic oil level check151
Hydraulic Pump152
Loading and pilot and brake pump152
Pump specifications152
Steering pump153
Steering pump specifications153
Hydraulic pump principle154
Hydraulic pump wear plate155
Hydraulic pump bushing lubrication155
Hydraulic Cylinder156
Boom cylinder156
Bucket cylinder156
Steering cylinder157
Hydraulic cylinder specifications158
Loading System159
Reducing Valve (for Pilot Pressure)160
Pilot valve (S/N 9001~9100)161
Pilot valve function163
Pilot valve operation (modulated position)163
Pre-detent and detent magnet solenoid165
Pilot valve (S/N 9101~9105)166
Pilot valve function168
Pilot valve operation (modulated position)168
Pre-detent and detent magnet solenoid170
Pilot valve (S/N 9106~)171
Pilot valve function173
Pilot valve operation (modulated position)173
Pre-detent and detent magnet solenoid175
Multiple Control Valve (KML35A/2T103)176
Multiple control valve specifications177
Multiple control valve main relief valve178
Main relief valve operation178
Adjusting set pressure179
Multiple control valve overload relief valve (with make-up function)180
Overload relief valve operation180
Make-up valve operation181
Multiple control valve make-up valve181
Make-up valve operation181
Multiple control valve bucket spool182
Bucket spool operation182
Multiple control valve boom spool184
Boom spool operation184
Adapter (Orifice)187
Ride Control (OPT)188
Ride control hydraulic circuit188
Ride control function188
Ride control operation189
Preparation mode (ride control switch is OFF)189
Running mode (ride control switch is ON)190
Ride control valve assembly (Reducing valve circuit)191
Reducing valve192
Check valve192
Solenoid valve193
Ride control valve assembly (Accumulator circuit)194
Shuttle valve195
Solenoid valve195
Selector valve196
Accumulator (for ride control)197
Accumulator function197
Steering System198
Orbitrol®199
Orbitrol® structure199
Valve part199
Rotor part200
Orbitrol® specifications200
Orbitrol® operation201
Neutral201
Turn202
Orbitrol® feed-back mechanism operation203
Steering speed and flow rate control204
Hydraulic pump oil amount and steering force204
Orbit rotor operation principle205
Steering Valve (KVS32-A40/21)206
Steering valve operation208
Neutral position (steering spool in “Neutral”)208
Left turn position209
Steering spool variable throttle210
Steering valve flow control spool211
Steering valve main relief valve212
When the pressure is at the preset value or less212
When the pressure exceeds the preset value213
Steering valve overload relief valve214
Overload relief valve operation215
Make-up valve operation215
Steering pilot circuit and its operation216
Flow amplifier notch and pilot orifice217
Stop Valve218
Stop valve function219
Stop valve operation219
Reducing Valve (for Orbitrol®)220
Steering Line Filter221
Efficient Loading System222
Efficient loading system outline222
The operation condition of ELS222
Mounting of the ELS valve223
Mounting of the variable kickout sensor224
Efficient loading system operation225
While the ELS is not operating225
While the ELS is operating225
Fan Motor System226
Mounting of fan motor226
Fan Motor Line227
Hydraulic circuit (fan motor normal rotation)229
Make-up valve229
Proportional relief valve (S/N 9001~9050)231
Proportional relief valve operation231
Proportional relief valve (S/N 9051~)233
Fan motor235
Reversing Fan Motor Line (OPT)238
Reversing fan motor function238
Reversing fan motor (OPT)239
Fan motor specifications239
Reversing fan control chart241
Hydraulic circuit (Reverse rotation)242
Secondary Steering243
Secondary steering circuit243
Secondary steering operation244
Secondary steering motor and pump245
43 Check & Adjustment Hydraulic Group246
Loading/Steering Circuit Relief Valve/Ride Control Circuit Reducing Valve (OPT)247
Loading circuit relief valve setting pressures247
Measuring loading circuit main relief pressure249
Measuring loading circuit overload relief pressure250
Measuring pilot circuit reducing valve pressure251
Ride control circuit reducing valve setting pressures (OPT)252
Measuring ride control circuit reducing pressure253
Steering circuit relief valve setting pressures254
Measuring steering circuit main relief pressure256
Measuring steering circuit overload relief pressure257
Measuring pilot circuit relief pressure (reducing pressure)258
Hydraulic Cylinder259
Cylinder natural drift259
Stop Valve261
Stop valve adjustment procedure261
52 Function & Structure Brake Group262
Brake System Outline263
Service brake263
Parking brake263
Adjustment of axle internal pressure263
Brake Units Layout264
Unloader Valve265
Unloader valve operation267
Valve Unit268
Accumulator low pressure sensor269
Accumulator270
Brake Valve271
Brake valve performance chart272
Brake valve outline273
While the valve is not operating273
Service Brake275
Service brake operation275
Service brake friction disc276
Service brake steel plate277
Service brake piston278
Service brake pedal stroke adjusting mechanism279
Tolerance ring280
Brake circuit air bleeding procedure281
Bleeding air from brake pipes and axle housing hubs282
Bleeding air from parking brake housing282
Parking Brake283
Parking brake operation286
Operation of parking brake286
Parking brake friction disc289
Parking brake steel plate289
Parking brake solenoid valve290
Solenoid valve operation290
Solenoid valve specifications290
Parking Brake Manual Release291
Brake Circuit Check Valve293
Auto Brake294
Auto brake circuit294
Auto brake operation set value294
Reducing valve (for Autobrake circuit)295
Solenoid valve (for Autobrake circuit)296
Solenoid specifications296
Pressure Sensor (for stop lamp and declutch)297
Pressure sensor (for declutch)297
Pressure sensor (for stop lamp)297
53 Check & Adjustment Brake Group300
Brake Circuit Oil Pressure301
Unloader valve setting pressure301
Unloader valve setting pressure measurement302
Brake valve oil pressure303
Brake valve oil pressure measurement303
Brake valve performance304
Service Brake305
Service brake performance check305
Service brake friction plate wear measurement306
Cautions on installing brake discs307
Parking Brake308
Parking brake performance check308
62 Function & Structure Electrical Group310
How to Use Electrical Wiring Diagram311
Utilisation des schémas des câblages électriques (FRANÇAIS)312
Verwendung des elektrischen Schaltplans (DEUTSCH)313
Modalità di utilizzo dello schema dei collegamenti elettrici (ITALIANO)314
Cómo utilizar un Diagrama de Alambrado Eléctrico (ESPAÑOL)315
Como Utilizar o Diagrama de Ligações Eléctricas (PORTUGUÊS)316
Electrical Cable Color Codes317
Electrical Circuit Symbols318
Sensor Mount319
Fuse320
Fuse box320
Fusible link321
Engine Start Circuit322
Engine start circuit diagram322
Neutral starter323
Shift lever neutral (N) position323
Shift lever forward/reverse (F/R) position323
Starter switch324
ECM safety features325
Battery relay325
Battery relay operation325
Alternator I terminal wire326
Diode unit326
Neutral relay327
Magnetic switch328
Voltage relay329
Power Generating/Charging Circuit330
Alternator330
ECM (Engine Controller)331
Function of ECM331
Connection diagram331
Monitor lamp test332
Failure diagnosis333
Engine diagnostic switch (option)333
Failure diagnostic chart334
Increment decrement switch (option)335
Quantum fault code information336
Accelerator pedal342
Accelerator pedal installation344
Transmission Control Circuit and Monitor Circuit345
Machine control unit (MCU)345
Connector346
MCU connection diagram (S/N 9001~9200)347
MCU connection diagram (S/N 9201~)349
Machine control unit (MCU) function351
Forward/reverse (F/R) shifting and speed change351
Automatic shift353
Automatic shift (with lock-up solenoid)354
Machine speed sensor355
Downshift button operation356
Modulation at clutch switching357
Modulator valve operation358
Adjustable declutch preset switch359
Back-up alarm360
Parking brake361
Auto brake363
Machine control unit (MCU) failure warning366
Secondary steering function (OPT)367
Monitoring system369
Items to be monitored and operation condition369
Operation monitor lamps371
Instrument Panel and Switch372
Instrument panel372
Instrument panel rear surface374
Gauge circuit376
Fuel gauge circuit378
MODM379
MODM function379
Monitor Changeover379
Changing display from one function to next380
Information Monitor382
Information monitor display382
Unit conversion and language selection385
Replacement Monitor386
Replacement time check386
Replacement interval set (timer reset)390
Replacement interval pop-up391
Display language392
Fault Log Monitor392
Fault log history check392
Selection of machine fault log and engine fault log393
Machine fault log navigation394
Engine fault log navigation394
Clear fault log394
Clear active fault log (error pop up) (S/N 9001~9006)395
Input/Output Monitor399
Input/Output monitor display399
Parameter Setting Monitor403
Parameter setting monitor display403
Parameter change411
Specification Setting Monitor412
Specification setting monitor display412
All setting reset415
Default position of specification setting monitor417
Electrical Detent Circuit418
Bucket leveler418
Proximity switch418
Detent solenoid419
Lift kickout & lower kickout420
Location420
Lift kickout420
Lower kickout420
Sensor assy421
Detent solenoid423
Preset height adjustment423
Diode424
Diode check method425
Caution for diode check method425
Continuity check mode425
Diode check mode425
Resistance check mode426
Surge voltage and surge suppression diodes427
72 Function & Structure Operator Station Group428
Cabin429
Glass431
1 Part number 32011-21690432
2 Part number 32011-21700432
3 Part number 32011-21500433
Wiper mount434
Front wiper434
Rear wiper434
Wiper motor435
Operator Seat437
Steering and Transmission Shift Lever438
Tilt case439
Column shaft440
Shift lever440
Air Conditioner441
Air conditioner components441
Air conditioner specifications (system performance)441
Denso air conditioner structure442
Cooling unit442
Heater and accessories444
Air distributor (hood & defroster selection box)444
Air compressor (with magnetic clutch)445
Condenser unit445
Control unit446
Function of cooling mechanism447
Principle of cooling447
Refrigerant448
Refrigerant characteristics449
Cooling circuit450
Electrical circuit451
Control schematic drawing451
Air conditioner functions of components452
Control panel452
Air conditioner unit459
Compressor and magnetic clutch468
Condenser unit471
Receiver dryer473
Sight glass475
Pressure switches475
Pressure relief valve477
Relay A478
Relay B478
Refrigerant hose479
Charge of refrigerant480
Work procedure481
Refrigerant charging tools483
Refrigerant charging procedure486
Troubleshooting using the gauge manifold492
Troubleshooting497
Air conditioner497
73 Check & Adjustment Operator Station Group506
Air Conditioner507
Adjustment of lubricating oil quantity when components of air conditioner are replaced507
When the compressor is replaced508
When the evaporator is replaced509
When the condenser is replaced509
Adjustment of air gap (between hub and rotor) in compressor magnetic clutch510
Compressor V-belt adjustment511
Belt adjustment procedure512
Belt adjustment value512
Parts to be replaced periodically513
Air filters513
Receiver dryer513
INDEX514
Maintenance Log521
Notes525
92 Drawing & Diagrams529
Axle Assembly530
Torque Converter and Transmission532
Hydraulic & Brake Circuit533
Brake Circuit534
Electrical Wiring Diagram (1/3) (S/N 9001~9006)535
Electrical Wiring Diagram (2/3) (S/N 9001~9006)536
Electrical Wiring Diagram (3/3) (S/N 9001~9006)537
Electrical Wiring Diagram (1/3) (S/N 9007~9050)538
Electrical Wiring Diagram (2/3) (S/N 9007~9050)539
Electrical Wiring Diagram (3/3) (S/N 9007~9050)540
Electrical Wiring Diagram (1/3) (S/N 9051~9100)541
Electrical Wiring Diagram (2/3) (S/N 9051~9100)542
Electrical Wiring Diagram (3/3) (S/N 9051~9100)543
Electrical Wiring Diagram (1/3) (S/N 9101~9200)544
Electrical Wiring Diagram (2/3) (S/N 9101~9200)545
Electrical Wiring Diagram (3/3) (S/N 9101~9200)546
Electrical Wiring Diagram (1/3) (S/N 9201~)547
Electrical Wiring Diagram (2/3) (S/N 9201~)548
Electrical Wiring Diagram (3/3) (S/N 9201~)549
Electrical Wiring Diagram550
Way of looking at connectors550
Electrical wiring diagram abbreviation chart552
Electrical Wiring Diagram (CAB)554
Electrical Wiring Diagram (Cabin Air Conditioner)556
Electrical Circuit Diagram (Cabin Air Conditioner)557
Equipment Operation Table (Cabin Air Conditioner)558
Electrical Connection Diagram (1/2) (S/N 9001~9050)559
Electrical Connection Diagram (2/2) (S/N 9001~9050)560
Electrical Connection Diagram (1/2) (S/N 9051~9100)561
Electrical Connection Diagram (2/2) (S/N 9051~9100)562
Electrical Connection Diagram (1/2) (S/N 9101~9200)563
Electrical Connection Diagram (2/2) (S/N 9101~9200)564
Electrical Connection Diagram (1/2) (S/N 9201~)565
Electrical Connection Diagram (2/2) (S/N 9201~)566
Electrical Equipment Layout567
Outline of MODM (Machine Operation Diagnostic Module) Operation576
MODM: Input/Output Monitor – Input/Output Signal Correspondence Table585
Traction Control Switch Mount586

S.M 4/2/2025