KCM WHEEL LOADER 115ZV SHOP MANUAL 93216-00226 – PDF DOWNLOAD

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KCM WHEEL LOADER 115ZV SHOP MANUAL 93216-00226 – PDF DOWNLOAD

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KCM WHEEL LOADER 115ZV SHOP MANUAL 93216-00226 – PDF DOWNLOAD

Language :English
Pages :606
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KCM WHEEL LOADER 115ZV SHOP MANUAL 93216-00226 – PDF DOWNLOAD

General Information
Standard Measurement Values for
Performance Check
Function & Structure
Check & Adjustment
Powered by CUMMINS QSK19-C ENGINE
Serial No. 11C4-0101~

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.

TABLE OF CONTENTS:

KCM WHEEL LOADER 115ZV SHOP MANUAL 93216-00226 – PDF DOWNLOAD

General Information
Standard Measurement Values for
Performance Check
Function & Structure
Check & Adjustment
Powered by CUMMINS QSK19-C ENGINE
Serial No. 11C4-0101~
11C4-9001~

Foreword 2
Machine Specification 2
Safety Symbols 3
CONTENTS 4
00 General Information 18
How to Use Manual 19
Safety precautions 19
Symbols 20
Outline 21
Layout of main components 21
Inspection and maintenance table 22
Recommended lubricants 25
Coolant 27
Coolant specification 27
Recommended mixture of antifreeze 27
Lubrication chart 28
Weight of main components 29
Bolt tightening torque 30
Hexagon bolt 30
Flanged hexagon bolt 33
Hose band tightening torque 34
Liquid gasket and screw lock agent 35
Cautions regarding parts removal 35
Cautions regarding reassembly 35
Screw lock agent application procedure 36
How to wind a seal tape 36
Cautions regarding welding repair service 37
Cautions 37
03 Measurement for Performance Check 40
Cautions on Safety 41
Standard Measurement Values for Performance Check 42
12 Function & Structure Chassis Group 46
Front Chassis 47
Loading linkage 47
Loading linkage pin 49
Rear Chassis 50
Fuel tank 50
Floor board mount 52
Floor board 52
Viscous mount 52
Center Pin 53
Upper center pin 53
Lower center pin 53
Dust seal 54
13 Check & Adjustment Chassis Group 56
Linkage Pin 57
Liner 57
Adjustment 58
Bucket hinge pin section (#1) 59
How to assemble 59
Bucket link pin section (#2) 60
How to assemble 60
Center Pin 61
Adjusting shim 61
Installing bearing cover 61
Installing bearing outer ring 61
22 Function & Structure Power Group 62
Power Line 63
Engine / Transmission 64
Engine / transmission mount 64
Radiator 65
Radiator mount 66
Propeller Shaft 67
First propeller shaft assembly 68
Second propeller shaft assembly 69
Third propeller shaft assembly 71
Axle Assembly 72
Axle Support 75
Differential Gear 81
Function of differential gear 85
Power transmission 85
Operation of differential gear 85
Straight 85
Turn 86
23 Check & Adjustment Power Group 88
Engine 89
Measuring engine speed 89
Measuring engine oil pressure 89
Propeller Shaft 90
Propeller shaft phase 90
Second propeller shaft alignment 90
Tightening torque 91
Axle 92
Axle nut tightening procedure 92
Planetary gear oil drain and refill 93
Differential gear adjustment procedure 94
Preload adjustment 95
Bearing installation 96
Oil seal installation 96
Greasing 96
Adjusting tooth contact 97
32 Function & Structure Torque Converter and Transmission Group 100
Torque Converter 101
Torque converter structure 102
Power flow path 102
Torque multiplication 102
Torque Converter Gear Pump 103
Gear pump specifications 103
Transmission 104
Clutch combination 105
Planetary gear 105
Shift lever position 105
Power up switch operation 105
Gear train and number of teeth 106
Clutch specifications 106
Friction plate 107
Steel plate 108
Clutch Pack 109
Power Flow Path in the Transmission 110
Forward 110
Forward 1st speed 110
Forward 2nd speed 111
Forward 3rd speed 111
Forward 4th speed 112
Reverse 113
Reverse 1st speed 113
Reverse 2nd speed 113
Reverse 3rd speed 114
Hydraulic System Diagram 115
Hydraulic Circuit Diagram 116
T/C and T/M Oil Circulation 117
Oil flow in the torque converter line 118
Oil flow to the clutch 118
Modulator Valve Unit 119
Interior schematic (not exact representation) 121
Modulation Mechanism 122
Modulator valve function 122
Modulator valve 1 122
Modulator valve 2 123
Pressure difference sensor (S/N ~0250) 123
Clutch oil pressure control at the time of engine starting 123
Modulator valve operation 124
Clutch Solenoid Valve 125
For high/reverse and speed clutches 127
After power-off (Clutch disengaged status) 127
After power-on (Clutch engaged status) 128
33 Check & Adjustment Torque Converter and Transmission Group 130
Clutch Oil Pressure and Time Lag 131
Measuring clutch oil pressure 131
Measurement instrument 131
Gauge port 131
Standard measurement value 132
Clutch oil pressure measurement procedure 132
Possible causes for low clutch oil pressure 132
Measuring clutch time lag 133
Time lag measurement procedure 133
Possible causes for clutch time lag 133
42 Function & Structure Hydraulic Group 134
Flushing Hydraulic Circuit 135
Purpose of flushing 135
Cautions on Hydraulic Parts Replacement 136
Hydraulic Circuit Symbols 137
Hydraulic lines 137
Pumps & motors 137
Cylinders 137
Operation methods 138
Pressure control valve 138
Flow control valve 138
Directional control valve 139
Check valve 139
Miscellaneous hydraulic symbols 140
Hydraulic System Operation 141
Hydraulic system operation outline 141
Loading system 141
Steering system 142
Fan motor system 142
Vibration damper system (OPT) 142
Layout of Hydraulic Units 143
Hydraulic Tank 144
Hydraulic tank specifications 144
Hydraulic oil level check 144
Hydraulic tank (S/N 0101~0200, 9001~) 145
Hydraulic tank breather valve (tank cap) (S/N 0101~0200, 9001~) 146
Hydraulic tank (S/N 0201~) 147
Hydraulic tank breather valve (tank cap) (S/N 0201~) 148
Hydraulic Pump 149
Loading and pilot and brake pump 150
Pump specifications 150
Steering pump 151
Steering pump specifications 151
Hydraulic pump principle 152
Hydraulic pump wear plate 153
Hydraulic pump bushing lubrication 153
Hydraulic Cylinder 154
Boom cylinder 154
Bucket cylinder 154
Steering cylinder 155
Hydraulic cylinder specifications 155
Loading System 156
Reducing Valve (for Pilot Pressure) 157
Pilot Valve (S/N 0101~0140, 9001~9020) 158
Pilot valve operation 160
Pilot valve detent magnet solenoid 162
Detent adjustment procedure 162
Pilot valve (S/N 0141~0172, 9021~) 163
Pilot valve operation 165
Pre-detent and detent magnet solenoid 167
Pilot valve (S/N 0173~0176) 168
Pilot valve function 170
Pilot valve operation (modulated position) 170
Pre-detent and detent magnet solenoid 172
Pilot valve (S/N 0177~) 173
Pilot valve function 175
Pilot valve operation (modulated position) 175
Pre-detent and detent magnet solenoid 177
Multiple Control Valve (KML35A/2T103) 178
Multiple control valve specifications 179
Multiple control valve main relief valve 180
Main relief valve operation 180
Adjusting set pressure 181
Multiple control valve overload relief valve 182
Overload relief valve operation 182
Make-up valve operation 183
Adjusting set pressure 183
Multiple control valve make-up valve 184
Make-up valve operation 184
Multiple control valve bucket spool 185
Bucket spool operation 185
Multiple control valve boom spool 187
Boom spool operation 187
Adapter (Orifice) 190
Vibration Damper (OPT) 191
Vibration damper function 191
Vibration damper operation 192
Vibration damper valve assembly (Reducing valve circuit) 194
Reducing valve 195
Check valve 195
Solenoid valve 196
Vibration damper valve assembly (Accumulator circuit) 197
Shuttle valve 198
Solenoid valve 198
Check valve 199
Accumulator (for vibration damper) 200
Vibration damper hydraulic line 201
Steering System 202
Orbitrol® 203
Orbitrol® structure 203
Valve part 203
Rotor part 204
Orbitrol® specifications 204
Orbitrol® operation 205
Neutral 205
Turn 206
Orbitrol® feed-back mechanism operation 207
Steering speed and flow rate control 208
Hydraulic pump oil amount and steering force 208
Orbit rotor operation principle 209
Steering Valve (KVS32-A4 0/21) 210
Steering valve operation 212
Neutral position (steering spool in “Neutral”) 212
Left turn position 213
Steering spool variable throttle 214
Steering valve flow control spool 215
Steering valve main relief valve 216
When the pressure is at the preset value or less 216
When the pressure exceeds the preset value 217
Steering valve overload relief valve 218
Overload relief valve operation 219
Make-up valve operation 219
Steering pilot circuit and its operation 220
Flow amplifier notch and pilot orifice 221
Stop Valve 222
Stop valve function 224
Stop valve operation 225
Reducing Valve (for Orbitrol®) 226
Steering Line Filter 227
Fan Motor System 228
Fan Motor Line (S/N 0101~0120, 9001~9010) 229
Fan Motor (GM30C) 231
Fan motor specifications 231
Valve Assembly (for Fan Motor) 232
Relief Valve (Two-step Relief) 233
Relief valve (Two-step relief) operation 234
Make-up valve operation 235
Solenoid Valve (for Fan Speed Control) 236
Solenoid valve (for fan speed control) operation 236
Solenoid valve specifications 236
Fan Motor Line (S/N 0121~, 9011~) 237
Fan Motor (GM30W) 239
Fan motor (FM30) (S/N 0168~) 241
Thermo Sensing Valve 243
Thermo sensing valve specifications 243
Thermo sensing valve operation 244
Fan Motor Relief Valve Assembly 245
Fan motor relief valve 246
Fan motor check valve (Make-up valve) 246
Emergency Steering 247
Emergency steering operation 248
Emergency steering hydraulic line 248
Emergency steering oil flow 249
Emergency steering pump 251
Emergency steering valve assembly 252
43 Check & Adjustment Hydraulic Group 254
Loading/Steering Circuit Relief Valve 255
Loading circuit relief valve setting pressures 255
Measuring loading circuit main relief pressure 257
Measuring loading circuit overload relief pressure 258
Measuring pilot circuit relief pressure 259
Steering circuit relief valve setting pressures 260
Measuring steering circuit main relief pressure 261
Measuring steering circuit overload relief pressure 262
Measuring pilot circuit relief pressure (reducing pressure) (S/N 0101~, 9004~) 263
Hydraulic Cylinder 264
Cylinder natural drift 264
Stop Valve 266
Stop valve adjustment procedure 266
Fan Motor Revolution 267
Fan maximum revolution measurement (S/N 0101~0120, 9001~9010) 267
Fan revolution adjustment procedure 268
Fan maximum revolution measurement (S/N 0121~, 9011~) 269
Fan revolution adjustment procedure 270
52 Function & Structure Brake Group 272
Brake System Outline 273
Service brake 273
Parking brake 273
Auto brake 273
Adjustment of axle internal pressure 273
Brake Units Layout 274
Unloader Valve 275
Unloader valve operation 277
Reducing valve 278
Valve Unit (Main Brake Manifold Block) 279
Brake Accumulator Line 280
Accumulator 281
In-Line Filter 282
Brake Valve 283
Brake main valve (left pedal) 283
Brake pilot valve (right pedal) 284
Brake valve performance chart 285
Brake valve outline 286
Main valve (tandem type) operation 287
Pilot valve operation 288
Stop Lamp Pressure Switch 289
Pressure switch (for stop lamp) 289
Pressure switch structure 289
Pressure switch specifications 290
Pressure switch (for Declutch) 290
Service Brake 291
Service brake operation 291
Service brake friction plate 292
Service brake steel plate 293
Service brake piston 294
Service brake pedal stroke adjusting mechanism 295
Tolerance ring 296
Brake circuit air bleeding procedure 297
Bleeding air from the brake valves 298
Bleeding air from brake pipes and axle housing hubs 298
Parking Brake 299
Parking brake operation 301
Parking brake solenoid valve 302
Solenoid valve operation 302
Solenoid valve specifications 302
Parking Brake Manual Release 303
Parking Brake Spring Chamber 305
Brake Circuit Check Valve 306
Auto Brake 307
Auto brake operation set value 307
Auto brake circuit 307
Solenoid valve (for auto brake circuit) 308
Solenoid specifications 308
Shuttle Valve 309
53 Check & Adjustment Brake Group 310
Brake Circuit Oil Pressure 311
Unloader valve setting pressure 311
Measurement procedure 312
Adjusting unloader valve setting pressure 312
Accumulator circuit pressure measurement and adjusting 313
Measuring reducing valve setting pressure 313
Measurement procedure 313
Adjusting reducing valve setting pressure 314
Brake valve oil pressure 315
Measurement instrument 315
Brake valve performance 316
Measurement procedure 316
Service Brake 317
Service brake performance check 317
Service brake friction plate wear measurement 318
Measurement procedure 319
Cautions on installing brake discs 320
Parking Brake 321
Parking brake performance check 321
Parking brake clearance adjustment 323
Adjustment procedure 323
Brake lining wear check 323
62 Function & Structure Electrical Group 324
How to Use Electrical Wiring Diagram 325
Utilisation des schémas des câblages électriques (FRANÇAIS) 326
Verwendung des elektrischen Schaltplans (DEUTSCH) 327
Modalità di utilizzo dello schema dei collegamenti elettrici (ITALIANO) 328
Cómo utilizar un Diagrama de Alambrado Eléctrico (ESPAÑOL) 329
Como Utilizar o Diagrama de Ligações Eléctricas (PORTUGUÊS) 330
Electrical Cable Color Codes 331
Electrical Circuit Symbols 332
Sensor Mount 333
Fuse 334
Fuse box location 334
Fuse box 335
Fusible link 336
Engine Start Circuit 337
Engine start circuit diagram (S/N 0101~0153, 9001~) 337
Engine start circuit diagram (S/N 0154~) 338
Neutral starter 339
Shift lever neutral (N) position 339
Shift lever forward/reverse (F/R) position 339
Starter switch 340
Battery relay 341
Battery relay operation 341
Alternator I terminal wire 341
Diode unit 342
Neutral relay 342
Magnet switch 343
Voltage relay 343
Power Generating/Charging Circuit 345
Alternator 345
ECM (Engine Controller) 346
Function of ECM 346
Connection diagram 346
Monitor lamp test 347
Failure diagnosis 348
Diag Inc/Dec switch assembly (option) 348
Engine diagnostic switch (option) 350
Failure diagnostic chart 351
Increment decrement switch (option) 352
Quantum fault code information 353
Power mode change 360
Accelerator pedal 361
Accelerator pedal installation 362
Accelerator pedal 363
Accelerator pedal installation 364
Transmission Control Circuit (S/N 0101~0153, 9001~) 365
Controller 365
LED inspection windows 366
Controller connection diagram 367
Controller function 368
Forward/reverse (F/R) shifting and speed change 368
Automatic shift 371
Machine speed sensor/Engine speed sensor 372
Switching from automatic to manual 373
QUAD (shift) switch operation 373
Modulation at clutch switching 374
Transmission cut off (Declutch) 376
Pressure switch for inching (Declutch) 377
Back-up alarm 378
Parking brake 379
Auto brake 381
Transmission controller failure warning 384
Emergency steering function (for Europe spec only) 385
Monitor controller 385
Transmission Control Circuit (S/N 0154~) 386
Machine control unit (MCU) 386
Connector 387
Machine control unit (MCU) connection diagram (S/N 0154~0222) 388
Machine control unit (MCU) connection diagram (S/N 0223~) 389
Machine control unit (MCU) failure warning 390
Monitor Circuit 391
Items to be monitored and operation condition 391
Operation monitor lamps 393
Monitor controller (S/N 0101~0153, 9001~) 394
Monitoring sensor and switch 396
Instrument Panel and Switch 397
Instrument panel 397
Instrument panel rear surface 399
Gauge circuit 401
Temperature sensor 402
Fuel gauge circuit 403
Tachometer circuit 404
Electrical Detent Circuit 405
Bucket leveler 405
Boom kick-out (option) 406
Float 406
Proximity switch 407
Detent solenoid 407
Diode 408
Diode check method 409
Caution for diode check method 409
Continuity check mode 409
Diode check mode 409
Resistance check mode 410
Surge voltage and surge suppression diodes 411
Diagnostic System (S/N 0101~0153, 9001~) 412
Transmission controller 412
Diagnostic system flow 412
Failure code (T/M controller) 413
Diagnostic (T/M controller) failure code detection condition 414
Fault diagnostic result storage condition 415
Monitor controller 416
Diagnostic system flow 416
Alarm monitor actuation and data storage 417
Diagnostic failure history indication and deletion 419
Failure history indication 419
Failure history deletion 420
Diagnostic switch 421
MODM (S/N 0154~) 422
MODM function 422
Monitor Changeover 422
Changing display from one function to next 422
MODM: Input/output monitor – Input/output signal correspondence table 429
63 Check & Adjustment Electrical Group 432
Cautions Regarding Electric Circuit Check 433
Disconnecting or reinstalling connector 433
How to attach the probes of the circuit tester 435
Electrical Transmission Control System Troubleshooting Flowchart (S/N 0101~0153, 9001~) 436
Standard troubleshooting flowchart 436
Transmission Controller Abnormal Operation Judgment (S/N 0101~0153, 9001~) 437
Transmission controller check 437
When the “controller failure” monitor lamp lights: 437
When the output units (solenoid valve, etc ) do not operate properly: 437
If the input units or circuit are not defective 438
Transmission controller LED indicator 439
Electrical Circuit Check (S/N 0101~0153, 9001~) 441
Shift lever input electrical circuit check 441
Inching (Declutch) input electrical circuit check 443
QUAD switch input electrical circuit check 445
Machine speed sensor input electrical circuit check 446
Clutch solenoid valve output electrical circuit check 447
Modulator valve output electrical circuit check 449
Neutral relay electrical circuit check 451
Parking brake electrical circuit check 452
Auto brake electrical circuit check 454
Gauge circuit electrical circuit check 456
Fuel level gauge electrical circuit check 458
Bucket positioner electrical circuit check 460
72 Function & Structure Operator Station Group 462
Cabin 463
Glass 465
1 Part number 32011-21690 466
2 Part number 32011-21700 466
3 Part number 32011-21500 467
Wiper mount 468
Front wiper 468
Rear wiper 468
Wiper motor 469
Operator Seat 471
Steering and Transmission Shift Lever 472
Tilt case 473
Column shaft 474
Shift lever 474
Air Conditioner 475
Air conditioner components 475
Air conditioner specifications (system performance) 475
Air conditioner structure 476
Cooling unit 476
Heater and accessories 478
Air distributor (hood & defroster selection box) 478
Air compressor (with magnetic clutch) 479
Condenser unit 479
Control unit 480
Cooling mechanism 481
Principle of cooling 481
Refrigerant 481
Refrigerant characteristics 482
Cooling circuit 483
Electrical circuit 484
Control schematic drawing 484
Air conditioner functions of components 485
Control panel 485
Air conditioner unit 492
Compressor and magnetic clutch 501
Condenser unit 504
Receiver dryer 506
Sight glass 508
Pressure switches 508
Pressure relief valve 509
Relay A 510
Relay B 510
Refrigerant hose 511
Charge of refrigerant 512
Work procedure 513
Refrigerant charging tools 514
Refrigerant charging procedure 517
Troubleshooting using the gauge manifold 522
Air conditioner troubleshooting 527
Fault diagnosis procedure 527
73 Check & Adjustment Operator Station Group 536
Air Conditioner 537
Adjustment of lubricating oil quantity when components of air conditioner are replaced 537
When the compressor is replaced 538
When the evaporator is replaced 539
When the condenser is replaced 539
Adjustment of air gap (between hub and rotor) in compressor magnetic clutch 540
Parts to be replaced periodically 541
Air filters 541
Receiver dryer 541
INDEX 542
Maintenance Log 549
Notes 553
92 Cross-section drawing & Diagrams 557
Axle Assembly 558
Torque Converter and Transmission 560
Loading/Steering Hydraulic Line (S/N 0101~0120) 561
Loading/Steering Hydraulic Circuit (S/N 0121~) 562
Loading/Steering Hydraulic Circuit (S/N 9001~9010) 563
Loading/Steering Hydraulic Circuit (S/N 9011~) 564
Brake Circuit 565
Electrical Wiring Diagram (1/2) (S/N 0101~0120) 566
Electrical Wiring Diagram (2/2) (S/N 0101~0120) 567
Electrical Wiring Diagram (1/2) (S/N 0121~0124) 568
Electrical Wiring Diagram (2/2) (S/N 0121~0124) 569
Electrical Wiring Diagram (1/2) (S/N 0125~0153) 570
Electrical Wiring Diagram (2/2) (S/N 0125~0153) 571
Electrical Wiring Diagram (1/3) (S/N 0154~0222) 572
Electrical Wiring Diagram (2/3) (S/N 0154~0222) 573
Electrical Wiring Diagram (3/3) (S/N 0154~0222) 574
Electrical Wiring Diagram (1/3) (S/N 0223~) 575
Electrical Wiring Diagram (2/3) (S/N 0223~) 576
Electrical Wiring Diagram (3/3) (S/N 0223~) 577
Electrical Wiring Diagram (1/2) (S/N 9001~9010) 578
Electrical Wiring Diagram (2/2) (S/N 9001~9010) 579
Electrical Wiring Diagram (1/2) (S/N 9011~) 580
Electrical Wiring Diagram (2/2) (S/N 9011~) 581
Electrical Wiring Diagram Abbreviation Chart (S/N 0101~0153, 9001~) 582
Electrical Wiring Diagram Abbreviation Chart (S/N 0154~0222) 583
Electrical Wiring Diagram Abbreviation Chart (S/N 0223~) 584
Electrical Wiring Diagram (CAB) 585
Electrical Connection Diagram (S/N 0101~0120) 587
Electrical Connection Diagram (S/N 0121~0124) 588
Electrical Connection Diagram (S/N 0125~0153) 589
Electrical Connection Diagram (S/N 0154~0222) 590
Electrical Connection Diagram (1/2) (S/N 0223~) 591
Electrical Connection Diagram (2/2) (S/N 0223~) 592
Electrical Connection Diagram (S/N 9001~9010) 593
Electrical Connection Diagram (S/N 9011~) 594
Electrical Circuit Diagram (Cabin Air Conditioner) 595
Electrical Wiring Diagram (Cabin Air Conditioner) 596
Equipment Operation Table (Cabin Air Conditioner) 597
Electrical Equipment Layout 598

S.M 6/2/2025