Kawasaki WHEEL LOADER 92ZV-2 SHOP MANUAL 93221-00080 (1)

92ZV-2

93221-00080 June 2009

SHOP MANUAL

SHOP MANUAL

Troubleshooting

WHEEL LOADER

92ZV-2 Troubleshooting Measurement for Performance Check Check & Adjustment

Printed in Japan (i) ( ヨーロッパ・オセアニア用 )

93221-00080

©2009 KCM Corporation. All rights reserved.

Powered by CUMMINS QSM11 ENGINE Serial No. 92C1-9001 and up

93221-00080 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 Operation and Maintenance Manual.

To effectively diagnose and repair the machine, it is important to follow the guidelines laid out in this Shop Manual.

Troubleshooting Measurement for Performance check Check & Adjustment 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 methods. 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 Precautions The most important point in providing repair service is safety. To ensure safety, observe the general cautions described below.

- This manual is intended for properly trained and equipped service technicians.

- Any work on the machine must be performed by the trained personnel only.

- Carefully read this manual to thoroughly understand the operation method before you operate or repair 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 movement.

- Remove the cable from the battery before starting the service work, and attach a "DO NOT OPERATE!" 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 starting 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 adequate 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.

- Contact tire manufacturer's local dealer for tire servicing and changing.

- Always store the tools in good condition, and use them properly.

- Keep the work area clean. Clean up spills immediately.

- Avoid the use of flammable solvents and cleaners.

- When working outdoors keep work areas, ladders, steps, decks and work platforms clear of snow, ice, and mud.

- Use safe work platforms to reach higher areas of the machine.

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.

Symbols For safe and effective service work, the following symbols are used for notes and useful information in this manual.

Symbol

Item

Description

Reference

Shows the condition or procedure that will be useful or efficient in doing service work.

Weight

Shows the weight of a part or unit. The weight should be considered in selecting wire rope or cable for slinging work or determining the working posture.

Tightening Shows the tightening torque of a section that should torque be carefully tightened during assembly work.

Coating

Shows the type of coating or adhesive and the coating section.

Oil or water supply

Shows the oil or water supply port and the refill amount.

Drainage

Shows the oil or water drain port and the drain 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 performance 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 following abbreviation list.

E/G ........... Engine T/C ........... Torque converter T/M ........... Transmission SOL ........... Solenoid valve SW ........... Switch F ........... Front or Forward A/M ........... Auto/Manual B ........... Battery R ........... Rear or Reverse

RH ........... Right hand side LH ........... Left hand side H ........... High L ........... Low GND ........... Ground OPT ........... Option Assy ........... Assembly 1st ........... 1st speed 2nd ........... 2nd speed

3rd ............3rd speed 4th ............4th speed M/C ............Machine min-1 ............RPM ELS ............Efficient loading system MODM ........Machine operation diagnostic module MCU............Machine control unit

CONTENTS • TROUBLESHOOTING....................................................01-1 • MEASUREMENT FOR PERFORMANCE CHECK.........03-1 • CHECK & ADJUSTMENT CHASSIS GROUP........................................................13-1 POWER GROUP .........................................................23-1 TORQUE CONVERTER AND TRANSMISSION GROUP .........................33-1 HYDRAULIC GROUP...................................................43-1 BRAKE GROUP ...........................................................53-1

MEMO

01-1

Troubleshooting 01 Cautions Regarding Troubleshooting ................................................................................................................ 01-3 How to Use Quick Troubleshooting Table ......................................................................................................... 01-4 Safety Precautions ............................................................................................................................................ 01-5 Quick Troubleshooting Table Torque Converter and Transmission Group ...................................................................................................... 01-6 1. Machine dose not move in any shift lever position. ................................................................................ 01-6 2. Machine dose not move at a certain shift lever position.

(OR:Machine moves only in a certain shift lever position.) ..................................................................... 01-7 3. Machine moves at the neutral position.

(Example: Machine moves forward at the neutral position.) ................................................................... 01-8 4. Large shock at starting or changing speed / direction ............................................................................ 01-9 5. Large time lag at starting or changing speed / direction ....................................................................... 01-10 6. Low power of traction / pushing (Defective torque converter or transmission) ..................................... 01-11 7. Torque converter oil is overheating. ..................................................................................................... 01-12 8. Machine moves reverse when starting to climb up on a slope using inching brake. ............................ 01-13 9. Automatic speed change is not possible. ............................................................................................. 01-14 10. Downshift button does not work. ........................................................................................................... 01-15

01-2

Hydraulic Group .............................................................................................................................................. 01-16 1. Boom and/or bucket do not move. ........................................................................................................ 01-16 2. Boom and/or bucket have low power, or move too slowly. ................................................................... 01-17 3. Excessive cylinder drift ......................................................................................................................... 01-18 4. Boom and/or bucket are spongy.

(Holding bucket against the ground is not possible-front wheels off the ground.) ................................ 01-19 5. Bucket leveler does not work. Boom lift kickout and lower kickout does not work. ............................... 01-20 6. Steering is not possible or hard to steer. .............................................................................................. 01-21 7. Machine sways, or has a shock during steering ................................................................................... 01-22 8. ELS (Efficient Loading System) does not work.

(Excavating and scooping tractive power does not become up during ELS working condition.) .......... 01-23 9. Ride control does not work. .................................................................................................................. 01-24 10. Fan motor rotates abnormally or does not rotate. ................................................................................. 01-25 11. Abnormal noise in hydraulic system. .................................................................................................... 01-26 12. Others ................................................................................................................................................... 01-27 Brake Group .................................................................................................................................................... 01-28 1. Brake does not work well. (In the worst case, the brake does not work at all.) .................................... 01-28 2. Brake is dragging when released. ......................................................................................................... 01-29 3. Stepping on the brake pedal sounds the buzzer. .................................................................................. 01-30 4. Accumulator pressure does not rise, or too slow in rising. .................................................................... 01-31 5. Parking brake does not work. (or: Releasing the parking brake is not possible.) ................................. 01-32 Electrical Group ............................................................................................................................................... 01-33 1. Instrument panel does not indicate properly. ........................................................................................ 01-33 2. Fuse for controller is blown. .................................................................................................................. 01-34 Error code (for chassis) ............................................................................................................................. 01-35 Error code (for engine) .............................................................................................................................. 01-38 Operator Station Group ................................................................................................................................... 01-45 Air conditioner ........................................................................................................................................... 01-45

01-3 92ZV-2 Troubleshooting Cautions Regarding Troubleshooting

Cautions Regarding Troubleshooting Important points The important points for troubleshooting is to carefully read the operation manual and shop manual to get enough information on the operation, circuits, structure, and function of each component. If you have enough knowledge of each component and system, you can easily determine the cause of the problem.

There may be various causes for each problem, therefore experience will be needed to determine which is the actual cause of the problem.

It is necessary to know the normal operation of each component. In addition, it is also important to know the abnormal condition when a problem occurs. This chapter shows various examples of past problems, and describes possible causes and remedies for each problem.

Before starting troubleshooting To prevent incorrect diagnosis, talk with the persons concerned, particularly with the operator, to get enough information on the problem. If possible, check the machine by repeating the symptom.

If the problem cannot be repeated, do not provide any repair service.

For instance, assume that the operator complains that the boom power is low, and the rim-pull is also low. In this case, there are two possible causes ; low hydraulic power and low rim-pull. The remedies against both causes are much different from each other.

If you hastily determine the wrong cause without checking the actual condition of the problem, it will take too much time and expense to solve the problem. As a result, you will not be trusted by the user.

The following questions will be helpful in determining of the cause. Answer the questions to prevent an incorrect diagnosis.

1. Did the problem occur suddenly ?

2. When did the operator notice the problem ?

3. Is there any past problem that may be the cause of this problem ?

4. When the problem occurred, what kind of work was the operator doing ?

5. Has the machine had the same kind of problem before ?

6. Has the machine been repaired or inspected recently ?

7. Does the machine have any other problem ?

Troubleshooting - Check before determination of cause A problem may be caused by poor daily maintenance, such as lack of grease, low or improper oil or a clogged filter. Be sure to check the machine for oil level, appearance, unpleasant odor, etc. to prevent time loss due to other unnecessary tests.

- Inspection procedure As a rule, check the easy-to-be-repaired system first (excluding the cases where the cause can be easily determined based on the past experiences).

This machine is controlled by electrical, hydraulic, and mechanical systems. The most easy-to-berepaired system is the electrical system. Check the electrical system first. If no problem is detected in the electrical system, check the hydraulic system, and then the mechanical system.

Note Check the error code on the MODM at first !

01-4 92ZV-2 Troubleshooting How to Use Quick Troubleshooting Table

How to Use Quick Troubleshooting Table To immediately determine the cause of the problem without disassembling parts, use the quick troubleshooting table. From the problem explained by the user and the check points written in the table, you can immediately determine the cause of the problem.

How to use quick troubleshooting table 1. According to the problem explained by the user, open the quick troubleshooting table to the page where the corresponding problem is described.

2. Check the machine according to the "Symptoms/ check point" field in the table. Start from the most easily checked point.

3. Operate the machine, and write the check marks " " in the corresponding circles " " if the problem occurs.

4. Generally, the possible cause that has many check marks will be actual cause. If two or more possible causes have several check marks, check each possible cause to prevent an incorrect diagnosis.

In this case, start from the most easily checked item.

01-5 92ZV-2 Troubleshooting Safety Precautions

Safety Precautions DANGER

WARNING

Entering the articulation area of the machine body while the engine is running may cause severe accidents.

Service work under the machine may cause an accident resulting in injury or death. To prevent such an accident, be sure to observe the following items.

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.

- Park the machine on level ground.

- Apply the parking brake.

- Block the tires with chocks to prevent the tires from moving.

- Stop the engine.

- Give signals to the person in the cab during the work.

WARNING Unexpected movement of the machine may cause an accident resulting in injury or death.

Therefore, to provide repair service with the engine running, be sure to observe the following items.

- Park the machine on level ground.

- 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 Standing under the boom or bucket during service work is dangerous. An accident resulting in injury or death may be caused.

To prevent such an accident, be sure to observe the following items.

- Park the machine on level ground.

- Apply the parking brake.

- Block the tires with chocks to prevent the tires from moving.

- Place a stand under the boom to support it.

- Apply the safety look of the boom and bucket control lever provided in the cab.

- Remove the starter key, and attach a "DO NOT OPERATE!" tag to the cab.

CAUTION Do not touch the fan or V-belt of the engine or a hightemperature section if the engine is running.

An accident resulting in injury may occur.

Be sure to stop the engine before you open the side cover of the engine room.

Avoid high temperature components even when the engine is stopped.

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.

01-6 92ZV-2 Troubleshooting Torque Converter and Transmission Group

Torque Converter and Transmission Group

Every hydraulic system do not work.

Pump produces an abnormal (shrieking) noise.

Pump is extremely heated.

F5 fuse blows.

Filter of the torque converter is clogged.

Temperature of the torque converter oil is too high.

Possible cause

Low clutch oil pressure at all the shift lever positions.

Check before starting work.

1. Check that the parking brake is released.

2. Check the error code No. shown on the MODM. 3. Check the transmission oil level.

4. Check "F5" fuse for the MCU (Main controller unit).

5. Check the 70 A fusible link.

(If the 70 A fusible link is off, no electrical circuits will operate except horn circuit and hazard flasher [opt.].)

6. Check that Input/Output signal of MODM shows correctly according to "Correspondence table".

Symptoms / check point

1. Machine dose not move in any shift lever position.

Solution

Air drawn into suction line of the torque converter pump

Tightening hose band

Defective torque converter pump

Pump replacement

Damaged torque converter

Disassembly & repair

Sticking clutch pressure regulator valve

Disassembly & repair

Broken all bolts of internal gear connecting with the engine flywheel

Switch replacement

Neutral relay, controller fault relay, lift kickout and lower kickout relay, parking switch wirings short circuited

Repairing wiring

Restricted suction line - pinched, plugged, or internally defective.

Replace hose

F5 fuse blows.

Clutch can be engaged at a certain shift lever position, though the clutch will not be engaged at any other position.

Clutch oil pressure is always high despite shift lever position.

Even when pressing solenoid valve, machine does not move.

24V power is not supplied to the solenoid valve.

Resistance of the solenoid valve coil is infinite Ω.

Clutch oil pressure is low at a certain position only. At all the other positions, the pressure is normal.

Torque converter oil looks and smells as if it was scorched (black).

Possible cause

Machine moves at a certain shift lever position, but hesitates to move at any other positions.

Check before starting work.

1. Check the error code No. shown on the MODM. 2. Check that Input/Output signal of MODM shows correctly according to "Correspondence table".

Symptoms / check point

2. Machine dose not move at a certain shift lever position.

(OR:Machine moves only in a certain shift lever position.)

Machine does not move at a certain shift lever position, but moves at all the other positions.

01-7 92ZV-2 Troubleshooting Torque Converter and Transmission Group

Solution

Clutch slipping

Disassembly & repair

Seized clutch

Disassembly & repair

Clutch oil leaks internally.

Disassembly & repair

Coil of clutch solenoid valve is defective.

Solenoid valve replacement

Harness of clutch solenoid valve disconnected

Repair cable

Clutch solenoid valve sticking in OFF position

Solenoid valve replacement

Clutch solenoid valve sticking in ON position

Solenoid valve replacement

Shift lever switch sticking in ON (regardless of position)

Shift lever replacement

Shift lever switch sticking in OFF (regardless of position)

Shift lever replacement

Defective controller

Controller replacement

Short circuited clutch solenoid or wiring

Repair cable

Oil is black and smells scorched.

Possible cause

When the lever is shifted to the reverse position, the machine does not move reverse (as if the brake is applied).

Check before starting work.

1. Check that the ground is level.

2. Check the error code No. shown on the MODM. 3. Check that Input/Output signal of MODM shows correctly according to "Correspondence table".

Symptoms / check point

3. Machine moves at the neutral position.

(Example: Machine moves forward at the neutral position.)

When the lever is shifted to the forward position, the machine moves forward.

01-8 92ZV-2 Troubleshooting Torque Converter and Transmission Group

Seized clutch on forward side ∗

T/M disassembly & repair

Malfunctioning forward solenoid valve (sticking at ON position) ∗

Solenoid valve replacement

Defective controller (malfunctioned after outputting "F") ∗

Controller replacement

Defective shift lever (switch stuck in "F" position) ∗

Shift lever replacement

∗ The same possible cause but involving the reverse clutch or circuit could occur with the opposite symptoms.

Remarks

Solution

01-9 92ZV-2 Troubleshooting Torque Converter and Transmission Group

4. Large shock at starting or changing speed / direction

Temperature of the torque converter oil is too high.

Large shock at a certain shift lever position only.

Possible cause

Large shock at all the shift lever positions.

Symptoms / check point

Check before starting work.

1. Check the error code No. shown on the MODM.

Solution

Malfunctioning control valve regulator valve (stuck)

Disassembly & repair

Malfunctioning trimmer plug (stuck)

Disassembly & repair

Defective solenoid valve for trimmer (Disconnected coil or stuck)

Solenoid valve replacement

Damaged or worn clutch disk (seized clutch)

T/M disassembly & repair

01-10 92ZV-2 Troubleshooting Torque Converter and Transmission Group

5. Large time lag at starting or changing speed / direction

Large time lag at a certain shift lever position only.

Main oil pressure is too low at all the shift lever positions.

Possible cause

Large time lag at all the shift lever positions.

Symptoms / check point

Check before starting work.

1. Check the error code No. shown on the MODM.

Solution

Malfunctioning of regulator valve in control valve (stuck)

Disassembly & repair

Malfunctioning trimmer plug (stuck)

Disassembly & repair

Control valve spring breakage or excessive wear-out

Spring replacement

Malfunctioning trimmer solenoid valve (spool stuck)

Disassembly & repair

Internally leaked clutch oil

T/M disassembly & repair

01-11 92ZV-2 Troubleshooting Torque Converter and Transmission Group

Pump produces an abnormal (shrieking) noise.

Pump is extremely heated.

Clutch oil pressure is too low at a certain shift lever position.

Silver powder (Aluminum) is on the line filter and strainer.

Torque converter oil is milky and cloudy in color.

Torque converter oil is discolored or emits nasty smell.

Temperature of the torque converter oil is too high.

Large time lag at a certain shift lever position only.

Output power is low at a certain shift lever position only.

Possible cause

Output power is low at all the shift lever positions.

Check before starting work.

1. Check the parking brake and service brake for dragging.

2. Check the torque converter oil level.

3. Check that no unusual load is applied to the hydraulic line (like excessive pilot pressure).

4. Check that the engine speed is standard value.

5. Check the error code No. shown on the MODM. 6. FE (fuel efficient mode switch) is not in "Economical mode".

Symptoms / check point

6. Low power of traction / pushing (Defective torque converter or transmission)

Solution

Air drawn into suction line of torque converter

Tightening suction hose band

Broken torque converter turbine and pump

T/C disassembly & repair

Torque converter internal pressure too low

Regulator valve check

Seized clutch

T/M disassembly & repair

Clutch slipping

T/M disassembly & repair

Internally leaking clutch oil

T/M disassembly & repair

Thermometer in T/C out line indicates less than 250ºF/120ºC when gauge or light indicates overheat.

Service or parking brake is excessively hot/discolored.

Pump produces an abnormal (shrieking) noise.

Pump is extremely heated.

Output power is too small at a certain shift lever position.

Foreigh material is on the filter-especially silver powder (Aluminum).

Torque converter oil is discolored or emits nasty smell.

Machine does not move at a certain shift lever position (or dragging is felt).

Torque converter inlet pressure is too low.

Clutch oil pressure is too low.

Possible cause

Torque converter oil is milky and cloudy in color.

Check before starting work.

1. Check the torque converter oil level.

2. Check the engine coolant for overheat.

3. Check the oil pressure-adjust to specification.

4. Check the error code No. shown on the MODM. 5. Check that the engine speed (High idle & T/C stall) shows standard value.

Symptoms / check point

7. Torque converter oil is overheating.

Less difference in torque converter oil temperature between cooler inlet and outlet.

01-12 92ZV-2 Troubleshooting Torque Converter and Transmission Group

Solution

Air drawn into suction line of torque converter

Tightening hose band

Internally torque converter leakage

T/C disassembly & repair

Damaged torque converter

T/C disassembly & repair

Torque converter pump discharge amount too small

T/C pump disassembly & repair

Seized clutch

T/M disassembly & repair

Clutch slipping

T/M disassembly & repair

Scale deposited in water line of torque converter cooler

Cooler cleaning

Restricted suction line-pinched, internally defective

Replace hose

Service or parking brake dragging

Test/repair brake circuit

Incorrect indication of gauge (no alarm)

Test/replace gauge or sensor

Malfunction of T/M oil temperature sensor

Replace switch

Contamination in oil cooler (oil side)

Replace cooler

01-13 92ZV-2 Troubleshooting Torque Converter and Transmission Group

8. Machine moves reverse when starting to climb up on a slope using inching brake.

Possible cause Large time lag in clutch engagement

After pedal release, too much time is required to move.

Symptoms / check point

Check before starting work.

1. Check the error code No. shown on the MODM.

∗

Solution Refer to description of time lag (No.5) ∗

Inching set-up condition abnormal

Set-up normally

Defective inching sensor

Replacement

One or more planetaries are excessively hot/parking brake is hot or discolored.

Actual speed increase or reduction does not correspond with the set speed.

Possible cause

Speed is fixed to 3rd speed, and is not increased to 4th speed.

Check before starting work.

1. Manually change the speed from 1st speed to 4th speed. If manual speed change is impossible, refer to "Machine does not move at a certain shift lever position."

(No.2) 2. Check the error code No. shown on the MODM. 3. Check that the engine speed (High idle & T/C stall) is standard value.

Symptoms / check point

9. Automatic speed change is not possible.

Speed is fixed to a certain position, and automatic speed change is not possible.

01-14 92ZV-2 Troubleshooting Torque Converter and Transmission Group

Solution

Defective shift lever "A" position or defective wiring to controller

Shift lever replacement or repairing wire

Damaged speed sensor or disconnected sensor

Sensor replacement or repairing wire

Speed sensor signal output error or improperly adjusted speed sensor

Sensor replacement or readjustment

Parking or service brakes dragging

Test/repair brake circuit

Enigine power too low / Engine speed too low

See E/G trouble shooting

01-15 92ZV-2 Troubleshooting Torque Converter and Transmission Group

Possible cause

Downshift button does not work.

Check before starting work.

1. Check that the downshift button is being used only at the 2nd forward/reverse speed position.

At the other positions, shifting down is not possible.

2. Check that the speed shift change from 1st to 2nd and 2nd to 1st can be done normally by manually.

3. Check the error code No. shown on the MODM.

Symptoms / check point

10. Downshift button does not work.

Solution

Defective downshift button

Downshift button replacement

Disconnected downshift button or wiring

Repair wire

Defective controller

Replacement

01-16 92ZV-2 Troubleshooting Hydraulic Group

Multiple control valve

Pump

Pump is extremely heated.

There is reliefing noise from main relief valve.

Bucket moves if the overload relief valves are exchanged with each other. ∗

Cylinder does not operate, though oil is discharged from the return port.

Pilot relief pressure is too low.

Main relief pressure is too low when the boom or bucket is operating.

Boom and bucket move with no load, though they do not move when loaded.

Possible cause

Either or both of the boom or/and bucket do(es) not move.

Check before starting work.

1. Check the oil level.

2. Check that the loading control lock lever is fully released.

3. Check that the pilot valve inline filter is not clogged.

4. Check the error code No. shown on the MODM.

Symptoms / check point

1. Boom and/or bucket do not move.

Boom and bucket do not move while the engine runs at idle rev. but they move while the engine rev. is high speed.

Hydraulic Group

Solution

Internally damaged steering pump.

Disassembly & repair

Internally damaged main pump.

Disassembly & repair

Internally damaged pilot pump.

Disassembly & repair

Main relief valve internal oil leakage or low setting pressure

Disassembly & readjustment

Overload relief valve internal oil leakage or low setting pressure

Disassembly & readjustment

Multiple control valve spool sticking

Plunger & replacement

Defective valve assembly (reducing valve for pilot)

Disassembly & readjustment

Internally damaged cylinder

Disassembly & repair

Remarks

∗ Exchange of the overload relief valve means that the valves should be changed between the rod and bottom sides.

01-17 92ZV-2 Troubleshooting Hydraulic Group

Pump makes noise (shrieking).

Oil is foamy or milky looking after operation.

Bucket drifts down when full.

Pump is extremely heated.

There is reliefing noise from main relief valve.

Only bucket "roll back" operation is abnormal.

Either the boom and bucket does not operate properly.

Both the boom and bucket do not operate properly.

Steering system operates properly.

Possible cause

Steering system does not operate properly.

Check before starting work.

1. Check the oil level.

2. Check that the loading control lock lever is fully released.

3. Check that the engine speed is standard value.

4. Check that the pilot valve filter is not clogged.

5. Check the error code No. shown on the MODM.

Symptoms / check point

2. Boom and/or bucket have low power, or move too slowly.

Solution

Internally damaged steering pump.

Disassembly & repair

Internally damaged main pump.

Disassembly & repair

Main relief valve internal oil leakage or low setting pressure

Disassembly & readjustment

Overload relief valve internal oil leakage (bucket bottom side)

Disassembly & readjustment

Internally damaged cylinder.

Disassembly & repair

Oil is cold or wrong oil viscosity (too thick).

Warm up hydraulics Replace oil w/proper oil

Air drawn into suction line of gear pump

Check & repair suction line

Suction line pinched or internally defective.

Check & repair suction line

Defective reducing valve

Disassembly & readjustment

Bucket or boom spool does not move smoothly.

Disassembly & repair

Solution

Internal boom cylinder piston seal oil leakage

Seal replacement

Internal bucket cylinder piston seal oil leakage

Seal replacement

Internal oil leakage from multiple control valve main spool

Disassembly & repair

Internal oil leakage from multiple control valve overload relief valve

Disassembly & repair

∗ This test may cause a serious accident. The test must be done carefully.

Remarks

Front wheels drift down when the front wheels are lifted off the ground by means of the boom cylinder.

Excessive drift of bucket.

Possible cause

Excessive drift of boom.

Symptoms / check point

The maximum drift rate is measured according to instructions on "Measuring Cylinder Drift".

When the piping for cylinder rod side is removed, pressurized oil spouts out. ∗ (The bucket hight should be 20~30 mm from the ground.)

3. Excessive cylinder drift

In the case that the overload relief valve is switched or replaced, excessive drift stops.

01-18 92ZV-2 Troubleshooting Hydraulic Group

Boom is spongy just after quick lowering.

Boom cannot support the lifted front wheels, or the lifted front wheels soon drop.

Boom and bucket are strong enough if the engine runs at the full speed while dumping or lowering.

Bucket is spongy just after dumping.

Overload relief pressure is too low.

In case that the overload relief valves are switched ∗, the boom and bucket are strong enough to support the front wheels.

Possible cause

Bucket cannot support the lifted front wheels, or the lifted front wheels soon drop.

Symptoms / check point

4. Boom and/or bucket are spongy.

(Holding bucket against the ground is not possible-front wheels off the ground.)

During digging operation, the bucket tilts back even though the lever is at the neutral position.

01-19 92ZV-2 Troubleshooting Hydraulic Group

Solution

Internal oil leakage from overload relief valve for bucket rod side

Disassembly & repair

Internal oil leakage from make-up valve for bucket rod side

Disassembly & repair

Make-up valve does not open on bucket rod side

Disassembly & repair

Internal oil leakage from make-up valve for boom rod side

Disassembly & repair

Make-up valve opening impossible on boom rod side

Disassembly & repair

Remarks

∗ Regarding check point above, switching the overload relief valves means that the valves should be changed between the rod and bottom sides of the bucket circuit.

Boom

Bucket

Check the relays and lines for lift kickout and lower kickout.

Remove the connector of the sensor assy and check that the harness (V) from chassis side supplies 5 V, harness (BY) is ground and harness (BrR) is conductive until MCU (Starter switch ON).

Magnet coil resistance value is indicated as infinity or 0 Ω.

Possible cause

Remove the connector of the proximity switch, and connect the wire harness (BrW), from the pilot valve to the ground (blue). Check that the lever is held properly.

Check before starting work.

1. Check the fuses.

2. For bucket / Check that the distance between the proximity switch and detection bar is properly adjusted.

5±2 mm (0.2±0.08 in) 3. For boom / Check that the rod and link are properly connected with the sensor assy and the bracket of the boom.

4. Check all the connectors of the electrical powerline to be sure they are properly connected.

5. Check the error code No. shown on the MODM.

Symptoms / check point

5. Bucket leveler does not work.

Boom lift kickout and lower kickout does not work.

LED lamp of the proximity switch does not light (starter switch ON & metal plate in front of proximity switch face).

01-20 92ZV-2 Troubleshooting Hydraulic Group

Solution

Defective proximity switch

Proximity switch replacement

Broken detent solenoid coil inside pilot valve

Magnet replacement

Disconnected electrical power line

Repair

Defective sensor assy

Replacement

Broken detent solenoid coil inside pilot valve

Replacement

Disconnected electrical power line for lift kickout and lower kickout

Repair

01-21 92ZV-2 Troubleshooting Hydraulic Group

Internally damaged Orbitrol

®

Sticking stop valve spool

Pump is extremely heated.

If the overload relief valves are exchanged ∗, steering problem switches sides.

Overload relief pressure is too low.

Steering relief pressure is too low.

Increasing the engine speed enables smooth operation (steering).

Steering is not possible at both the idling and full speeds.

Steering relief valve produces a noise.

Steering is possible in either the right or left direction.

Steering is not possible (or hard) in both the right and left directions.

Boom is too slow in rising.

Steering wheel is too loose (too light).

Possible cause

Steering wheel does not rotate or is heavy to rotate.

Check before starting work.

1. Check the oil level in the hydraulic tank.

2. Check that the stop bolts for the stop valves are properly adjusted.

3. Check operating conditions. Full brake application & heavy loading may create hard steering even when steering system is normal.

4. Measure steering wheel force to see if it is greater than normal.

5. Check that the inline filter is not clogged.

6. Check the error code No. shown on the MODM.

Symptoms / check point

6. Steering is not possible or hard to steer.

Solution Disassembly & repair Disassembly & repair

Internally damaged steering pump (deteriorated performance)

Disassembly & repair

Malfunctioning steering valve or flow control spool

Disassembly & repair

Defective main relief valve or flow control spool stuck

Disassembly & repair

Defective overload relief valve

Disassembly & repair

Defective steering cylinder

Disassembly & repair

Suction line is pinched or internally defective

Check & repair

Steering spool stuck

Disassembly & repair

Cold oil / viscosity too thick for weather

Warm up hydraulics Replace oil w/proper oil

Defective steering pilot line reducing valve

Disassembly & repair

Remarks

∗ Regarding check point above, exchange of the overload relief valve means that the valves should be changed between the left and right sides. The problem will switch sides also (weak steering to the left will, after exchange, become weak steering to the right).

Steering cylinders or circuit recently repaired.

Shock is noticed only when steering fully to right or left.

Possible cause

Shock is applied to the machine after quick steering.

Symptoms / check point

Check before starting work.

1. Check the error code No. shown on the MODM.

Machine sways after quick steering.

7. Machine sways, or has a shock during steering

While the machine is travelling straight, the machine sways even if the steering wheel is held steady.

01-22 92ZV-2 Troubleshooting Hydraulic Group

Solution

Loose steering cylinder pin ∗

Pin replacement or shim add

Tire having different diameter

Use of equal diameter tires

Large difference in air pressure of tires

Air pressure adjustment

Steering stopper bolt or bolts misadjusted or missing

Adjust stopper bolts

Air trapped in steering cylinders

Steer full L & R several times to purge air

Remarks

∗ Have an operator quickly move the steering wheel right and left a few degrees. If the cylinder pin moves back & forth replace the pin & bushing. If the cylinders jump up & down, add shims.

01-23 92ZV-2 Troubleshooting Hydraulic Group

At upper position of ELS setting, ELS works.

Without pressing ELS switch, if functions.

Possible cause

Pressing ELS switch, it does not function.

Check before starting work.

1. Check the error code No. shown on the MODM.

Symptoms / check point

8. ELS (Efficient Loading System) does not work.

(Excavating and scooping tractive power does not become up during ELS working condition.)

Solution

ELS switch defective

Repair

Solenoid valve coil or wiring failure

Disassembly & repair

Solenoid valve spool stuck

Disassembly & repair

Relief valve set pressure is extremely low.

Disassembly & repair

Main controller failure

Replacement

Kickout sensor defective or link, rod bent

Replacement or repair

Speed sensor failure

Replacement

01-24 92ZV-2 Troubleshooting Hydraulic Group

9. Ride control does not work.

Damping condition too hard.

Damping condition too soft.

It takes a time to function.

Possible cause

Ride control does not work.

Symptoms / check point

Check before starting work.

1. Check the error code No. shown on the MODM.

Solution

Ride control switch defective

Replacement

Charge spool stuck

Disassembly & repair

Malfunctioning reducing valve

Disassembly & repair

Malfunctioning solenoid valve

Disassembly & repair or replacement

Main spool stuck or moving slowly

Disassembly & repair

Flow control spool stuck or moving slowly

Disassembly & repair

Accumulator piston seal failure

Disassembly & repair

Accumulator gas pressure low

Check & charge gas

Depressure valve loosened

Retighten

Bucket fully roll-back till touching with stopper

Make a clearance between stoppers

01-25 92ZV-2 Troubleshooting Hydraulic Group

10. Fan motor rotates abnormally or does not rotate.

For reverse fan (OPT)

Reverse fan rotates slow or extremely slow.

OPT: Reverse fan does not rotates.

Fan motor makes noise.

Fan motor does not rotates.

Fan motor rotates faster than specified speed.

Possible cause

Fan motor rotates slow or extremely slow.

Symptoms / check point

Check before starting work.

1. Check the error code No. shown on the MODM.

Solution

Sensor (for E/G water or T/C oil or HYD. oil temperature) failure

Replacement

Safety valve setting pressure low

Check & adjust or repair

Flow control solenoid valve stuck or not enough to move

Check & repair

Wiring or connector failure

Check & repair

Reducing valve defective

Check & repair

Main controller malfunction

Replacement

Check valve failure

Replacement

Flow control spool stuck

Repair

Adjusting screw loosened

Readjust

Strainer clogged or spring (flow con.) damaged

Clean or replacement

Fan motor damaged (bearing, shoe, etc.)

Replacement

Wiring or connector failure

Repair

Main spool stuck

Repair

Reverse fan solenoid valve stuck

Repair

01-26 92ZV-2 Troubleshooting Hydraulic Group

Noise may vary with engine speed or circuit being used.

Possible cause

Pump emits a shrieking sound.

Symptoms / check point

Check before starting work.

1. Check the error code No. shown on the MODM.

Increasing the engine speed emits a whining sound. (Hydraulics slow)

11. Abnormal noise in hydraulic system.

Solution

Air drawn into pump suction line

Hose band tightening & inspection

Internally broken pump

Disassembly & repair

High-pressure hose contact with chassis-loose sheet metal

Hose clamp check & repair

Suction hose pinched or internally defective

Inspect or replace hose

Suction line or strainer restricted

Drain & inspect tank

Oil milky white

Hydraulic cylinder packings leak repeatedly.

Hydraulic oil is mixed with the torque converter oil.

Hydraulic oil is foaming in the tank.

Boom or bucket lever operation is heavy or too light.

Possible cause

When the boom lever is switched from "DOWN" to "NEUTRAL", the boom will continue to lower. ∗

Symptoms / check point

Check before starting work.

1. Check the error code No. shown on the MODM.

When the bucket lever is set to "Roll-back" position, the bucket will be dumped slightly down first and then tilt back.

12. Others

When the boom lever is set to "UP" position, the boom will drop slightly first and then rise.

01-27 92ZV-2 Troubleshooting Hydraulic Group

Solution

Defective (incompletely closed) load check valve in multiple control valve boom line

Disassembly & repair

Defective (incompletely closed) load check valve in multiple control valve bucket line

Disassembly & repair

Clogged orifice of adapter in boom line ∗

Disassembly & repair

Pilot valve is sticking or not enough movement

Disassembly & repair

Air drawn into pump suction line

Tightening hose band

Damaged hydraulic oil pump (Seal)

Repair

Excessive hydraulic oil temp, due to cooler problems or improper operation

Test cooling Change operation

Water in hydraulic oil

Drain & replace oil

Remarks

∗ Very cold or thick oil will also cause this symptom. If the problem stops when the oil warms up or the proper viscosity oil is used the orifice is normal. Clogged adapter orifice will cause slow boom response in both up and down directions.

01-28 92ZV-2 Troubleshooting Brake Group

Brake pedal stroke is large.

Brake is hard to work when the right pedal is depressed.

Possible cause

When the pedal is pressed, the brake oil pressure greatly differs between the front axle brake and rear axle brake.

Check before starting work.

1. Check the Nitrogen gas pressure in the accumulator.

2. Check the brake piping for leakage.

3. Check the error code No. shown on the MODM. 4. Check brake oil pressure and accumulator pressure by MODM.

Symptoms / check point

1. Brake does not work well.

(In the worst case, the brake does not work at all.)

Measure the wear of the brake disk using calipers. The obtained wear value is less than the specified limit value.

Brake Group

Solution

Worn brake disk

Disassembly & repair

Sticking brake valve spool

Disassembly & repair

Damaged brake oil pipe

Pipe replacement

Damaged brake piston seals one wheel

Seal replacement

Defective shaft between left and right

Disassembly & repair

Defective pedal stroke adjustment

Disassembly & repair

01-29 92ZV-2 Troubleshooting Brake Group

2. Brake is dragging when released.

Tire can not be rotated by manually.

Either the front or rear axle causes dragging.

Possible cause

Brake is dragging.

Check before starting work.

1. Check the error code No. shown on the MODM.

Symptoms / check point

How to check dragging.

1. Check that the cover of the planetary gear is too hot (more than 100ºC [212ºF]).

2. Jack up the tires, and check if tire can be rotated by hand.

Solution

Stepping on brake pedal during traveling

Instruction for operator

Insufficient return of brake pedal

Disassembly & repair

Deformed brake disc

Disassembly & repair

Insufficient return of brake piston

Disassembly & repair

Non-returned brake piston after replacement of brake disk

Disassembly & repair

Defective pedal stroke adjustment

Disassembly & repair

Defective brake valve

Disassembly & repair

01-30 92ZV-2 Troubleshooting Brake Group

3. Stepping on the brake pedal sounds the buzzer.

Parking brake is not released.

Too much time is required for accumulator charging.

Buzzer sounds when the pedal is repeatedly depressed.

Possible cause

Buzzer sounds each time when the brake pedal is stepped on.

Check before starting work.

1. Check the accumulator Nitrogen gas pressure.

2. Step on the pedal, and check that oil is not leaking.

3. Check the error code No. shown on the MODM. 4. Check the accumulator pressure by MODM.

Symptoms / check point

Conditions for buzzer sounding.

1. Low accumulator pressure [3.9 MPa (40 kgf/cm2) (569 psi) or less].

Solution

Insufficient pressure in accumulator

Adjust gas pressure

Unloader valve "Cut-in" pressure is too low

Inspection & readjustment

Delay in working unloader valve

Inspection & readjustment

Large amount of oil leakage from brake piping

Disassembly & repair

Defective pilot pump

Replace pump

01-31 92ZV-2 Troubleshooting Brake Group

4. Accumulator pressure does not rise, or too slow in rising.

Low accumulator pressure in a certain accumulator only.

Possible cause

Low accumulator pressure in all two accumulators.

Symptoms / check point

Check before starting work.

1. Check the error code No. shown on the MODM. 2. Check the accumulator pressure by MODM.

Solution

Unloader valve "Cut-in" pressure is too low

Inspection & readjustment

Defective unloader valve

Disassembly & repair

Internally damaged accumulator

Disassembly & repair

Defective pilot pump

Replace pump

Heavy movement of solenoid valve manual release knob.

Coil of the solenoid valve has extremely high or zero resistance.

Turning on/off the parking brake switch activates the link under the cylinder.

Parking brake can be released by manually.

Parking brake remains unreleased.

Possible cause

Brake does not work even if the parking switch is turned to "ON" position.

Check before starting work.

1. Check the fuses of the electrical system.

2. Check the main accumulator pressure.

3. Check the error code No. shown on the MODM.

Symptoms / check point

5. Parking brake does not work. (or: Releasing the parking brake is not possible.)

Turning on/off the parking brake switch causes a solenoid valve emitting noise.

01-32 92ZV-2 Troubleshooting Brake Group

Solution

Defective coil of parking solenoid valve

Solenoid valve replacement

Sticking spool of parking solenoid valve

Solenoid valve replacement

Oil leaking from line between solenoid valve and parking brake cylinder

Inspection & repair

Defective parking brake switch

Switch replacement

Disconnected or defective electrical line

Repair cable

Defective link between parking brake cylinder and brake drum

Inspection & repair

Worn brake lining

Readjustment

Accumulator pressure is low.

Inspection & repair

01-33 92ZV-2 Troubleshooting Electrical Group

Electrical Group

Energized T/M solenoid valve does not correspond with the shift lever position.

Hour meter does not operate.

Pointers of all the gauges are deflected to their limits.

One of the gauges does not indicate properly. ∗

All the gauge pointers do not move.

One of the gauge pointers does not move.

During operation, two or more monitor lamps light improperly.

During operation, one of the monitor lamps lights improperly.

Two or more monitor lamps will not light after setting the starter key to ON.

Possible cause

One of the monitor lamps will not light after setting the starter key to ON.

Check before starting work.

1. Check the fuses.

2. Check if bulb(es) of monitor is / are burnt out.

3. Check the error code No. shown on the MODM.

Symptoms / check point

1. Instrument panel does not indicate properly.

Solution

Bulb of monitor lamp burnt out

Bulb replacement

Defective sensor or improper wiring

Sensor replacement

Loosen connector or improper electrical wiring

Repairing cable

Defective controller

Controller replacement

Defective gauge or meter

Replacement

Defective instrument panel

Replacement

T/M solenoid valve improperly connected.

Properly connect

01-34 92ZV-2 Troubleshooting Electrical Group

Fuse blows off when a certain speed or direction is selected.

Coil of the solenoid valve has extremely low resistance.

Fuse blows off if the machine sways during travelling.

Possible cause

Fuse blows off immediately after replacing.

Symptoms / check point

Check before starting work.

1. Check the error code No. shown on the MODM.

Parking brake remains unreleased regardless of the parking brake switch position.

2. Fuse for controller is blown.

Solution

Controller power line contacts with chassis.

(Wire pinched by other components, etc.)

Inspection & repair

Controller power line occasional contacts with chassis.

Inspection & repair

Clutch solenoid valve coil shortcircuited

Solenoid valve replacement

Clutch solenoid valve diode failed

Solenoid valve replacement

Neutral or controller failure or kickout relay power line contacts with chassis.

Inspection & repair

Neutral or controller failure or kickout relay power line occasional contacts with chassis.

Inspection & repair

Parking brake solenoid valve power line contacts with chassis.

Inspection & repair

Parking brake solenoid valve power line occasional contacts with chassis.

Inspection & repair

01-35 92ZV-2 Troubleshooting Electrical Group

Error code (for chassis) Failure code (Input side) Code

Failure

Detection condition (In case of)

CN121

Shift lever F & R switch malfunction

Shift lever F & R contact ON at the same time Failure continues for more than 3 seconds

CN122

Shift lever 1•2•3•A switch malfunction (1)

Shift lever any of more than two 1•2•3•A contact ON at the same time Failure continues for more than 3 seconds

CN123

Shift lever 1•2•3•A switch malfunction (2)

All 1•2•3•A signal OFF continues for more than 3 seconds

CN141

Shift-up switch malfunction

Switch is ON for more than 10 seconds

CN142

Shift-down switch malfunction

Switch is ON for more than 10 seconds

CN143

Shift-up switch & shift-down switch malfunction

Shift-up switch & shift-down switch contact ON at the same time Failure continues for more than 3 seconds

CN145

Kick-down switch malfunction

Switch is ON for more than 10 seconds

CN146

Shift hold switch malfunction

Switch is ON for more than 10 seconds

CN151

T/M oil pressure switch malfunction (This applies to the model 115ZV-2/135ZV-2 only)

Signal OFF continues for more than 10 seconds during engine running

CN152

T/M oil pressure sensor malfunction (This applies to the model 95ZV-2 only)

T/M pressure below 294 kPa (3.0 kgf/cm2) (43 psi) continues for more than 10 seconds during engine running

CN161

Machine speed sensor malfunction (1)

Input circuit is disconnected for more than 3 seconds

CN162

Machine speed sensor malfunction (2)

Input value is over 70 km/h (44 mile/h) for more than 3 seconds

CN163

E/G speed sensor 1 (ECM output) malfunction (1)

No E/G speed sensor input for more than 3 seconds when E/G speed sensor selection is OFF (Input circuit is disconnected)

CN164

E/G speed sensor 1 (ECM output) malfunction (2)

Input value is more than 3,000 min-1 for more than 3 seconds when E/G speed sensor selection is OFF

CN165

E/G speed sensor 2 (Sensor output) malfunction (1)

No E/G speed sensor input for more than 3 seconds when E/G speed sensor selection is ON (Input circuit is disconnected)

CN167

E/G speed sensor 2 (Sensor output) malfunction (2)

Input value is more than 3,000 min-1 for more than 3 seconds when E/G speed sensor selection is ON

CN213

Inching sensor malfunction (1)

Voltage is lower than 0.2 V for more than 3 seconds

CN214

Inching sensor malfunction (2)

Voltage is larger than 4.6 V for more than 3 seconds

CN232

S/S potentiometer malfunction (1)

Voltage is lower than 0.1 V for more than 3 seconds

CN234

S/S potentiometer malfunction (2)

Voltage is larger than 4.9 V for more than 3 seconds

CN236

S/S shift switch (F & R contact) malfunction

Failure continues for more than 3 seconds

CN251

Secondary steering oil pressure sensor malfunction(1)

Voltage is lower than 0.2 V for more than 3 seconds

CN252

Secondary steering oil pressure sensor malfunction (2)

Voltage is larger than 4.6 V for more than 3 seconds

CN254

Low secondary steering oil pressure

Oil pressure sensor detects secondary steering oil pressure below 306 kPa (3.1 kgf/cm2) (44 psi) for more than 3 seconds during engine running

CN262

Kickout potentiometer malfunction (1)

Voltage is lower than 0.2 V for more than 3 seconds

CN263

Kickout potentiometer malfunction (2)

Voltage is larger than 4.6 V for more than 3 seconds

CN271

Efficient loading system hydraulic oil pressure senVoltage is lower than 0.2 V for more than 3 seconds sor malfunction (1)

CN272

Efficient loading system hydraulic oil pressure senVoltage is larger than 4.6 V for more than 3 seconds sor malfunction (2)

CN312

Brake oil pressure sensor 1 malfunction (1)

CN313

Brake oil pressure sensor 1 malfunction (2)

Voltage is larger than 4.6 V for more than 3 seconds

CN315

Brake oil pressure sensor 2 malfunction (1)

Voltage is lower than 0.2 V for more than 3 seconds

Voltage is lower than 0.2 V for more than 3 seconds

CN316

Brake oil pressure sensor 2 malfunction (2)

Voltage is larger than 4.6 V for more than 3 seconds

CN321

E/G coolant temperature sensor malfunction (1)

Input voltage is larger than 3.56 V for more than 3 seconds

CN323

E/G coolant temperature sensor malfunction (2)

Input voltage is lower than 0.263 V for more than 3 seconds

CN341

T/M oil temperature sensor malfunction (1)

Input voltage is larger than 3.56 V for more than 3 seconds

CN342

T/M oil temperature sensor malfunction (2)

Input voltage is lower than 0.263 V for more than 3 seconds

01-36 92ZV-2 Troubleshooting Electrical Group

Code

Failure

Detection condition (In case of)

CN351

Hydraulic oil temperature sensor malfunction (1)

Input voltage is larger than 3.56 V for more than 3 seconds

CN352

Hydraulic oil temperature sensor malfunction (2)

Input voltage is lower than 0.263 V for more than 3 seconds

CN381

Fuel level sensor malfunction

Input signal corresponds to "any other pattern" in fuel level indication table

CN391

Air temperature probe malfunction (1)

Input voltage is larger than 4.35 V for more than 3 seconds

CN392

Air temperature probe malfunction (2)

Input voltage is lower than 0.13 V for more than 3 seconds

CN412

Abnormal brake oil pressure (1)

Brake oil pressure sensor 1 detects pressure below 4,081 kPa (41.6 kgf/ cm2) (592 psi) for more than 1 second during engine running

CN413

Abnormal brake oil pressure (2)

Brake oil pressure sensor 2 detects pressure below 4,081 kPa for (41.6 kgf/cm2) (592 psi) more than 1 second during engine running

CN414

Abnormal brake oil pressure difference

Brake oil pressure difference switch is in abnormal condition for more than 1 second

CN415

Abnormal brake oil amount

Brake oil amount switch is in abnormal condition for more than 1 second

CN421

Abnormal engine oil pressure

Engine oil pressure switch is OFF for more than 2 seconds during engine running

CN431

Abnormal engine coolant temperature (1)

Engine coolant temperature switch is ON for more than 2 seconds

CN432

Abnormal engine coolant temperature (2)

Engine coolant temperature sensor is in 101 deg. C (214 deg. F) condition for more than 2 seconds

CN451

Abnormal T/M oil temperature (1)

T/M oil temperature switch is ON for more than 2 seconds

CN452

Abnormal T/M oil temperature (2)

T/M oil temperature sensor is in 122 deg. C (252 deg. F) condition for more than 2 seconds

CN461

Abnormal hydraulic oil temperature

Hydraulic oil temperature sensor is in 100 deg. C (212 deg. F) condition for more than 2 seconds

CN471

Clogged T/M oil filter

30 minutes after starter switch is ON, T/M oil filter switch is ON for more than 2 seconds when T/M oil temperature sensor detects oil temperature more than 60 deg. C (140 deg. F)

CN481

Clogged air cleaner element

Air cleaner switch is ON for more than 2 seconds

CN491

Abnormal cooling water level in radiator

Radiator cooling water level switch is OFF for more than 2 seconds when the engine is off.

CN496

Abnormal hydraulic oil level

Hydraulic oil level switch is in abnormal condition for more than 30 seconds

CN497

Abnormal brake disc oil temperature (This applies to the model 135ZV-2 only)

Brake disc oil temperature switch is ON for more than 1 second

CN498

Abnormal disc wear (This applies to the model 135ZV-2 only)

Brake disc wear switch is ON for more than 1 second

CN801

CAN disconnect

CAN line is disconnected

CN802

Abnormal engine coolant temperature (CAN)

No engine coolant temperature data received for more than 3 seconds

CN912

Abnormal MCU voltage (1)

Voltage is larger than 30±1 V

CN913

Abnormal MCU voltage (2)

Voltage is lower than 22±0.5 V for more than 10 seconds during engine running

Fuel level display table Input

Note This table applies to the 95/115/135ZV-2 units.

Output

1/8

1/4

1/2

3/4

F

x

x

x

x

x

x

x

x

x

x

x

x

—

x

x

—

—

x

—

—

—

—

—

—

—

—

—

—

—

Other than above : No input signal given x : Input signal given

E

: Lamp on — : Lamp off

1/4

1/2

3/4

F

—

—

—

—

—

—

—

—

—

—

—

—

— —

: Lamp flashing

—

01-37 92ZV-2 Troubleshooting Electrical Group

Failure code (Output side) Code CN512

Failure

Detection condition

F solenoid valve malfunction

F solenoid valve is short-circuited or disconnected

CN514

R solenoid valve malfunction

R solenoid valve is short-circuited or disconnected

CN516

1st solenoid valve malfunction

1st solenoid valve is short-circuited or disconnected

CN518

2nd solenoid valve malfunction

2nd solenoid valve is short-circuited or disconnected

CN521

3rd solenoid valve malfunction

3rd solenoid valve is short-circuited or disconnected

CN524

4th solenoid valve malfunction

4th solenoid valve is short-circuited or disconnected

CN526

D solenoid valve malfunction

D solenoid valve is short-circuited or disconnected

CN528

H solenoid valve malfunction

H solenoid valve is short-circuited or disconnected

CN531

LU solenoid valve malfunction

LU solenoid valve is short-circuited or disconnected

CN534

Auto brake solenoid valve malfunction

Auto brake solenoid valve is short-circuited or disconnected

CN536

Speed change control solenoid valve malfunction (1)

Speed change control solenoid valve is short-circuited

CN537

Speed change control solenoid valve malfunction (2)

Speed change control solenoid valve is disconnected

CN621

S/S solenoid valve R malfunction (1)

S/S solenoid valve R is short-circuited

CN622

S/S solenoid valve R malfunction (2)

S/S solenoid valve R is disconnected

CN623

S/S solenoid valve L malfunction (1)

S/S solenoid valve L is short-circuited

CN624

S/S solenoid valve L malfunction (2)

S/S solenoid valve L is disconnected

CN631

Pressure increase solenoid valve malfunction

Pressure increase solenoid valve is short-circuited or disconnected

CN641

Ride control solenoid valve malfunction

Ride control solenoid valve is short-circuited or disconnected

CN681

Efficient loading system selection solenoid valve malfunction

Efficient loading system selection solenoid valve is short-circuited or disconnected

CN693

Lower kickout relay malfunction (1)

Lower kickout relay (coil) is short-circuited

CN694

Lower kickout relay malfunction (2)

Lower kickout relay (coil) is disconnected

CN712

Cooling fan solenoid valve malfunction (1)

Cooling fan solenoid valve is short-circuited

CN713

Cooling fan solenoid valve malfunction (2)

Cooling fan solenoid valve is disconnected

CN721

Hour meter drive malfunction

Hour meter drive is short-circuited

01-38 92ZV-2 Troubleshooting Electrical Group

Error code (for engine) These codes show the fault codes for the engine failure displayed on the MODM error log monitor, or checked by the diagnostic switch (option).

EG111 Red

Engine Control Module (ECM) - critical internal failure.

EG113 Yellow

Engine Timing Actuator Circuit - shorted high.

EG114 Yellow

Engine Timing Actuator Circuit - shorted low.

EG115 Red

Engine Speed / Camshaft Position Sensor Circuit - lost both of two signals from the magnetic pickup sensor.

EG121 Yellow

Engine Speed / Position Sensor Circuit - lost one of two signals from the magnetic pickup sensor.

EG122 Yellow

Intake Manifold Pressure Sensor #1 Circuit - shorted high.

EG123 Yellow

Intake Manifold Pressure Sensor #1 Circuit - shorted low.

EG124 Yellow

Intake Manifold Pressure - above normal operation.

EG131 Red

Accelerator Pedal Position Sensor Circuit - shorted high.

EG132 Red

Accelerator Pedal Position Sensor Circuit - shorted low.

EG133 Red

Remote Accelerator Pedal Position Sensor Circuit - shorted high.

EG134 Red

Remote Accelerator Pedal Position Sensor Circuit - shorted low.

EG135 Yellow

Engine Oil Pressure Sensor Circuit - shorted high.

EG141 Yellow

Engine Oil Pressure Sensor Circuit - shorted low.

EG143 Yellow

Engine Oil Pressure Low - warning.

EG144 Yellow

Engine Coolant Temperature Sensor Circuit - voltage above normal or shorted high.

EG145 Yellow

Engine Coolant Temperature Sensor Circuit - voltage below normal or shorted low.

EG146 Yellow

Engine Coolant Temperature High - warning.

EG151 Red

Engine Coolant Temperature High - critical.

EG153 Yellow

Intake Manifold Air Temperature Sensor Circuit - voltage above normal or shorted high.

EG154 Yellow

Intake Manifold Air Temperature Sensor Circuit - voltage below normal or shorted low.

QST30 (135ZV-2)

QSK19 (115ZV-2)

QSX15 (95ZV-2)

QSM11 (92ZV-2)

QSM11 (90ZV-2)

QSC8.3 (85ZV-2)

QSC8.3 (80ZV-2)

DESCRIPTION

QSB6.7 (70ZV-2) (70TMV-2)

FAULT CODE/ LAMP

QSB4.5 (60ZV-2)

Please note that not all are used in the 92ZV-2 machine application. Refer to Cummins Engine troubleshooting fault codes list for more information.

EG155 Red

Intake Manifold Air Temperature Sensor High - critical.

EG166 Yellow

Rack Position Sensor #1 Circuit - shorted high.

EG172 Red

Rack Actuator Position #1 Circuit - grounded circuit.

EG173 Yellow

Rack Actuator - mechanically stuck open.

EG184 Yellow

Engine Control Module Identification Input State Error.

EG185 Yellow

Engine Control Module Network Communication Error.

EG187 Yellow

Sensor Supply Voltage #2 Circuit - shorted low.

EG212 Yellow

Engine Oil Temperature Sensor Circuit - shorted high.

EG213 Yellow

Engine Oil Temperature Sensor Circuit - shorted low.

EG214 Red

Engine Oil Temperature High - Critical.

EG221 Yellow

Ambient Air Pressure Sensor Circuit - shorted high.

EG222 Yellow

Ambient Air Pressure Sensor Circuit - shorted low.

EG227 Yellow

Sensor Supply Voltage #2 Circuit - shorted high.

EG231 Yellow

Engine Coolant Pressure Sensor Circuit - shorted high.

EG232 Yellow

Engine Coolant Pressure Sensor Circuit - shorted low.

EG233 Yellow

Engine Coolant Pressure Low - warning.

EG234 Red

Engine Speed High - critical.

EG238 Yellow

Sensor Supply Voltage #3 Circuit - shorted low.

EG254 Red

Fuel Shutoff Valve Circuit - shorted low.

EG255 Yellow

Fuel Shutoff Valve Circuit - shorted high.

EG259 Red

Fuel Shutoff Valve - stuck open.

EG261 Yellow

Fuel Temperature High - warning.

EG263 Yellow

Fuel Temperature Sensor Circuit - shorted high.

EG265 Yellow

Fuel Temperature Sensor Circuit - shorted low.

EG266 Red

Engine Fuel Temperature - data valid but above normal operational range - most severe level.

EG271 Yellow

Fuel Control Actuator Circuit - shorted low.

EG272 Yellow

Fuel Control Actuator Circuit - shorted high.

QST30 (135ZV-2)

QSK19 (115ZV-2)

QSX15 (95ZV-2)

QSM11 (92ZV-2)

QSM11 (90ZV-2)

QSC8.3 (85ZV-2)

QSC8.3 (80ZV-2)

DESCRIPTION

QSB6.7 (70ZV-2) (70TMV-2)

FAULT CODE/ LAMP

QSB4.5 (60ZV-2)

01-39 92ZV-2 Troubleshooting Electrical Group

EG281 Yellow

Injection Pump Mechanical System - signal not in range from ECM.

EG284 Yellow

Engine Speed / Position Sensor #1 (Crankshaft) Supply Voltage Circuit - shorted low.

EG285 Yellow

SAE J1939 Data Link Multiplexing PGN Timeout Error.

EG286 Yellow

SAE J1939 Data Link Multiplexing Configuration Error.

EG287 Red

SAE J1939 Multiplexing Accelerator Pedal Sensor System Error.

EG295 Yellow

Ambient Air Pressure Sensor Circuit - data incorrect.

EG299 Yellow

Engine stopped not using Starter Switch.

EG311 Yellow

Injector Solenoid Valve Cylinder #1 Circuit - grounded circuit.

EG312 Yellow

Injector Solenoid Valve Cylinder #5 Circuit - grounded circuit.

EG313 Yellow

Injector Solenoid Valve Cylinder #3 Circuit - grounded circuit.

EG314 Yellow

Injector Solenoid Valve Cylinder #6 Circuit - grounded circuit.

EG315 Yellow

Injector Solenoid Valve Cylinder #2 Circuit - grounded circuit.

EG319 Yellow

Real Time Clock - power Interrupt.

EG321 Yellow

Injector Solenoid Valve Cylinder #4 Circuit - grounded circuit.

EG322 Yellow

Injector Solenoid Valve Cylinder #1 Circuit - open circuit.

EG323 Yellow

Injector Solenoid Valve Cylinder #5 Circuit - open circuit.

EG324 Yellow

Injector Solenoid Valve Cylinder #3 Circuit - open circuit.

EG325 Yellow

Injector Solenoid Valve Cylinder #6 Circuit - open circuit.

EG331 Yellow

Injector Solenoid Valve Cylinder #2 Circuit - open circuit.

EG332 Yellow

Injector Solenoid Valve Cylinder #4 Circuit - open circuit.

EG334 Yellow

Coolant Temperature Sensor Circuit - data erratic, intermittent, or incorrect.

EG341 Yellow

Engine Control Module - data lost.

EG342 Red

Engine Control Module - out of calibration.

EG343 Yellow

Engine Control Module - warning internal hardware failure.

EG346 Yellow

Engine Control Module - warning software error.

EG351 Yellow

Injector Power Supply.

EG352 Yellow

Sensor Supply Voltage #1 Circuit - shorted low.

QST30 (135ZV-2)

QSK19 (115ZV-2)

QSX15 (95ZV-2)

QSM11 (92ZV-2)

QSM11 (90ZV-2)

QSC8.3 (85ZV-2)

QSC8.3 (80ZV-2)

DESCRIPTION

QSB6.7 (70ZV-2) (70TMV-2)

FAULT CODE/ LAMP

QSB4.5 (60ZV-2)

01-40 92ZV-2 Troubleshooting Electrical Group

EG378 Yellow

Fueling Actuator #1 Circuit - open circuit.

EG379 Yellow

Fueling Actuator #1 Circuit - grounded circuit.

EG386 Yellow

Sensor Supply Voltage #1 Circuit - shorted high.

EG387 Yellow

Accelerator Pedal Position Sensor Supply Voltage Circuit - shorted high.

EG394 Yellow

Timing Actuator #1 Circuit - open circuit.

EG395 Yellow

Timing Actuator #1 Circuit - grounded circuit.

EG396 Yellow

Fueling Actuator #2 Circuit - open circuit.

EG397 Yellow

Fueling Actuator #2 Circuit - grounded circuit.

EG398 Yellow

Timing Actuator #2 Circuit - open circuit.

EG399 Yellow

Timing Actuator #2 Circuit - grounded circuit.

EG415 Red

Engine Oil Pressure Low - critical.

EG418 Yellow

Water in Fuel Indicator High - maintenance.

EG419 Yellow

Intake Manifold Boost Pressure Imbalance.

EG423 Yellow

Fuel Timing Pressure or Timing Actuator Stuck.

EG428 Yellow

Water in Fuel Sensor Circuit - shorted high.

EG429 Yellow

Water in Fuel Sensor Circuit - shorted low.

EG431 Yellow

Accelerator Pedal Idle Validation Circuit - data incorrect.

EG432 Red

Accelerator Pedal Idle Validation Circuit - out of calibration.

EG433 Yellow

Intake Manifold Pressure Sensor Circuit - data incorrect.

EG434 Yellow

Voltage to ECM less than 6 V

EG435 Yellow

Engine Oil Pressure Switch Circuit - data incorrect.

EG441 Yellow

Battery #1 Voltage Low - warning.

EG442 Yellow

Battery #1 Voltage High - warning.

EG443 Yellow

Accelerator Pedal Position Sensor Supply Voltage Circuit - shorted low.

EG449 Yellow

Fuel Pump Delivery Pressure High - warning.

EG451 Yellow

Injector Metering Rail #1 Pressure Sensor Circuit - shorted high.

EG452 Yellow

Injector Metering Rail #1 Pressure Sensor Circuit - shorted low.

QST30 (135ZV-2)

QSK19 (115ZV-2)

QSX15 (95ZV-2)

QSM11 (92ZV-2)

QSM11 (90ZV-2)

QSC8.3 (85ZV-2)

QSC8.3 (80ZV-2)

DESCRIPTION

QSB6.7 (70ZV-2) (70TMV-2)

FAULT CODE/ LAMP

QSB4.5 (60ZV-2)

01-41 92ZV-2 Troubleshooting Electrical Group

EG465 Yellow

Turbocharger #1 Wastegate Control Circuit - shorted high.

EG466 Yellow

Turbocharger #1 Wastegate Control Circuit - shorted low.

EG482 Yellow

Fuel Pressure Low - warning.

EG483 Yellow

Injector Metering Rail #2 Pressure Sensor Circuit - shorted high.

EG484 Yellow

Injector Metering Rail #2 Pressure Sensor Circuit - shorted low.

EG485 Yellow

Injector Metering Rail #2 Pressure High - warning.

EG486 Yellow

Injector Metering Rail #2 Pressure Low - warning.

EG488 Yellow

Intake Manifold Temperature High - warning.

EG491 Yellow

Turbocharger #2 Wastegate Control Circuit - shorted high.

EG492 Yellow

Turbocharger #2 Wastegate Control Circuit - shorted low.

EG496 Yellow

Engine Speed / Position Sensor #2 (Camshaft) Supply Voltage.

EG524 Yellow

OEM Alternate Droop Switch Validation - data incorrect.

EG527 Yellow

Auxiliary Input / Output #2 Circuit - shorted high.

EG528 Yellow

OEM Alternate torque validation switch - data incorrect.

EG529 Yellow

Auxiliary Input / Output #3 Circuit - shorted high.

EG546 Yellow

Fuel Delivery Pressure Sensor Circuit - shorted high.

EG547 Yellow

Fuel Delivery Pressure Sensor Circuit - shorted low.

EG551 Yellow

Accelerate Pedal Idle Validation Circuit - shorted low.

EG553 Yellow

Injector Metering Rail #1 Pressure High - warning level.

EG554 Yellow

Fuel Pressure Sensor Error.

EG559 Yellow

Injector Metering Rail #1 Pressure Low - data valid but below normal operational range - moderately severe level.

EG596 Yellow

Electrical Charging System Voltage High - warning level.

EG598 Red

Electrical Charging System Voltage Low - critical level.

EG689 Yellow

Crankshaft Engine Speed Signal Error.

EG731 Yellow

Mechanical Timing Misalignment.

EG753 Yellow

Crankshaft Position Sensor and Camshaft Position Sensor - data erratic, intermittent, or in correct.

EG757 Yellow

Electronic Control Module Data Lost.

QST30 (135ZV-2)

QSK19 (115ZV-2)

QSX15 (95ZV-2)

QSM11 (92ZV-2)

QSM11 (90ZV-2)

QSC8.3 (85ZV-2)

QSC8.3 (80ZV-2)

DESCRIPTION

QSB6.7 (70ZV-2) (70TMV-2)

FAULT CODE/ LAMP

QSB4.5 (60ZV-2)

01-42 92ZV-2 Troubleshooting Electrical Group

EG758 Yellow

Injector Metering Rail #2 Pressure Malfunction.

EG778 Yellow

Engine Speed Sensor (Camshaft) - data erratic, intermittent, or incorrect.

EG951 None

Cylinder Power Imbalance Detected.

EG1117 None

Power Lost with Ignition ON - data erratic, intermittent, or incorrect.

EG1358 Yellow

Accelerator Pedal Position Sensor 1 Circuit - voltage above normal or shorted high.

EG1359 Yellow

Accelerator Pedal Position Sensor 1 Circuit - voltage below normal or shorted low.

EG1361 Yellow

Remote Accelerator Pedal Position Sensor 1 Circuit - voltage below normal or shorted low.

EG1376 Orange

Engine Camshaft Speed / Position Sensor - data erratic, intermittent, or incorrect.

EG1595 Yellow

Remote Accelerator Pedal Position Sensor 1 Circuit - voltage above normal or shorted high.

EG1597 Orange

Engine Control Module Critical Internal Failure - bad intelligent device or component.

EG1845 Orange

Water in Fuel Indicator Sensor Circuit - voltage above normal or shorted to high source.

EG1846 Orange

Water in Fuel Indicator Sensor Circuit - voltage below normal or shorted to low source.

EG1852 Yellow

Water in Fuel Indicator - data valid but above normal operational range moderately severe level.

EG1911 Yellow

Injector Metering Rail 1 Pressure - above normal operating range.

EG2185 Yellow

Sensor Supply Voltage #4 Circuit - shorted high.

EG2186 Yellow

Sensor Supply Voltage #4 Circuit - shorted low.

EG2215 Yellow

Fuel Pump Delivery Pressure - data valid but below normal operational range moderately severe level.

EG2249 Yellow

Fuel Pump Delivery Pressure Sensor Circuit - shorted low.

EG2261 Orange

Fuel Pump Delivery Pressure - data valid but above normal operational range least severe level.

EG2262 Orange

Fuel Pump Delivery Pressure - data valid but below normal operational range least severe level.

EG2265 Yellow

Fuel Priming Pump Control Signal Circuit - shorted high.

EG2266 Yellow

Fuel Priming Pump Control Signal Circuit - shorted low.

EG2311 Yellow

Fueling Actuator #1 Circuit Error - condition exists.

EG2321 None

Engine Speed Sensor #1 - data erratic, intermittent, or incorrect.

EG2322 None

Engine Speed Sensor #2 - data erratic, intermittent, or incorrect.

EG2697 Orange

Accelerator Pedal Position Sensor Circuit and Idling Position Detection Switch Circuit - data erratic, intermittent, or incorrect.

EG2963 None

Engine Coolant Temperature High - warning.

QST30 (135ZV-2)

QSK19 (115ZV-2)

QSX15 (95ZV-2)

QSM11 (92ZV-2)

QSM11 (90ZV-2)

QSC8.3 (85ZV-2)

QSC8.3 (80ZV-2)

DESCRIPTION

QSB6.7 (70ZV-2) (70TMV-2)

FAULT CODE/ LAMP

QSB4.5 (60ZV-2)

01-43 92ZV-2 Troubleshooting Electrical Group

EG2964 None

Intake Manifold Temperature High - warning.

EG2973 Yellow

Intake Manifold Pressure Sensor Circuit - data erratic, intermittent, or incorrect.

(09D20E)

QST30 (135ZV-2)

QSK19 (115ZV-2)

QSX15 (95ZV-2)

QSM11 (92ZV-2)

QSM11 (90ZV-2)

QSC8.3 (85ZV-2)

QSC8.3 (80ZV-2)

DESCRIPTION

QSB6.7 (70ZV-2) (70TMV-2)

FAULT CODE/ LAMP

QSB4.5 (60ZV-2)

01-44 92ZV-2 Troubleshooting Electrical Group

01-45 92ZV-2 Troubleshooting Operator Station Group

Operator Station Group Air conditioner

∗ Error code table

Fault diagnosis procedure

Display

Hearing check

Error code check ∗

Phenomenon check

Basic check In accordance with fault phenomenon

1) Control mechanism 2) V-belt 3) Sight glass 4) Piping connection

Refrigerant cycle check - Pressure check - Gas leak check

Electrical system check

Repair/check

End

80V2E01012

Failure mode

E-

No failure

E11

Wire breakage in inside air sensor

E12

Short-circuit in inside air sensor

E13

Wire breakage in outside air sensor

E14

Short-circuit in outside air sensor

E15

Wire breakage in water temperature sensor

E16

Short-circuit in water temperature sensor

E18

Short-circuit in insolation sensor

E21

Wire breakage in vent sensor

E22

Short-circuit in vent sensor

E43

Abnormality in vent damper

E44

Abnormality in air mixing damper

E45

Abnormality in inside/outside air

E51

Abnormality in refrigerant pressure

01-46 92ZV-2 Troubleshooting Operator Station Group Basic check 1. Check of control mechanism Operate the switch arranged on the control panel, to check that it is operable smoothly and securely.

2. Check of V-belt Check that the V-belt is tensioned properly, and that it is not damaged.

3. Check of refrigerant level through sight glass When the air bubble is observed a lot through sight glass, the refrigerant is probably insufficient.

In such a case, therefore, perform the checking with using a gauge manifold.

Sight glass

Receiver joint

Receiver drier

95ZVE01003

4. Check of piping connection At the piping connection where the oil stain is seen, there is probably a refrigerant leakage.

In such a case, remove the stain, and then check for gas leakage.

Cooling failure

Normal air flow rate

With diagnostic display: E51 (refrigerant high/ lower pressure error)

With diagnostic display: E44 (A/M servo motor error)

Without diagnostic display

Air flow rate failure

<Trouble shooting charts>

Close the window and door.

Adjust the inside/outside air changeover damper.

Re-set the link.

See D-2 .

See D-1 .

See C-3 .

Check the wiring.

Replace the servo motor with a new one.

Remove the foreign matter.

Replace the V-belt with a new one.

Replace the compressor with a new one.

Repair the magnet switch, or replace it with a new one.

Check the wiring.

Insufficient refrigerant.

See C-4 .

See C-5 .

See C-1 .

Servomotor failure Blocked foreign matter

Wiring failure, disconnection, disengaged connector

Magnet clutch failure Clutch engagement failure due to electrical system failure

Broken or slipped belt Compressor failure (locking)

High pressure both at high-pressure side and low-pressure side Low pressure both at high-pressure side and low-pressure side

Too low pressure at high-pressure side(Pressure is not increased to approx. 981kPa[10kgf/cm2] or over) Too low pressure at low-pressure side(Pressure is decreased to approx. 49kPa[0.5kgf/cm2] or less

See C-2 .

See C-3 .

∗ Examine the cause before taking the corrective measure,and then replace the fuse with that of the same capacity.

See B-1 .

Replace the blower main relay with a new one.

Replace the blower motor with a new one.

Correct the interference.

Replace the panel with a new one.

Earth the body securely.

Check the wiring.

Replace the motor with a new one.

Too high pressure at low-pressure side(approx. 294kPa[3kgf/cm2] or over)

Disengaged A/M link

Mixing of outside air

Body earth failure Wiring failure, disconnected connector Operation of BLC protective function due to locked motor

Blower motor failure Interference of blower with case Blower switch failure

Blown fuse Blower main relay failure

Operation of BLC over-voltage protective function

Examine the cause of over-voltage before taking the corrective measure.

Check the battery charging system.

Correct the contact failure.

Replace the blower motor with a new one.

Replace the BLC with a new one.

Decreased supply voltage Battery terminal contact failure Blower motor rotation failure BLC failure

See A-1 .

Operation of low-pressure cut function

Pressure error

Normal pressure

Rotation failure for all modes

Blower is rotated only when the fan switch is selected to High-speed position.

Slow rotation

Adhesion of dust to surface of evaporator

Deformed or damaged blower Frosting in evaporator

Operation of high-pressure cut function

Compressor rotation failure

Compressor normal rotation

Blower motor rotation failure

Blower motor rotation

Normal rotation

Clean the filter.

Clean the filter.

Remove the obstacle.

Replace the blower with a new one.

Stop the air compressor, to melt the ice.

Examine the cause before taking the corrective measure.

Clean the surface of evaporator.

Clogged inner air filter Clogged outer air filter Existence of obstacle at vicinity of suction port

01-47 92ZV-2 Troubleshooting Operator Station Group

80V2E01013

C-2

C-1

B-1

A-1

Voltage not applied to magnet clutch

Voltage applied to magnet clutch Check for characteristic.

Thermister(frosting sensor) characteristic failure

Excessively opened expansion valve

Replace the valve with a new one.

Correction Contact failure in pressure needle valve

Replace the compressor with a new one.

Valve failure

Foreign matter caught by suction valve

Broken suction valve

Discharge the refrigerant to proper level.

Over-filled refrigerant Broken head gasket

Fully discharge the refrigerant, and execute the evacuation, and fill the refrigerant again to proper level.

Compressor failure

Discharge the refrigerant to proper level.

Mixing of air during refrigerating cycle

Clean(Washing with water) the fin.

Over-filled refrigerant

Insufficiently cooled condenser

Unusually high outside air temperature

Check the wiring.

Evaporator

Perform the checking, referring to the wiring diagram.

Replace the blower motor with a new one.

Sort-circuit wiring

Clogging of dust or mud, etc. in fin.

12 ± 5 mm Replace the magnet clutch with a new one.

Thermister (frosting sensor)

Adjust the gap(12 ± 5 mm).

Replace the thermister(frosting sensor) with a new one.

Correction

Replace the clutch relay with a new one.

Erroneous wiring

Locked blower motor

Magnet clutch failure

Adjustment failure of gap between the thermister(frosting sensor) and evaporator

Check the short-circuit.

Check the clutch circuit.

Thermister(frosting sensor) wiring failure

Magnet clutch circuit failure

01-48 92ZV-2 Troubleshooting Operator Station Group

80V2E01014

C-5

C-4

C-3

Over-filled refrigerant

Clogging of dust or mud, etc. in fin.

Discharge the refrigerant to proper level.

Clean(washing with water) the fin.

Execute the evacuation fully after replacing the valve and receiver with a new one respectively.

Temporary clogging(mixing of moisture content) due to frozen valve

Insufficiently cooled condenser

Replace the valve with a new one.

Relieved gas from pressure needle valve

to A-1

Replace the valve with a new one.

Replacement

Replacement

Clogged valve(mixing of foreign matter)

Clogging due to foreign matter in the course of piping

Clogged receiver & drier

Perform the leak test and repair the location of failure before filling the refrigerant.

Gas leakage

Execute the evacuation fully after replacing the valve and receiver with a new one respectively.

Clogging(mixing of moisture content) due to frozen valve

Fill the refrigerant to proper level.

Replace the valve with a new one.

Relieved gas from pressure needle valve

Limited amount of refrigerant filled

Replace the valve with a new one.

Clogged valve(mixing of foreign matter)

Suction/discharge valve failure

Locked piston

Replace the compressor with a new one.

Perform the leak test and repair the location of failure before filling the refrigerant.

Gas leakage

Swash plate shoe seizure

Fill the refrigerant to proper level.

Limited amount of refrigerant filled

Frosted evaporator

Expansion valve failure

Clogging during refrigerating cycle

Limited refrigerant

Unusually low outside air temperature

Expansion valve failure

Compressor failure

Limited refrigerant

Unusually low outside air temperature

01-49 92ZV-2 Troubleshooting Operator Station Group

80V2E01015

D-2

D-1

2

C-4

Replacement

High/low-pressure switch failure

Excessively low pressure [981 kPa(10kgf/cm )or lower]

Replacement

Thermo-sensor failure

C-1

Replacement

Compressor clutch relay failure

Excessively high pressure [2452 kPa(25kgf/cm2)or over]

Replace the control panel with a new one.

Blower switch failure

High-pressure error

Replace the control panel with a new one.

Re-charging

Battery voltage drop

Air conditioner switch failure

Replacement

Rare-short in coil

Disassembling/repair

Remove the oil.

Stained clutch surface due to oil

Foreign matter caught between rotor and stator

Replace the key with a new one.

Slippage due to broken key or key insertion failure

Repair or replacement

Excessive air gap between rotor and stator

Slipped clutch

Replacement

Disconnected stator coil

01-50 92ZV-2 Troubleshooting Operator Station Group

80V2E01016

Leakage of water in operator's cabin

Heating failure

Normal wind force

Insufficient wind force

Fill the coolant to proper level.

Replace the heater core with a new one.

Limited engine cooling water Broken heater core

Replacement

Cleaning

Check the wiring.

Servo motor failure

Remove the foreign matter.

Foreign matter caught

Wiring failure, disconnection, disconnected connector

Re-set the link.

Disengaged temperature controller link

IN side and OUT side reversed.

The temperature controller LED is not operated properly.

Clogged drain hole

Repair or replacement

Clogged or bent piping Excessively low outside air temperature

Discharge the air.

The air is mixed in hot-water circuit.

Note: Do not fail to check that the pump pressure is normal, and that the heater hose is not connected with

The temperature controller LED is operated properly.

Normal water temperature

Low water temperature

Same as "Cooling failure"

01-51 92ZV-2 Troubleshooting Operator Station Group

80V2E01017

(without inside air sensor error)

Without diagnostic display

(short-circuit inside air sensor)

setting temperature

With diagnostic display: E12

higher or lower than

(disconnected inside air sensor)

With diagnostic display: E11

(inside air/outside air servo motor abnormal)

With diagnostic display: E45

(inside air/outside air servo motor normal)

Without diagnostic display

(blow-off servo motor abnormal)

With diagnostic display: E43

Room temperature

changeover failure

Outside air/inside air

failure

Blow-off changeover

(blow-off servo motor normal)

Without diagnostic display

Cooling failure, heating failure

Short-circuit inside air sensor

Perform the checking in accordance with the paragraph "Cooling failure/heating failure".

Replacement

Check the wiring.

Replacement

Disconnected inside air sensor Short-circuit harness

Re-check the wiring.

Remove the foreign matter.

Foreign matter caught

Disconnected harness, disengaged connector

Replacement

Re-check the wiring

Wiring failure, disconnection, disconnected connector Servo motor failure

Re-set the link.

Remove the foreign matter.

Foreign matter caught

Disengaged link

Replacement

Check the wiring.

Wiring failure, disconnection, disconnected connector Servo motor failure

Re-set the link.

Disengaged link

01-52 92ZV-2 Troubleshooting Operator Station Group

80V2E01018

03-1

Measurement for Performance Check 03 Cautions on Safety ............................................................................................................................................ 03-2 Standard Measurement Values for Performance Check ................................................................................... 03-3 Preparation for Performance Check ................................................................................................................. 03-6 Engine ............................................................................................................................................................... 03-8 Measuring engine speed ............................................................................................................................. 03-8 Clutch Oil Pressure ......................................................................................................................................... 03-12 Measuring clutch oil pressure ................................................................................................................... 03-12 Hydraulic Cylinder ........................................................................................................................................... 03-13 Cylinder natural drift .................................................................................................................................. 03-13 Boom Rising Time ........................................................................................................................................... 03-14 Full Steering Cycle Time ................................................................................................................................. 03-16 Loading/Steering Circuit Relief Valve .............................................................................................................. 03-18 Loading circuit relief valve setting pressures ............................................................................................ 03-18 Steering circuit relief valve setting pressures ............................................................................................ 03-23 Service Brake .................................................................................................................................................. 03-29 Service brake performance check ............................................................................................................ 03-29 Parking Brake ................................................................................................................................................. 03-30 Parking brake performance check ............................................................................................................ 03-30 Brake Circuit Oil Pressure ............................................................................................................................... 03-31 Unloader valve setting pressure ............................................................................................................... 03-31 Brake valve oil pressure ............................................................................................................................ 03-34 Accumulator Circuit Charging Time ................................................................................................................ 03-36 Number of Brake Pedal Applications .............................................................................................................. 03-38 Declutch Engagement ..................................................................................................................................... 03-39

03-2 92ZV-2 Measurement for Performance Check Cautions on Safety

Cautions on Safety WARNING Unexpected movement of the machine may cause an accident resulting in injury or death.

Therefore, to provide repair service with the engine running, be sure to observe the following items: - Park the machine on level ground.

- 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 accidents.

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.

CAUTION Touching the fan or the V belt of the engine or the hot area while the engine is running may cause severe accidents.

Make sure to stop the engine before opening the engine room access panel.

03-3 92ZV-2 Measurement for Performance Check Standard Measurement Values for Performance Check

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) Standard measurement values for performance check

Item Measurement item

System

Minimum no-load speed, Low Idle (LI)

Transmission

Engine

Maximum no-load speed, High Idle (HI) Engine speed (min-1) (rpm)

Fuel efficient mode

Normal

800±50 2,200±50

Remarks

725 in hibernate mode

2,000±50

Maximum speed in torque converter stall mode

2,000±100

Maximum speed in multiple control valve relief mode

1,970±100

Maximum speed in torque converter stall plus multiple control valve relief mode

1,620 +150 - 100

Idling (LI)

1.8±0.15 (18±1.5) (256±21)

Maximum (HI)

1.9±0.15 (19±1.5) (270±21)

Clutch pressure MPa (kgf/cm2) (psi)

Engine speed

Clutch time lag (sec)

Neutral→Forward 1st speed (engine speed: 1,500 min-1 (rpm))

0.3±0.1

Before wheels move

03-4 92ZV-2 Measurement for Performance Check Standard Measurement Values for Performance Check

Standard measurement values for performance check

Item Measurement item

System

Cylinder drift (when boom and bucket are horizontal and with no load) (mm/min) (in/min) Boom rising time (no load) (sec)

Hydraulic line

Full steering time (sec)

Relief valve setting pressure MPa (kgf/cm2) (psi)

Fan maximum revolution (HI) min-1 (rpm) Fan minimum revolution (LI) min-1 (rpm)

Boom cylinder

3 (1/8) or less

Bucket cylinder

4 (5/32) or less Idling (LI)

Engine speed

Engine speed

Remarks

19±3.0 -1

1,500 min (rpm)

9.3±1.0

Maximum (HI)

6.4±0.5

Idling (LI)

5.1±0.5 -1

1,500 min (rpm)

3.4±0.3

Maximum (HI)

2.8±0.3

Loading line main relief pressure (HI)

20.6±0.5 (210±5) (2,986±71)

Loading line overload relief pressure (LI)

23.5±0.5 (240±5) (3,413±71)

Steering line main relief pressure (HI)

20.6±0.5 (210±5) (2,986±71)

Steering line overload relief pressure (LI)

+10 24.5 +1.0 0 (250 0 ) +142 (3,555 0 )

Run engine at lowest possible speed while setting

Pilot line reducing pressure (LI)

3.5 (36) (512)

Run engine at lowest possible speed while setting

Engine water temp. <80ºC (180ºF) T/C oil temp. <110ºC (230ºF) Hydraulic oil temp. <90ºC (195ºF)

910 +75 - 200

Engine water temp. >95ºC (205ºF) T/C oil temp. >115ºC (240ºF) Hydraulic oil temp. >95ºC (205ºF)

1,300 +100 - 50

Engine water temp. <60ºC (140ºF) Engine idle revolution

715 +50 - 200

Run engine at lowest possible speed while setting

03-5 92ZV-2 Measurement for Performance Check Standard Measurement Values for Performance Check

Item Measurement item

System

Shift lever position

2nd speed reverse

Engine speed

Maximum (HI)

Shift lever position

3rd speed reverse

Engine speed

Maximum (HI)

Performance of service brake

Brake

Performance of parking brake

Brake line setting pressure MPa (kgf/cm2) (psi)

Standard measurement values for performance check Slowly increase the engine speed, and check that the machine does not move at the maximum engine speed.

↑

Unloader valve setting pressure (LI)

Off (Cut-out)

11.8±0.5 (120±5) (1,706±71)

On (Cut-in)

6.9±1.0 (70±10) (995±142)

Low-pressure alarm switch setting pressure (For brake accumulator circuit) The time from the low-pressure alarm is turned off till the unloading valve cuts off pressure

Accumulator charge time (sec)

Engine speed (LI)

Number of brake pedal applications

Run engine 1 minute high idle, then stop the engine.

(Turn key switch "ON" with engine off.)

Step on the brake pedal and release, and check the number of times until the low-pressure alarm is turned on.

Declutch engagement (cm) (in)

Engine: Maximum speed/ Declutch pedal: Quick release (Distance the loader rolls back before moving forward.)

Note These are the standard measurement values for the machines at the time when delivered from the factory.

Remarks

Before brake check, be sure to disconnect the cable connector of parking brake solenoid valve.

3.9±0.5 (40±5) (569±71) 15

at least 13 times

Repeat stepping on the brake pedal as follows: On: 5 sec.

Off: 5 sec.

15 (6) or less

1/5 slope (approx. 11º), unladen, 1st speed

03-6 92ZV-2 Measurement for Performance Check Preparation for Performance Check

Preparation for Performance Check WARNING Unexpected movement of the machine may cause an accident resulting in injury or death. Therefore, to provide repair service with the engine running, be sure to observe the following items: - Park the machine on level ground.

- Apply the parking brake.

- Block the tires with chocks to prevent the tires from moving.

- Determine the signals between the service men.

- Prohibit any person from walking into dangerous areas.

- Near articulation area of the machine - Under the machine - Around the engine - In front of or behind the machine

CAUTION Do not touch the fan or V-belt of the engine or a high temperature section if the engine is running. An accident 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.

Avoid high temperature components even when the engine is stopped.

Preparation of measurement units - To measure pressure, be sure to prepare the hose, adapter, and wrench for pressure port plug in addition to the measurement instruments.

- Check operation of the measurement instruments.

Carefully handle the instruments. If something comes in contact with an instrument or large shock is applied to an instrument, the instrument may be damaged. In addition, periodic inspection of the instruments is also important. If the zero point of an instruments is not properly adjusted, the value indicated by the instrument may be wrong.

Cautions regarding measurement - Take safety precautions before starting measurement work, and carefully measure and record the valves.

- Measure a value three times or more. If the obtained values greatly differs from each other, an error has been made in measuring the value.

Measure the value again.

Calculate the average value from the various readings.

Warm-up - If the machine is too cold, measured values may be wrong. To prevent incorrect readings, be sure to warm up the machine until the torque converter oil, hydraulic oil, and engine coolant are heated to the specified temperature.

03-7 92ZV-2 Measurement for Performance Check Preparation for Performance Check Procedure for warm-up Gauge

Engine water temperature 97ºC(206ºF)

T/C. T/M oil temperature 110ºC(230ºF)

100ºC(212ºF)

35ºC(95ºF)

103ºC(217ºF)

100ºC(212ºF)

120ºC(248ºF)

50ºC(122ºF)

125ºC(257ºF)

Indication

White

Red

Red

White

Resistance between S and E (Ω)

120~125

75~80

Resistance between S and V (Ω)

120~125

85~90

Resistance between E and V (Ω)

170~190

130~150

1. Torque converter oil temperature Perform torque converter stall operation by referring to "Stall speed measurement procedure".

Check the approximate temperature using the temperature gauge in the instrument panel.

2. Hydraulic oil temperature Perform multiple control valve relief operation by referring to "Engine speed measurement procedure in multiple control valve relief mode".

Check the approximate temperature using the contact thermometer attached to the outside surface of the hydraulic tank.

3. Engine coolant temperature Warming up the torque converter oil and hydraulic oil also warms up the engine.

Check the engine coolant temperature using the temperature gauge in the instrument panel.

03-8 92ZV-2 Measurement for Performance Check Engine

Engine WARNING Unexpected movement of the machine may cause an accident resulting in injury or death.

Therefore, to provide repair service with the engine running, be sure to observe the following items: - Park the machine on level ground.

- Apply the parking brake.

- Block the tires with chocks to prevent the tires from moving.

- Determine the signals between the service men.

- Prohibit any person from walking into dangerous areas.

- Near articulation area of the machine - Under the machine - Around the engine - In front of or behind the machine

CAUTION Do not touch the fan or V-belt of the engine or hightemperature section if the engine is running.

An accident resulting in injury may occur.

Be sure to stop the engine before you open the access panel of the engine room.

Keep all guards in place.

Avoid high temperature components even when the engine is stopped.

Use a photo tachometer when checking engine revolution.

Measuring engine speed Measurement instrument - Tachometer (MODM)

Measurement conditions Temperature of torque converter oil : 50~80ºC (120~180ºF) Temperature of hydraulic oil : 50~80ºC (120~180ºF) Temperature of engine coolant : 50~80ºC (120~180ºF) 1. Press the brake pedal.

Set and confirm the transmission shift lever is neutral position.

2. Set and confirm the parking brake to the "ON" position.

3. Lower the bucket onto the ground.

4. Set the boom and bucket control lever to "Neutral position".

5. Set the shift lever to the forward position.

Note To avoid "Hibernate mode". In "Hibernate mode", decrease the engine speed 800 min-1 to 725 min-1 under following condition.

When the transmission shift lever is placed in "N" position, the engine coolant temperature is higher than 60ºC, and the engine speed is held at 950 min-1 or less for 10 seconds.

6. Record low idle speed.

7. Set and confirm the transmission shift lever is neutral.

8. Gradually increase the engine speed.

Measure the speed (high Idle) when the accelerator pedal is fully pressed down.

9. Record high idle speed.

Standard measurement value (Normal mode) Low idle (min-1): 800±50 High idle (min-1): 2,200±50

03-9 92ZV-2 Measurement for Performance Check Engine Stall speed measurement procedure

WARNING Unexpected movement of the machine for abnormal brake performance may cause an accident resulting in injury or death.

Before measuring, make sure that the machine has sufficient brake performance.

IMPORTANT In the stall mode, the torque converter oil temperature rises rapidly. Therefore, long stall operation may damage the seals, and the damaged seal may cause oil leakage.

This is why stall test should be limited to 20 seconds.

The torque converter oil temperature should not be exceeded 120°C (250°F).

To repeat the stall operation, be sure to wait more than 10 seconds with medium engine speed before next stall operation so that the torque converter oil is cooled enough.

1. Press the brake pedal.

Set and confirm the transmission shift lever is neutral position.

2. Set and confirm the parking brake to the "ON" position.

Engine speed measurement procedure in multiple control valve relief mode

IMPORTANT When the relief valve is activated, the oil temperature rises rapidly. Therefore, long relief operation may damage the seals or cause the spool to stick inside the valve.

This is why relief operation should be limited to 10 seconds.

To repeat the relief operation, be sure to wait more than 10 seconds with medium engine speed before next relief operation, and cool the inside of the valve.

Using this cycle safely warms up cold oil.

1. Press the brake pedal.

Set and confirm the transmission shift lever is neutral position.

2. Set and confirm the parking brake to the "ON" position.

3. Lower the boom to the lowest limit. Roll back the bucket fully until the bucket contacts to the stopper.

4. Set the engine speed to HI. 5. Place the bucket control lever in roll back position.

Measure the engine speed.

3. Lower the boom to the lowest limit. Roll back the bucket fully until the bucket contacts to the stopper.

4. Set the parking brake to the "OFF" position.

5. Set the declutch ON/OFF switch to OFF. 6. Press the brake pedal all the way to the floor, and then set the transmission shift lever to the forward 3rd speed position.

7. Gradually increase the engine speed. Measure the engine speed when the accelerator pedal is fully pressed down.

8. Record the engine speed at T/C stall.

(During stall speed measurement, do not operate the steering system, boom, bucket, etc.)

97ZV03002

03-10 92ZV-2 Measurement for Performance Check Engine Maximum speed in torque converter stall plus multiple control valve relief mode.

WARNING Unexpected movement of the machine for abnormal brake performance may cause an accident resulting in injury or death.

Before measuring, make sure that the machine has sufficient brake performance.

1. Press the brake pedal.

Set and confirm the transmission shift lever is neutral position.

2. Set and confirm the parking brake to the "ON" position.

3. Lower the boom to the lowest limit. Roll back the bucket fully until the bucket contacts to the stopper.

4. Set the parking brake to the "OFF" position.

IMPORTANT In the stall mode, the torque converter oil temperature rises rapidly. Therefore, long stall operation may damage the seals, and the damaged seal may cause oil leakage.

This is why stall test should be limited to 20 seconds.

The torque converter oil temperature should not be exceeded 120°C (250°F).

To repeat the stall operation, be sure to wait more than 10 seconds with medium engine speed before next stall operation so that the torque converter oil is cooled enough.

5. Set the declutch ON/OFF switch to OFF. 6. Press the brake pedal all the way to the floor, and then set the transmission shift lever to the 3rd speed position.

7. Gradually increase the engine speed.

8. Place the bucket control lever in roll back position.

9. Measure the engine speed when the accelerator pedal is fully pressed down.

IMPORTANT When the relief valve is activated, the oil temperature rises rapidly. Therefore, long relief operation may damage the seals or cause the spool to stick inside the valve.

This is why relief operation should be limited to 10 seconds.

To repeat the relief operation, be sure to wait more than 10 seconds with medium engine speed before next relief operation, and cool the inside of the valve.

Using this cycle safely warms up cold oil.

97ZV03002

03-11 92ZV-2 Measurement for Performance Check Engine Cause of extremely high or low measurement value and solution Minimum no-load speed (LI) or maximum no-load speed (HI) low

Possible cause Insufficient warm up Malfunctioning accelerator pedal or harness

Solution Warm up

Clean

Defective fuel pump

Repair

Defective fuel injection nozzle

Repair

Insufficient compression pressure

Possible cause

Solution

Relief valve pressure too low

Adjustment or disassembly

Defective pump / pump seals

Disassembly & repair

Inspection & repair

Clogged fuel filter

Valve clearances incorrect

The engine speed is too high in multiple control valve relief mode.

Adjustment Repair

The engine speed is too low in multiple control valve relief mode.

Possible cause

Solution

Engine low power

Inspection & repair

Extremely high relief pressure of multiple control valve

Adjustment

The engine speed is too high in torque converter stall mode.

Possible cause

Solution

Slipping transmission clutch or defect inside of transmission

Disassembly & repair

Defect inside torque converter

Disassembly & repair

The engine speed is too low in torque converter stall mode.

Caused by reduction in engine power Possible cause Clogged air cleaner element Improper type of fuel Clogged fuel filter or suction strainer Frozen fuel / wax build up Malfunctioning accelerator pedal or harness

The engine speed is too high in torque converter stall plus multiple control valve relief mode.

Possible cause

Solution

Slipping transmission clutch or defect inside of transmission or T/C

Disassembly & repair

Relief pressure too low

Adjustment

Defective pump / pump seals

Disassembly & repair

The engine speed is too low in torque converter stall plus multiple control valve relief mode.

Solution Cleaning Fuel replacement Clean or replace Use antifreeze mixture Inspection & repair

Defective fuel pump

Repair

Defective fuel injector nozzle

Repair

Insufficient compression pressure

Repair

Hydraulic load is extremely large

Inspection & repair

Malfunctioning torque converter

Inspection & repair

Possible cause

Solution

Engine low power

Inspection & repair

Extremely high relief pressure of multiple control valve or steering valve

Adjustment

Malfunctioning torque converter

Repair

03-12 92ZV-2 Measurement for Performance Check Clutch Oil Pressure

Clutch Oil Pressure Measuring clutch oil pressure

Torque converter inlet oil pressure measurement port : PF1/4

3rd speed clutch oil pressure measurement port : PF1/4

Reverse clutch oil pressure measurement port : PF1/4 2nd speed clutch oil pressure measurement port : PF1/4

Forward clutch oil pressure measurement port : PF1/4 4th speed clutch oil pressure measurement port : PF1/4 1st speed clutch oil pressure measurement port : PF1/4

92V2U33001

WARNING Unexpected movement of the machine may cause an accident resulting in injury or death.

To prevent such an accident during clutch oil pressure measurement, be sure to closely communicate with the person in the cab by giving signals to each other. Also use a gauge with a hose long enough to reach outside from the articulation area.

- Pressure gauge 3 MPa (30 kgf/cm2) (500 psi) with 2~3 m hose - Clutch oil pressure measurement value : 1.8±0.15 MPa (18±1.5 kgf/cm2) (256±21 psi) at engine idling speed (LI) 1.9±0.15 MPa (19±1.5 kgf/cm2) (270±21 psi) at engine maximum speed (HI) - Torque converter oil temperature : 50~80ºC (120~180ºF)

03-13 92ZV-2 Measurement for Performance Check Hydraulic Cylinder

Hydraulic Cylinder Cylinder natural drift

5. Lock the boom and bucket control levers using the loading control lever lock. (Set to "lock position")

WARNING Standing under the boom or bucket during service work is dangerous. An accident resulting in injury or death may be caused.

To prevent such an accident, be sure to lock the boom and bucket control levers in the cab, securely support the boom, and remove the starter key.

In addition, hang a "DO NOT OPERATE!" tag on the steering wheel.

Measurement instrument

6. Stop the engine.

7. Attach vinyl tape to the cylinder rod at a point 100~150 mm (4~6 in) away from the cylinder head cover.

8. Measure the accurate distance from the cylinder head cover to the vinyl tape. This is distance "A" mm (in). Measure the distance again 5 minutes later. This is distance "B" mm (in).

Cylinder drift (mm/min) A – B (mm) (in) = -------------(in/min) 5 (min)

- Scale 150~300 mm (1 ft.)

Reference

- Stop watch - Black vinyl "electrician's" type Note Warm-up the hydraulic oil before measuring cylinder drift.

Vinyl tape

Standard measurement value (mm/min) (in/min)

Scale 95ZV43009

Boom cylinder

3 (1/8) or less

Bucket cylinder

4 (5/32) or less

Measurement procedure

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.

1. Unload the bucket.

2. Press the brake pedal.

Set and confirm the transmission shift lever is neutral position.

3. Set and confirm the parking brake switch to the "ON" position.

4. Keep the boom and bucket horizontal.

IMPORTANT At the completion of measurement, if the vinyl tape used for measurement is not removed from the cylinder rod, the tape may be caught by the rod seal. The tape will cause oil leakage from the rod seal. To prevent oil leakage, be sure to remove the vinyl tape.

03-14 92ZV-2 Measurement for Performance Check Boom Rising Time

Boom Rising Time WARNING Standing under the boom or bucket during service work is dangerous. An accident resulting in injury or death may occur.

Stay out of the area around the raised boom.

Note To avoid "Hibernate mode". In "Hibernate mode", decrease the engine speed 800 min-1 to 725 min-1 under following condition.

When the transmission shift lever is placed in "N" position, the engine coolant temperature is higher than 60ºC, and the engine speed is held at 950 min-1 or less for 10 seconds.

8. Adjust the engine speed to low idle (LI) speed.

Measurement instrument

9. Measure the time required for the boom from the lowest to the highest limit.

- Stop watch - Tachometer (MODM)

10. Set and confirm the transmission shift lever is neutral.

Warm-up the engine before measuring boom rising time.

11. Adjust the engine speed to 1,500 min-1.

12. Measure the time required for the boom from the lowest to the highest limit.

13. Adjust the engine speed to high idle (HI).

Standard measurement value (sec) Engine speed

Idling (LI)

19±3.0

1,500 min-1 (rpm)

9.3±1.0

Maximum (HI)

6.4±0.5

14. Measure the time required for the boom from the lowest to the highest limit.

Note Even if the boom kick out system is installed, the boom control lever should be held in the UP position until the boom rises to the highest limit.

Measurement procedure 1. Unload the bucket.

2. Press the brake pedal.

Set and confirm the transmission shift lever is neutral position.

3. Set and confirm the parking brake switch to the "ON" position.

4. Depress brake pedal.

97ZV03005

5. Lower the boom to the lower limit, and roll back the bucket.

6. Set ELS switch to the OFF. 7. Set the shift lever to the forward position.

03-15 92ZV-2 Measurement for Performance Check Boom Rising Time Possible causes of slow boom rising time: Possible cause

Solution

Damaged main pump / seals

Disassembly & repair

Damaged steering pump / seals

Disassembly & repair

Multiple control valve spool sticking

Disassembly & repair

Malfunctioning ELS valve

Disassembly & repair

Malfunctioning ELS switch or harness

Inspection & repair

Malfunctioning controller or harness

Inspection & repair

Internal oil leakage of boom cylinder

Inspection & repair

Malfunctioning steering valve

Disassembly & repair

How to determine the cause (damaged main pump or steering pump): Measure the full steering time.

If normal the main pump is damaged.

If steering time is also slow the steering pump is damaged.

Boom cylinder

To steering line Steering valve Steering pump

Multiple control valve ELS valve Main pump

Hydraulic tank 95ZV03004

03-16 92ZV-2 Measurement for Performance Check Full Steering Cycle Time

Full Steering Cycle Time Measurement procedure

WARNING Standing in the articulation area during service work is dangerous. An accident resulting in injuly or death may occur.

During this test, prevent any person from walking around the machine or in the articulation area.

1. Adjust the stopper bolts of the front chassis so that the front chassis stopper contacts to the rear chassis.

2. Unload the bucket.

3. Press the brake pedal.

Set and confirm the transmission shift lever is neutral position.

Measurement instrument

4. Set and confirm the parking brake switch to the "ON" position.

- Stop watch - Tachometer (MODM)

5. Lower the boom, and roll back the bucket.

(Bucket and boom are not on to ground for steering)

Warm-up the engine before measuring full steering time.

6. Set the parking brake switch to the "OFF" position and release the brake pedal.

7. Set the shift lever to the forward position.

Standard measurement value (sec) Engine speed

Idling (LI)

5.1±0.5

1,500 min-1 (rpm)

3.4±0.3

Maximum (HI)

2.8±0.5

Note To avoid "Hibernate mode". In "Hibernate mode", decrease the engine speed 800 min-1 to 725 min-1 under following condition.

When the transmission shift lever is placed in "N" position, the engine coolant temperature is higher than 60ºC, and the engine speed is held at 950 min-1 or less for 10 seconds.

8. Adjust the engine speed to low idle (LI) speed.

9. Measure and record the time required for full steering.

10. Set and confirm the transmission shift lever is neutral.

11. Adjust the engine speed to 1,500 min-1.

12. Measure and record the time required for full steering.

13. Adjust the engine speed to maximum (HI).

03-17 92ZV-2 Measurement for Performance Check Full Steering Cycle Time 14. Measure and record time required for full steering.

- From full left to full right or - From full right to full left Turn the steering wheel as fast as possible during the test.

IMPORTANT After measuring, return the stopper bolts.

(Refer to "Stop valve" in Check & Adjustment.)

97ZV03007

Full steering Possible causes for slow steering times: Possible cause

Solution

Damaged steering pump / seals

Disassembly & repair

Malfunctioning steering valve flow control plunger or steering spool

Disassembly & repair

Flow control plunger

(G) P MR

Pb

Steering valve

Pa

T

95ZV03005

03-18 92ZV-2 Measurement for Performance Check Loading/Steering Circuit Relief Valve

Loading/Steering Circuit Relief Valve Loading circuit relief valve setting pressures WARNING Unexpected movement of the machine may cause an accident resulting in injury or death.

Therefore, to provide repair service with the engine running, be sure to observe the following items : - Park the machine on level ground.

- 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

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 open the cap of the hydraulic tank before removing the plug from the pressure measurement port.

CAUTION Do not touch the fan or V-belt of the engine or a hightemperature section if the engine is running. An accident resulting in injury may occur.

Be sure to stop the engine before you open the access panel of the engine room. Keep all guards in place.

Avoid high temperature components even when the engine is stopped.

Measurement instruments Pressure gauge 30 MPa (300 kgf/cm2) (5,000 psi) (for loading line with 3 m (10 ft.) hose) 5 MPa (50 kgf/cm2) (1,000 psi) (for pilot line) with 2~3 m (6~10 ft.) hose Note For safety, route the gauge to an area where it may be safely read by the person doing the test.

Gauge port Gauge port location

Port size

Main relief pressure (1), (2), (3) Overload relief pressure

Pilot line pressure (Reducing valve)

(1), (2), (3) G (PF) 1/4 with O-ring (1), (2), (3) (4) G (PF) 3/8 with O-ring (4), (5) (5) G (PF) 1/4 with O-ring

03-19 92ZV-2 Measurement for Performance Check Loading/Steering Circuit Relief Valve

Standard measurement value MPa (kgf/cm2) (psi) Loading line main relief pressure (at maximum speed)

20.6±0.5 (210±5) (2,986±71)

Loading line overload relief pressure (at idling speed)

23.5±0.5 (240±5) (3,413±71)

Pilot line

3.5 (36) (512)

Measuring loading circuit main relief pressure 1. Unload the bucket.

2. Lower the boom to the lowest limit.

3. Attach the pressure gauge 30 MPa (300 kgf/cm2) (5,000 psi) to the bucket cylinder bottom side (2).

4. Set the parking brake switch to the "ON" position.

Hydraulic oil temp 50±5ºC (120±9ºF) Reference Releasing residual pressure from tank and pipes Keep the bottom surface of the bucket horizontal, and stop the engine when the bucket is approximately 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.

Push down on, then open the cap of the hydraulic tank to release the residual pressure.

5. Move the bucket control lever to the roll back position. Hold the lever at that position.

6. Increase the engine speed to the maximum, and measure and record the pressure using the pressure gauge.

Adjusting main relief pressure Loosen the lock nut and adjust the pressure by the adjusting screw.

Turn clockwise the adjusting screw to raise the set pressure, or turn counterclockwise the adjusting screw to lower the set pressure.

IMPORTANT At the completion of check and adjustment of main relief valve pressure, be sure to tighten the lock nut.

03-20 92ZV-2 Measurement for Performance Check Loading/Steering Circuit Relief Valve Main relief valve

Bucket cylinder

Cap Lock nut

(2) Note North America equipped (1) M/c's have a quick connector in port (3) for testing.

K97V2J43003

Multiple control valve

Make-up valve

Overload relief valve

Main relief valve

Overload relief valve

(3) 95ZV43002

Valve assembly (4) (PPI)

(Z2) (PA) (PARKING)

(Z)

(Z1) ACF

(ACCF)

(ACCR)

(TA) (T)

(P)

Reducing valve (for pilot) 85V2E43006

Adjusting screw

95ZV43004

03-21 92ZV-2 Measurement for Performance Check Loading/Steering Circuit Relief Valve

Measuring loading circuit overload relief pressure 1. Attach the pressure gauge to the port (3). ((1) for the rod side, (2) for the bottom side, (3) for the both sides.)

2. Adjust the main relief valve pressure to 24.5 MPa (250 kgf/cm2) (3,555 psi) + 1/4 additional turn, so the pressure is above the overload relief pressure.

Bucket cylinder bottom side (gauge port (2) or (3)) 1. Lower the boom to the lowest limit.

2. Move the bucket control lever to the roll back position.

Adjusting overload relief pressure Loosen the lock nut and adjust the pressure by the adjusting screw.

Turn clockwise the adjusting screw to raise the set pressure, or turn counterclockwise the adjusting screw to lower the set pressure.

IMPORTANT At the completion of check and adjustment of overload relief valve pressure, be sure to reset the main relief valve to the original condition.

Overload relief valve

3. Set the shift lever to the forward position.

Note To avoid "Hibernate mode".

In "Hibernate mode", decrease the engine speed 800 min-1 to 725 min-1 under following condition.

When the transmission shift lever is placed in "N" position, the engine coolant temperature is higher than 60ºC, and the engine speed is held at 950 min-1 or less for 10 seconds.

4. Keep the engine speed at low idle.

5. Hold the bucket control lever at the roll back position and record the pressure.

Bucket cylinder rod side (gauge port (1) or (3)) 1. Keep the boom horizontal.

2. Move the bucket control lever to the dump position, hold and then measure and record the pressure.

Lock nut

Adjusting screw

95ZV43005

03-22 92ZV-2 Measurement for Performance Check Loading/Steering Circuit Relief Valve

Measuring pilot circuit relief pressure

Reducing valve

WARNING Trapped pressure in brake circuit could cause serious injury when the plug is removed.

Fully release all residual accumulator pressure before servicing.

Lock nut

1. Attach the pressure gauge to the port (4).

2. Set the shift lever to the forward position.

Note To avoid "Hibernate mode".

In "Hibernate mode", decrease the engine speed 800 min-1 to 725 min-1 under following condition.

When the transmission shift lever is placed in "N" position, the engine coolant temperature is higher than 60ºC, and the engine speed is held at 950 min-1 or less for 10 seconds.

3. Keep the engine speed at low idle (when the brake line pressure is normal) and then measure and record the pressure.

Adjusting pilot line pressure Loosen the lock nut and adjust the pressure by the adjusting screw.

Turn clockwise the adjusting screw to raise the pilot line pressure.

IMPORTANT After the completion of the adjustment of the pilot line pressure, be sure to tighten the lock nut.

Adjusting screw

90ZVE43004

03-23 92ZV-2 Measurement for Performance Check Loading/Steering Circuit Relief Valve

Steering circuit relief valve setting pressures WARNING Unexpected movement of the machine may cause an accident resulting in injury or death.

Therefore, to provide repair service with the engine running, be sure to observe the following items : - Park the machine on level ground.

- 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

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 open the cap of the hydraulic tank before removing the plug from the pressure measurement port.

CAUTION Do not touch the fan or V-belt of the engine or a hightemperature section if the engine is running. An accident resulting in injury may occur.

Be sure to stop the engine before you open the access panel of the engine room. Keep all guards in place.

Avoid high temperature components even when the engine is stopped.

Measurement instruments Pressure gauge 30 MPa (300 kgf/cm2) (5,000 psi) (for loading line with 3 m (10 ft.) hose and steering line with 1.5~3 m (4~10 ft.) hose) 5 MPa (50 kgf/cm2) (1,000 psi) (for pilot line) with 2~3 m (6~10 ft.) hose Note For safety, route the gauge to an area where it may be safely read by the person doing the test.

Gauge port Gauge port location

Port size

Main relief pressure (1), (2)

G (PF) 1/4 with O-ring

(3)

Rc (PT 1/8)

Overload relief pressure Reducing pressure

03-24 92ZV-2 Measurement for Performance Check Loading/Steering Circuit Relief Valve

Standard measurement value MPa (kgf/cm2) (psi) Steering line main relief pressure (at maximum speed)

20.6±0.5 (210±5) (2,986±71)

Steering line overload relief pressure (at idling speed)

24.5 +1.0 0 (250 +100 ) (3,555 +1420 )

Pilot line

3.5 (36) (512)

Hydraulic oil temp : 50±5ºC (120±9ºF) Reference Releasing residual pressure from tank and pipes Steer the machine in a straight position.

Keep the bottom surface of the bucket horizontal, and stop the engine when the bucket is approximately 30 cm (1 ft.) above the ground.

Measuring steering circuit main relief pressure 1. Unload the bucket.

2. Press the brake pedal.

Set and confirm the transmission shift lever is neutral position.

3. Set and confirm the parking brake switch to the "ON" position.

4. Depress the brake pedal.

5. Attach the pressure gauge to the gauge port ((1) or (2)).

6. In case the pressure gauge is installed to (1), steer the machine to the left until the front and rear chassis contact each other.

Continue to hold the steering wheel fully turned.

7. Increase the engine speed to high idle, and measure and record the pressure.

Note Because the stop valve is installed into the steering line, oil pressure does not reach the set point when the steering is fully turned.

When measuring oil pressure, be sure to apply the articulation stopper or screw the stopper (bolt) in until the front and rear chassis contact each other.

WARNING If the machine begins to move with the articulation stopper applied, it may cause an accident resulting in injury or death.

After the measurement, be sure to disconnect and store the articulation stopper.

03-25 92ZV-2 Measurement for Performance Check Loading/Steering Circuit Relief Valve Reducing valve

Adjusting steering line main pressure

Adjusting screw Lock nut

Steering cylinder

(2)

(A)

Note North America equipped M/c's have quick connectors at ports (1) and (2).

(3)

(1)

70ZV43007

115ZV43006a

(B)

Steering valve Loosen the lock nut and adjust the pressure by the adjusting screw.

Main relief valve

Turn clockwise the adjusting screw to raise the steering line main pressure.

Overload relief valve 95ZV43006

03-26 92ZV-2 Measurement for Performance Check Loading/Steering Circuit Relief Valve

Measuring steering circuit overload relief pressure

Main relief valve

Lock nut Adjusting screw

Stopper (bolt)

95ZV43007

Port B To steering valve

Port A From Orbitrol®

Spool

Installed on front chassis

Check valve Installed on rear chassis 90V2U42003

1. Attach the pressure gauge to the port ((1) for the left turn, (2) for the right turn).

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.

3. Steer the machine until the front and rear chassis contact each other. Continue to hold the steering wheel fully turned.

Note Because the stop valve is installed into the steering line, oil pressure does not reach the set point when the steering is fully turned.

When measuring oil pressure, be sure to apply the articulation stopper or screw the stopper (bolt) in until the front and rear chassis contact each other.

4. Set the shift lever to the forward position.

Note To avoid "Hibernate mode".

In "Hibernate mode", decrease the engine speed 800 min-1 to 725 min-1 under following condition.

When the transmission shift lever is placed in "N" position, the engine coolant temperature is higher than 60ºC, and the engine speed is held at 950 min-1 or less for 10 seconds.

5. 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.

03-27 92ZV-2 Measurement for Performance Check Loading/Steering Circuit Relief Valve

Measuring pilot circuit relief pressure (reducing pressure)

Adjusting overload relief pressure Lock nut Adjusting screw

Adjusting screw Lock nut

95ZV43008 (T)

Loosen the lock nut and adjust the pressure by the adjusting screw.

Turn clockwise the adjusting screw to raise the set pressure, or turn counterclockwise the adjusting screw to lower the set pressure.

(A)

(3) (TS)

WARNING If the machine begins to move with the articulation stopper applied, it may cause an accident resulting in injury or death.

After the measurement, be sure to disconnect and store the articulation stopper.

(B)

115ZV43007

1. Attach the pressure gauge to the port (3).

IMPORTANT At the completion of check and adjustment of overload relief valve pressure, be sure to reset the main relief valve to the original condition.

Gauge port plug width across flat 5 mm 2. Move the bucket control lever to the roll back position.

3. Set the shift lever to the forward position.

Note To avoid "Hibernate mode".

In "Hibernate mode", decrease the engine speed 800 min-1 to 725 min-1 under following condition.

When the transmission shift lever is placed in "N" position, the engine coolant temperature is higher than 60ºC, and the engine speed is held at 950 min-1 or less for 10 seconds.

4. Keep the engine speed at low idle and record the pressure.

5. Hold the bucket control lever at the roll back position and record the pressure.

03-28 92ZV-2 Measurement for Performance Check Loading/Steering Circuit Relief Valve Adjusting pilot line pressure Loosen the lock nut and adjust the pressure by the adjusting screw.

Turn clockwise the adjusting screw to raise the pilot line pressure.

IMPORTANT After the completion of the adjustment of the pilot line pressure, be sure to tighten the lock nut.

03-29 92ZV-2 Measurement for Performance Check Service Brake

Service Brake Service brake performance check

Method 2

Method 1

If no test course available as described "Method 1", carry out the following method.

WARNING

IMPORTANT

Separate the test course by using rope etc. and keep persons away from the test course. In addition, post persons in several positions near the course to warn others and avoid an accident while checking the service brake performance.

The following method is easy and simple, however it is not an accurate way, because the braking force and rim-pull may vary on each machine. Confirm engine & transmission performance via using a stall test. See page 03-3.

Reconfirm the brake performance by the method 1 as soon as possible.

Condition 1. Test course Level, straight, dry and the paved ground.

2. Run the machine and depress the brake pedal at 35 km/h (22 mph).

Measure and record the braking distance.

Standard measurement value

WARNING Unexpected movement of the machine may cause an accident resulting in injury or death.

Before starting brake performance check, be sure to observe the following items: - Place the machine on level ground.

- 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 the bucket fully until the bucket contacts to the stopper.

Braking distance 20 m (22 1/4 yd) or shorter Possible causes of extremely long braking distance

2. Set the parking brake switch to the "OFF" position.

Possible cause

Solution

Low brake line pressure

Check and repair

Friction plate wear

Check and repair

Brake valve malfunction

Check and repair

Note The brake performance check methods 1 and 2 are based on the law and the regulation in Japan.

When checking the service brake performance, follow the law and/or local regulation in your country, state, or province.

3. Set the declutch switch to OFF, and then depress the brake pedal all the way to the floor.

4. Set the shift lever to 2nd reverse speed.

5. Gradually increase the engine speed. The machine should not move at the maximum engine speed.

Possible cause of machine moving during brake performance check.

Possible cause

Solution

Low brake line pressure

Check and repair

Friction plate wear

Check and repair

Brake valve malfunction

Check and repair

03-30 92ZV-2 Measurement for Performance Check Parking Brake

Parking Brake Parking brake performance check

Method 2

Method 1

If no test course available as described "Method 1", carry out the following method.

WARNING

IMPORTANT

Unexpected movement of the machine may cause an accident resulting in injury or death.

Before starting brake performance check, be sure to observe the following items: - Check that there is enough clearance for brake performance check around the machine.

- During performance check, prohibit any person to walking near the machine.

The following method is easy and simple, however it is not an accurate way, because the braking force and rim-pull may vary on each machine.

Confirm engine & transmission performance via stall test. See page 03-3. Reconfirm the brake performance by the method 1 as soon as possible.

WARNING Unexpected movement of the machine may cause an accident resulting in injury or death.

Before starting brake performance check, be sure to observe the following items: - Place the machine on level ground.

- Check that there is enough clearance for brake performance check around the machine.

- During performance check, prohibit any person to walking near the machine.

Condition 1. Test course 1/5 slope (Approx. 11º 19') 2. Bucket empty 3. Parking switch ON

1. Set the parking brake switch to the "ON" position.

Standard measurement value

2. Disconnect the cable connector of parking brake solenoid valve.

No movement on 1/5 slope.

3. Place the shift lever to the 3rd reverse position.

Possible cause of machine moving during brake performance check Possible cause

4. Gradually increase the engine speed. The machine should not move at the maximum speed.

Solution

Wear or breakage of brake disc

Check and repair

Parking brake switch malfunction

Check and repair

Parking brake solenoid valve malfunction

Check and repair

Note The brake performance check methods 1 and 2 are based on the law and the regulation in Japan.

When checking the service brake performance, follow the law and/or local regulation in your country, state, or province.

IMPORTANT If the machine begins to move with the parking brake applied, the brake shoes are burnt or misadjusted.

At the completion of parking brake test, be sure to connect the connector of electrical line to the solenoid valve again.

Possible cause

Solution

Wear or breakage of brake disc

Check and repair

Parking brake switch malfunction

Check and repair

Parking brake solenoid valve malfunction

Check and repair

03-31 92ZV-2 Measurement for Performance Check Brake Circuit Oil Pressure

Brake Circuit Oil Pressure WARNING Unexpected movement of the machine may cause an accident resulting in injury or death. Therefore, to provide repair service with the engine running, be sure to observe the following items: - Park the machine on level ground.

- Apply the parking brake.

- Block the tires with chocks to prevent the tires from moving.

- Determine the signals between the service men.

Unloader valve setting pressure

(PPI)

(Z2)

(Z)

(Z1)

(PA)

ACF

(ACCF)

(ACCR)

(PARKING) (TA)

(T)

(P)

ACF port

Valve assembly

85V2E53001

WARNING

Injection Hazard Depress brake pedal 80~100 times to completely discharge the brake accumulators prior to removing these test plugs.

135ZV52035

Brake line main pressure is regulated by the unloader valve.

03-32 92ZV-2 Measurement for Performance Check Brake Circuit Oil Pressure Method 1

Measurement procedure

Refer to "Brake Main pressure 1" "Brake Main pressure 2" of MODM "Input/Output Monitor" section.

1. Lower the boom to the lowest limit, and tilt the bucket down to the ground.

Then set the parking brake switch to the "ON" position.

Method 2 If the pressure gauge is not available as described "Method 2", apply the "Method 1".

Measurement instrument Hydraulic pressure gauge 20 MPa (200 kgf/cm2) (3,000 psi)

Gauge port ACF port on valve assembly Rc (PT) 1/8

Standard measurement value Cut-out

11.8±0.5 MPa (120±5 kgf/cm2) (1,706±71 psi)

Cut-in

6.9±1.0 MPa (70±10 kgf/cm2) (995±142 psi)

2. Stop the engine. Repeatedly depress and release the brake pedal till you feel light brake to discharge accumulator pressure.

3. Remove one of the ACF port plug on the valve assembly and attach the pressure gauge to the port.

4. Start the engine, and keep the speed at low idle.

Measure and record the pressure when the pointer of the pressure gauge stops rising (cut-out pressure).

5. Keep the engine at low idle, and repeatedly depress and release the brake pedal to reduce the accumulator pressure. Measure and record the pressure when the pointer of the pressure gauge stops and then starts rising again (cut-in pressure).

03-33 92ZV-2 Measurement for Performance Check Brake Circuit Oil Pressure Adjusting unloader valve setting pressure

21

22 Fan motor port

Pump port Unloader valve

K115ZV53002

1. Loosen the lock nut (22).

2. Adjust the pressure by the adjusting screw (21).

Turn the screw clockwise to raise the pressure.

Note In a case that the "ON" or "OFF" pressure does not match the standard setting pressure, set the "ON" (cutin) pressure to the standard setting pressure.

Tightening torque : ACF port plug: 11.3 N-m (1.15 kgf-m) (8.3 lb-ft) : Lock nut (22): 16.7 N-m (1.7 kgf-m) (12.3 lb-ft) : Cap nut (24): 78.5 N-m (8.0 kgf-m) (57.86 lb-ft)

03-34 92ZV-2 Measurement for Performance Check Brake Circuit Oil Pressure

Brake valve oil pressure

Gauge port

Force

Size of air bleeder port Rc (PT) 3/8

19

Pe

da

la ng

le

Remove air bleeder nipple fitting on the axle housing, and then install the pressure gauge to the bleeder position.

15

(In case of the bleeder valve M10 X 1.0)

0

45

m m

Air bleeder nipple fitting [59 N-m (6.0 kgf-m) (43 lb-ft)]

85V2E53002

Method 1 Refer to "Brake Pedal Output Oil Pressure" of MODM "Input/Output Monitor" section.

85ZVE53001

Method 2 If the pressure gauge is not available as described "Method 2", apply the "Method 1".

Measurement procedure Check to be sure the brake valve is fully released.

Measurement instrument

Press down the brake pedal to check that the oil pressure rises in proportion to the pedal angle.

Hydraulic pressure gauge 10 MPa (105 kgf/cm2) (1,500 psi)

Release the brake pedal to check that the oil pressure drops to zero in proportion to the pedal angle. In addition, visually check for brake oil leakage.

03-35 92ZV-2 Measurement for Performance Check Brake Circuit Oil Pressure

Brake valve performance

Output oil pressure (brake port)

MPa (kgf/cm2) (psi) 4 (40) (580)

4.01 (41) (581)

2 (20) (290) 0.57 (6) (83) 0

10

3.9 5

15

18.5 19

(deg)

Pedal stroke

90V2E53001

Refer to the curve shown in the above figure.

When the measured value does not match the performance curve, check the following points.

Possible cause Malfunctioning brake valve

Solution Repair or replacement

Brake line oil pressure low (Pump, reducing valve malfunction)

Check and repair

IMPORTANT After measuring oil pressure, be sure to tighten the air bleeder valve. Also be sure to bleed air.

03-36 92ZV-2 Measurement for Performance Check Accumulator Circuit Charging Time

Accumulator Circuit Charging Time WARNING Unexpected movement of the machine may cause an accident resulting in injury or death.

Therefore, to provide repair service with the engine running, be sure to observe the following items: - Park the machine on level ground.

- Apply the parking brake.

- Block the tires with chocks to prevent the tires from moving.

- Determine the signals between the service men.

- 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

(PPI) (PA)

(Z2)

(Z) (Z1) (ACCF)

(ACCR) (PI)

(TA) (P) (T)

ACF port

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 open the cap of the hydraulic tank before removing the plug and hose from the pressure measurement port.

Valve assembly 95V2E03003

Measurement instrument - Hydraulic pressure gauge 20 MPa (200 kgf/cm2) (3,000 psi) - Stop watch

Gauge installation position - Valve assembly ACF port size Rc (PT) 1/8

03-37 92ZV-2 Measurement for Performance Check Accumulator Circuit Charging Time

Standard measurement valve (sec) Engine speed : Low idle Unloader valve pressure 3.9 MPa (40 kgf/cm2) (569 psi)

→

11.8 MPa (120 kgf/cm2) (1,706 psi)

15

Measurement procedure 1. Lower the boom to the lowest limit, and tilt down the bucket to the ground.

2. Set the parking brake switch to the "ON" position.

3. Stop the engine. Repeatedly depress and release the brake pedal to discharge accumulator pressure.

4. Attach the pressure gauge to the valve assembly ACF port.

5. Start the engine, and keep the engine speed at low idle speed.

6. Measure and record the time from the low pressure alarm is turned off 3.9±0.5 MPa (40±5 kgf/cm2) (569±71 psi) till the pointer of the pressure gauge stops rising 11.8±0.5 MPa (120±5 kgf/cm2) (1,706±71 psi).

Possible causes of extremely high measurement value and solution The accumulator charging time is too long.

Possible cause

Solution

Defective unloader valve

Disassembly & repair

Oil leakage from pipe

Check & repair

Defective pilot pump

Disassembly & repair

03-38 92ZV-2 Measurement for Performance Check Number of Brake Pedal Applications

Number of Brake Pedal Applications Standard measurement value

WARNING Unexpected movement of the machine may cause an accident resulting in injury or death.

Therefore, to provide repair service with the engine running, be sure to observe the following items: - Park the machine on level ground.

- Apply the parking brake.

- Block the tires with chocks to prevent the tires from moving.

- Determine the signals between the service men.

- 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

CAUTION Do not touch the fan or V-belt of the engine or a high temperature section if the engine is running. An accident 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.

Avoid high temperature components even when the engine is stopped.

Run engine 1 minute high idle, then stop the engine.

Turn the key to the "ON" position.

Step on the brake pedal and release, and check the number of times until the low pressure alarm is turned on 3.9±0.5 MPa (40±5 kgf/cm2) (569±71 psi)

at least 13 times

Measurement procedure 1. Lower the boom to the lowest limit, and tilt down the bucket to the ground.

2. Set the parking brake switch to the "ON" position.

3. Run engine 1 minute high idle, then stop the engine.

4. Turn the starter switch to "ON".

5. Depress the right brake pedal all the way to the floor, and hold down the pedal for 5 seconds.

Release the pedal, and wait for 5 seconds to depress the pedal again. Repeat.

6. Count and record the number of pedal applications until the low pressure alarm buzzer starts to sound.

Possible causes of extremely low measurement value and solution Possible cause

Solution

Insufficient accumulator pressure due to defective unloader valve

Check & repair

Insufficient accumulator gas (N2) pressure

Charging

Insufficient accumulator pressure due to defective pilot pump

Check & repair

Defective brake valve

Check & repair

Defective service brake piston seal

Check & repair

Oil leakage from pipe

Check & repair

03-39 92ZV-2 Measurement for Performance Check Declutch Engagement

Declutch Engagement Standard measurement value

WARNING Brake performance check on a slope is dangerous work. An accident resulting in injury or death may occur.

Before starting declutch engagement test observe the following: - Check that the slope is smooth.

- Check that the brake works well.

- Prohibit any person from walking into the dangerous.

- Determine the signs between the service men.

- Do not enter the area near the moving machine.

1/5 slope (approx. 11º19'), unloaded bucket, engine maximum speed at 1st speed position, quickly released inching pedal

15 cm (6 in) or less

Cause of extremely high measurement value and solution Possible cause

Solution

Too much delay in resetting declutch switch

Check and replace declutch switch

Too much time lag in engaging clutch

Refer to "Time lag measurement procedure".

Measurement procedure 1. Park the machine on level ground.

2. Attach the measurement rod to the step.

3. Position the boom approximately 50 cm (11/2ft.) above the ground. Roll the bucket fully back until the bucket contacts to the stopper.

4. Stop the machine on a 1/5 slope (approx. 11°19') so that the machine is in the climbing direction (bucket up hill).

97ZV03010

Measurement rod attached to step

Measurement instrument - Chalk - Scale (approx. 1 m) (3 ft.) or tape measure - Thin rod (approx. 1 m) (3 ft.) used as measurement rod - Vinyl tape - Assistant / operator - Nylon tie straps (2 or 3)

Warm-up the engine before measuring declutch engagement

5. Set the inching cut-off switch to ON. 6. Set the parking brake switch to the "OFF" position.

7. Press the inching brake pedal (left pedal) all the way to floor.

8. Mark the ground at the pointer position with chalk or tape. Increase the engine speed to its maximum, and set the transmission shift lever to the 1st forward speed.

9. Quickly release the inching brake pedal, and mark the point at which the machine stops rolling back (using the pointer) and starts moving up the slope.

10. Measure and record the distance on the slope.

03-40 92ZV-2 Measurement for Performance Check

MEMO

Check & Adjustment 13, 23, 33, 43, 53, 73 92ZV-2 Check & Adjustment Chassis Group ........................................................................................................ 13-1 Linkage Pin ....................................................................................................................................................... 13-2 Liner ............................................................................................................................................................ 13-2 Center Pin ......................................................................................................................................................... 13-5 Adjusting shim ............................................................................................................................................. 13-5 Installing bearing cover ............................................................................................................................... 13-5 Installing bearing outer ring ......................................................................................................................... 13-6 92ZV-2 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 nut tightening procedure ..................................................................................................................... 23-5 Differential gear adjustment procedure ....................................................................................................... 23-6 92ZV-2 Check & Adjustment Torque Converter and Transmission Group ........................................................... 33-1 Clutch Oil Pressure ........................................................................................................................................... 33-2 Measuring clutch oil pressure ..................................................................................................................... 33-2

92ZV-2 Check & Adjustment Hydraulic Group ...................................................................................................... 43-1 Loading/Steering Circuit Relief Valve/Ride Control Circuit Reducing Valve (OPT) ........................................... 43-2 Loading circuit relief valve setting pressures .............................................................................................. 43-2 Ride control circuit reducing valve setting pressures (OPT) ....................................................................... 43-7 Steering circuit relief valve setting pressures ............................................................................................ 43-10 Hydraulic Cylinder ........................................................................................................................................... 43-15 Cylinder natural drift .................................................................................................................................. 43-15 Stop Valve ....................................................................................................................................................... 43-17 Stop valve adjustment procedure .............................................................................................................. 43-17 92ZV-2 Check & Adjustment Brake Group ............................................................................................................ 53-1 Brake Circuit Oil Pressure ................................................................................................................................. 53-2 Unloader valve setting pressure .................................................................................................................. 53-2 Brake valve oil pressure .............................................................................................................................. 53-4 Service Brake .................................................................................................................................................... 53-6 Service brake performance check ............................................................................................................... 53-6 Service brake friction plate wear measurement .......................................................................................... 53-7 Cautions on installing brake discs ............................................................................................................... 53-8 Parking Brake .................................................................................................................................................... 53-9 Parking brake performance check .............................................................................................................. 53-9

13-1 92ZV-2 Check & Adjustment Chassis Group

92ZV-2 Check & Adjustment Chassis Group Linkage Pin ............................................................. 13-2 Center Pin ............................................................... 13-5

13-2 92ZV-2 Check & Adjustment Chassis Group Linkage Pin

Linkage Pin WARNING

CAUTION

Unexpected movement of the machine may cause an accident resulting in injury or death.

Before starting adjustment work, be sure to observe the following items: - Park the machine on level ground.

- Apply the parking brake.

- Remove the starter key, and hang a "DO NOT OPERATE!" tag on the steering wheel.

- Block the tires with chocks to prevent the tires from moving.

Unexpectedly dropped parts may cause an accident resulting in injury.

- Before liner insertion, be sure to lift the cylinder using a crane to prevent the cylinder from unexpectedly dropping during liner insertion.

- Wear protective clothes like work gloves and steel toed shoes.

Liner

4

5

3 7

6 2 1

92V2U13001

Adjustment portion

1

2

3

4

5

6

7

Liner hole diameter mm (in)

110 (4.33)

71 (2.79)

101 (3.98)

81 (3.19)

111 (4.37)

Adjustment unnecessary

51 (2.01)

13-3 92ZV-2 Check & Adjustment Chassis Group Linkage Pin

Adjustment

*

*

95ZV12005

Adjust the clearance (*) to 1.0 mm (0.04 in) or less for #1 (split type), to 1.2 mm (0.05 in) or less for #2 ~ #7 between the bosses using liners.

For the steering cylinder, be sure to adjust the clearance on the rear chassis side first and then on the front chassis side while checking that the cylinder is not inclined.

13-4 92ZV-2 Check & Adjustment Chassis Group Linkage Pin

Bucket hinge pin section Boom Bushing A

Bucket

Bushing B

Hinge pin

Bolt Dust seal

Shim

Adjust the clearance ( pin (#1).

Seal retainer assy

Shim (as required)

90V2E13002

) to 1.0 mm or less for the hinge

How to assemble 2. Align the pin holes in the bucket and the boom then insert the pin.

R122

.5

3. Place the shim between the bucket boss and the seal ring assy so that the clearance between the boom boss and the seal ring (* marked) is less than 1 mm.

R5

5

Tighten the bolt for the seal retainer assy. : 441 N-m (45 kgf-m) (326 lb-ft) Shim

Shim thickness 90V2E13001

1.0, 0.5 mm (0.039, 0.020 in) (2 kinds of shim thickness) 1. Attach the seal retainer assy to the bushings.

(When installing the dust seal to the seal retainer assy, be sure to check the direction of the dust seal.)

13-5 92ZV-2 Check & Adjustment Chassis Group Center Pin

Center Pin Adjusting shim

Installing bearing cover 4 7

9

Front

10

3 5 6

3

Front chassis

Rear chassis

11 8

Upper

2

1 92V2U12004

The clearance between the front chassis and bearing cover (3) is 0.75±0.5 mm (0.03±0.02 in) before shim adjustment.

Add shims (5) so that the clearance is 0.1±0.05 mm (0.004±0.002 in).

Grease nipple installation direction

18º 90ZVE12011

Install bearing cover (3) so that the grease nipple mounting hole is positioned at the specified angle as shown in the figure.

13-6 92ZV-2 Check & Adjustment Chassis Group Center Pin

Installing bearing outer ring 5 8

7

6

4 2 1 3

Rear chassis Front chassis

Lower

92V2U12005

Front

3

Grease nipple installation position

20º

Split of outer bearing

90ZVE12013

Install bearing outer ring (3) so that the split is perpendicular to the front–rear line of the machine.

23-1 92ZV-2 Check & Adjustment Power Group

92ZV-2 Check & Adjustment Power Group Engine ..................................................................... 23-2 Propeller Shaft......................................................... 23-3 Axle ......................................................................... 23-5

23-2 92ZV-2 Check & Adjustment Power Group Engine

Engine WARNING Unexpected movement of the machine may cause an accident resulting in injury or death.

Therefore, to provide repair service with the engine running, be sure to observe the following items: - Park the machine on level ground.

- Apply the parking brake.

- Block the tires with chocks to prevent the tires from moving.

- Determine the signals between the service men.

- Prohibit any person from walking into dangerous areas.

- Near articulation area of the machine - Under the machine - Around the engine - In front of or behind the machine

CAUTION Do not touch the fan or V-belt of the engine or hightemperature section if the engine is running.

An accident resulting in injury may occur.

Be sure to stop the engine before you open the access panel of the engine room.

Keep all guards in place.

Avoid high temperature components even when the engine is stopped.

Use a photo tachometer when checking engine revolution.

Measuring engine oil pressure Measurement instrument - Pressure gauge

Install position 1. Location (A) 2. Measuring port: NPTF 1/4 3. Oil pressure gauge: 1.0 MPa (10 kgf/cm2) (142 psi)

Standard measurement value Engine speed 2,200 min

-1

Service standard (Regulator set pressure) 0.2~0.5 MPa (2.1~4.6 kgf/cm2) (30~65 psi)

[Engine coolant temperature 50ºC (120ºF)]

A

Measuring engine speed Measurement instrument - Tachometer QSM11 Engine

Standard measurement value Low idle (min-1): 800±50 High idle (min-1): 2,200±50

90ZV23004

23-3 92ZV-2 Check & Adjustment Power Group 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 transmission torque and the reaction force. As a result, the propeller shaft will extremely vibrate, and the service 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 92ZV-2 Check & Adjustment Power Group Propeller Shaft

Tightening torque 2nd propeller shaft

Front diff.

Pillow block (Center bearing)

1

4 7

2

3rd propeller shaft

3 Rear diff.

6

Front diff. side

5 92V2U23001

IMPORTANT Never reuse universal joint or driveline bolts or locks.

Always use new bolts and secure with loctite® 262 and primer. : 1. 142 N-m (14.5 kgf-m) (105 lb-ft) 2. 142 N-m (14.5 kgf-m) (105 lb-ft) 3. 142 N-m (14.5 kgf-m) (105 lb-ft) 4. 417 N-m (42.5 kgf-m) (307 lb-ft) 5. 162 N-m (16.5 kgf-m) (120 lb-ft) 6. 77 N-m (7.9 kgf-m) (57 lb-ft) 7. 27.5±1.0 N-m (2.8±0.1 kgf-m) (20.3±0.74 lb-ft) #1, 2, 3, 4: Screw lock agent (Loctite® 262)

23-5 92ZV-2 Check & Adjustment Power Group Axle

Axle Axle nut tightening procedure 6

9

8

7

A

PT3/8 Brake oil inlet

2

4 1 10 5 3 92V2U23002

1. Tighten axle nut (6) with 2,300 N-m (235 kgf-m) (1,696 lb-ft) tightening torque to install taper roller bearings (7)(8).

2. Loosen the axle nut.

3. Tighten the axle nut again with 2,300 N-m (235 kgfm) (1,696 lb-ft) tightening torque.

4. Turn wheel hub (9) 2~3 turns back and forth, and measure the preload applied to section (∗ part).

Preload of section (∗ part) 226~265 N (23~27 kgf) (51~59 lbf) ∗∗ ∗∗This is "breakaway" force. The force required to start the wheel turning.

Note Use jig to install the floating seal to the axle assembly.

Adjust the clearance between axle nut and axle extension to A (1.14~2.26 mm) (0.05~0.09 in). : 1. 89.7 N-m (9.15 kgf-m) (66 lb-ft) 2. 216 N-m (22.0 kgf-m) (159 lb-ft) 3. 33.3 N-m (3.40 kgf-m) (25 lb-ft) 4. 53.0 N-m (5.40 kgf-m) (39 lb-ft) 5. 86.3 N-m (8.80 kgf-m) (64 lb-ft) #1, 2, 4: Screw lock agent (Loctite® 262) #10: Liquid gasket (Three Bond 1215 or a locally procured Room Temperature Vulcanizer (RTV) that does not contain Acetic Acid)

23-6 92ZV-2 Check & Adjustment Power Group Axle

Differential gear adjustment procedure 1

9 7

2

6

8

4

5 3

Preload adjustment Measure the preload at the bolt hole of cage (7).

Standard preload∗∗ 57~66 N (5.8~6.7 kgf) (13~14 lbf) If the preload is out of the above range, replace the spacer (6) to adjust the preload to the specified range. ∗∗Preload is the force required to start the cage movingbreakaway force.

90V2U23001

Note There are 14 types of spacers from 16.70 mm (0.657 in) to 16.98 mm (0.668 in) in increments of 0.02 mm (0.0007 in). Thicker spacers reduce preload; thinner spacers increase preload.

23-7 92ZV-2 Check & Adjustment Power Group Axle

Bearing installation Install bearing (8) so that ∗ part faces to the drive pinion.

Pinion gear Snap ring

Bearing (8)

K85ZV23003

Note A snap ring is set to bearing (8) as shown above. Incorrect installation of bearing (8) may cause the snap ring to drop, resulting in a serious mechanical trouble.

Oil seal installation Before installing oil seal (9), be sure to apply grease to the lip.

Apply grease when assembling.

K85ZV23004

23-8 92ZV-2 Check & Adjustment Power Group Axle

Adjusting tooth contact Tooth contact

Possible cause

Adjusting method

A

Correct

B

Ring gear is too close to the drive pinion

Loosen the bearing adjuster on the rear side of ring gear, and tighten the adjuster of tooth side at the same quantity as loosening, so that the ring gear is far apart from the drive pinion. Check again the backlash and tooth contact.

C

Ring gear is too far from the drive pinion

Do the reverse adjusting as B.

Drive pinion is too close to the ring gear.

Increase the thickness of shim at the part of bearing cage being installed and makes drive pinion apart from the ring gear.

Check again the backlash and tooth contact.

D

2

2

2

1

E

Drive pinion is too far from the ring gear.

Decrease the thickness of shim reverse as D, and makes drive pinion approach the ring gear.

Check again the backlash and tooth contact.

2

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.

23-9 92ZV-2 Check & Adjustment Power Group Axle Three types of tooth contact shown below are acceptable as the best tooth contact.

Tooth contact position and length (rate)

10 Pattern A

1

5 TOP

4

HEEL

4~5

Pitch line TOE

10

BOTTOM

10 Pattern B

2 Pitch line

4 TOP

4

HEEL

4~5

10

TOE BOTTOM

10 3 Pattern C

4 TOP

TOE

3 HEEL

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 pinion as a unit.

Note Single sale of the bevel gear or the drive pinion is not possible.

23-10 92ZV-2 Check & Adjustment Power Group

MEMO

33-1 92ZV-2 Check & Adjustment Torque Converter and Transmission Group

92ZV-2 Check & Adjustment Torque Converter and Transmission Group Clutch Oil Pressure ................................................. 33-2

33-2 92ZV-2 Check & Adjustment Torque Converter and Transmission Group Clutch Oil Pressure

Clutch Oil Pressure Measuring clutch oil pressure

Torque converter inlet oil pressure measurement port : PF1/4

3rd speed clutch oil pressure measurement port : PF1/4

Reverse clutch oil pressure measurement port : PF1/4 2nd speed clutch oil pressure measurement port : PF1/4

Forward clutch oil pressure measurement port : PF1/4 4th speed clutch oil pressure measurement port : PF1/4 1st speed clutch oil pressure measurement port : PF1/4

92V2U33001

WARNING Unexpected movement of the machine may cause an accident resulting in injury or death.

To prevent such an accident during clutch oil pressure measurement, be sure to closely communicate with the person in the cab by giving signals to each other. Also use a gauge with a hose long enough to reach outside from the articulation area.

- Pressure gauge 3 MPa (30 kgf/cm2) (500 psi) with 2~3 m hose - Clutch oil pressure measurement value : 1.8±0.15 MPa (18±1.5 kgf/cm2) (256±21 psi) at engine idling speed (LI) 1.9±0.15 MPa (19±1.5 kgf/cm2) (270±21 psi) at engine maximum speed (HI) - Torque converter oil temperature : 50~80ºC (120~180ºF)

43-1 92ZV-2 Check & Adjustment Hydraulic Group

92ZV-2 Check & Adjustment Hydraulic Group Loading/Steering Circuit Relief Valve/Ride Control Circuit Reducing Valve (OPT) ................................ 43-2 Hydraulic Cylinder ................................................... 43-15 Stop Valve ............................................................... 43-17

43-2 92ZV-2 Check & Adjustment Hydraulic Group Loading/Steering Circuit Relief Valve/Ride Control Circuit Reducing Valve (OPT)

Loading/Steering Circuit Relief Valve/Ride Control Circuit Reducing Valve (OPT) Loading circuit relief valve setting pressures WARNING Unexpected movement of the machine may cause an accident resulting in injury or death.

Therefore, to provide repair service with the engine running, be sure to observe the following items : - Park the machine on level ground.

- 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

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 open the cap of the hydraulic tank before removing the plug from the pressure measurement port.

CAUTION Do not touch the fan or V-belt of the engine or a hightemperature section if the engine is running. An accident resulting in injury may occur.

Be sure to stop the engine before you open the access panel of the engine room. Keep all guards in place.

Avoid high temperature components even when the engine is stopped.

Measurement instruments Pressure gauge 30 MPa (300 kgf/cm2) (5,000 psi) (for loading line with 3 m (10 ft.) hose) 5 MPa (50 kgf/cm2) (1,000 psi) (for pilot line) with 2~3 m (6~10 ft.) hose Note For safety, route the gauge to an area where it may be safely read by the person doing the test.

Gauge port Gauge port location

Port size

Main relief pressure (1), (2), (3) Overload relief pressure

Pilot line pressure (Reducing valve)

(1), (2), (3) G (PF) 1/4 with O-ring (1), (2), (3) (4) G (PF) 3/8 with O-ring (4), (5) (5) G (PF) 1/4 with O-ring

43-3 92ZV-2 Check & Adjustment Hydraulic Group Loading/Steering Circuit Relief Valve/Ride Control Circuit Reducing Valve (OPT)

Standard measurement value MPa (kgf/cm2) (psi) Loading line main relief pressure (at maximum speed)

20.6±0.5 (210±5) (2,986±71)

Loading line overload relief pressure (at idling speed)

23.5±0.5 (240±5) (3,413±71)

Pilot line

3.5 (36) (512)

Measuring loading circuit main relief pressure 1. Unload the bucket.

2. Lower the boom to the lowest limit.

3. Attach the pressure gauge 30 MPa (300 kgf/cm2) (5,000 psi) to the bucket cylinder bottom side (2).

4. Set the parking brake switch to the "ON" position.

Hydraulic oil temp 50±5ºC (120±9ºF) Reference Releasing residual pressure from tank and pipes Keep the bottom surface of the bucket horizontal, and stop the engine when the bucket is approximately 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.

Push down on, then open the cap of the hydraulic tank to release the residual pressure.

5. Move the bucket control lever to the roll back position. Hold the lever at that position.

6. Increase the engine speed to the maximum, and measure and record the pressure using the pressure gauge.

Adjusting main relief pressure Loosen the lock nut and adjust the pressure by the adjusting screw.

Turn clockwise the adjusting screw to raise the set pressure, or turn counterclockwise the adjusting screw to lower the set pressure.

IMPORTANT At the completion of check and adjustment of main relief valve pressure, be sure to tighten the lock nut.

43-4 92ZV-2 Check & Adjustment Hydraulic Group Loading/Steering Circuit Relief Valve/Ride Control Circuit Reducing Valve (OPT) Main relief valve

Bucket cylinder

Adjusting screw Tank port

(2)

Cap nut Lock nut

(1) K90V2J43001

Multiple control valve

Overload relief valve

(3)

Main relief valve 90ZVE43001

Valve assembly (5) (PPI)

(4)

(Z2) (PA) (PARKING) (TA)

(T)

(Z)

(Z1) ACF

(ACCF)

(ACCR)

(P)

Reducing valve (for pilot) 85V2E43001

90ZVE43002

43-5 92ZV-2 Check & Adjustment Hydraulic Group Loading/Steering Circuit Relief Valve/Ride Control Circuit Reducing Valve (OPT)

Measuring loading circuit overload relief pressure 1. Attach the pressure gauge to the port ((2) for the bottom side, (1) for the rod side, (3) for the both sides).

Overload relief valve

Lock nut

2. Adjust the main relief valve pressure to 24.5 MPa (250 kgf/cm2) (3,555 psi) + 1/4 additional turn, so the pressure is above the overload relief pressure.

Bucket cylinder bottom side 1. Lower the boom to the lowest limit.

2. Move the bucket control lever to the roll back position.

3. Keep the engine speed at low idle.

4. Hold the bucket control lever at the roll back position and record the pressure.

Bucket cylinder rod side 1. Keep the boom horizontal.

2. Move the bucket control lever to the dump position, hold and then measure and record the pressure.

Adjusting overload relief pressure Loosen the lock nut and adjust the pressure by the adjusting screw.

Turn clockwise the adjusting screw to raise the set pressure, or turn counterclockwise the adjusting screw to lower the set pressure.

IMPORTANT At the completion of check and adjustment of overload relief valve pressure, be sure to reset the main relief valve to the original condition.

Adjusting screw

90ZVE43003

43-6 92ZV-2 Check & Adjustment Hydraulic Group Loading/Steering Circuit Relief Valve/Ride Control Circuit Reducing Valve (OPT)

Measuring pilot circuit relief pressure

Reducing valve

WARNING Trapped pressure in brake circuit could cause serious injury when the plug is removed.

Fully release all residual accumulator pressure before servicing.

Lock nut

1. Attach the pressure gauge to port (4) or (5).

Adjusting screw

WARNING

90ZVE43004

Injection Hazard Depress brake pedal 80~100 times to completely discharge the brake accumulators prior to removing these plugs.

K65ZV42022

2. Keep the engine speed at low idle (when the brake line pressure is normal) and then measure and record the pressure.

Adjusting pilot line pressure Loosen the lock nut and adjust the pressure by the adjusting screw.

Turn clockwise the adjusting screw to raise the pilot line pressure.

IMPORTANT After the completion of the adjustment of the pilot line pressure, be sure to tighten the lock nut.

43-7 92ZV-2 Check & Adjustment Hydraulic Group Loading/Steering Circuit Relief Valve/Ride Control Circuit Reducing Valve (OPT)

Ride control circuit reducing valve setting pressures (OPT) WARNING Unexpected movement of the machine may cause an accident resulting in injury or death.

Therefore, to provide repair service with the engine running, be sure to observe the following items : - Park the machine on level ground.

- 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

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 open the cap of the hydraulic tank before removing the plug from the pressure measurement port.

CAUTION Do not touch the fan or V-belt of the engine or a hightemperature section if the engine is running. An accident resulting in injury may occur.

Be sure to stop the engine before you open the access panel of the engine room. Keep all guards in place.

Avoid high temperature components even when the engine is stopped.

Measurement instruments Pressure gauge 15 MPa (150 kgf/cm2) (3,000 psi) (for ride control line) with 3 m (10 ft.) hose Note For safety, route the gauge to an area where it may be safely read by the person doing the test.

Gauge port Gauge port location Reducing pressure

SP2

Port size G (PF) 3/4 with O-ring

43-8 92ZV-2 Check & Adjustment Hydraulic Group Loading/Steering Circuit Relief Valve/Ride Control Circuit Reducing Valve (OPT)

Standard measurement value MPa (kgf/cm2) (psi) Ride control line pressure (reducing valve)

Measuring ride control circuit reducing pressure

7.4±0.3 (75±3) (1,067)

23

Hydraulic oil temp : 50±5ºC (120±9ºF)

(18)

Reference

From pump

1

(11)

P

(12)

Depressure valve section

85V2E43003

KAYABA INDUSTRY CO,LTD TOKYO JAPAN

(18) B

B T

SP2

A

: Valve (18): 7 N-m (0.7 kgf-m) (5 lb-ft) : Nut (23): 13.6 N-m (1.4 kgf-m) (10 lb-ft)

B

(15)(16) Boom cylinder bottom side

1. Loosen the lock nut (23) and depressure valve (18) for releasing internal pressure from accumulator circuit.

Boom cylinder rod side 85V2E43002

Releasing residual pressure from tank and pipes Keep the bottom surface of the bucket horizontal, and stop the engine when the bucket is approximately 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.

Push down on, then open the cap of the hydraulic tank to release the residual pressure.

2. Attach the pressure gauge to the gauge port SP2. : Plug SP2: 165 N-m (16.8 kgf-m) (121 lb-ft) 3. Keep the engine speed at low idle and then measure and record the pressure.

43-9 92ZV-2 Check & Adjustment Hydraulic Group Loading/Steering Circuit Relief Valve/Ride Control Circuit Reducing Valve (OPT) Adjusting reducing valve pressure

P

1 21

22

Reducing valve section

70V2U43001

Loosen the lock nut (21) and adjust the pressure by the adjusting screw (22). : Lock nut (21): 29 N-m (3.0 kgf-m) (22 lb-ft) Turn clockwise the adjusting screw to raise the set pressure, or turn counterclockwise the adjusting screw to lower the set pressure.

IMPORTANT At the completion of check and adjustment of reducing valve pressure, be sure to tighten the lock nut.

43-10 92ZV-2 Check & Adjustment Hydraulic Group Loading/Steering Circuit Relief Valve/Ride Control Circuit Reducing Valve (OPT)

Steering circuit relief valve setting pressures WARNING Unexpected movement of the machine may cause an accident resulting in injury or death.

Therefore, to provide repair service with the engine running, be sure to observe the following items : - Park the machine on level ground.

- 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

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 open the cap of the hydraulic tank before removing the plug from the pressure measurement port.

CAUTION Do not touch the fan or V-belt of the engine or a hightemperature section if the engine is running. An accident resulting in injury may occur.

Be sure to stop the engine before you open the access panel of the engine room. Keep all guards in place.

Avoid high temperature components even when the engine is stopped.

Measurement instruments Pressure gauge 30 MPa (300 kgf/cm2) (5,000 psi) (for steering line with 1.5 m (4 ft.) hose) 5 MPa (50 kgf/cm2) (1,000 psi) (for pilot line) with 2~3 m (6~10 ft.) hose Note For safety, route the gauge to an area where it may be safely read by the person doing the test.

Gauge port Gauge port location

Port size

Main relief pressure (1), (2)

G (PF) 1/4 with O-ring

(3)

Rc (PT 1/8)

Overload relief pressure Reducing pressure

43-11 92ZV-2 Check & Adjustment Hydraulic Group Loading/Steering Circuit Relief Valve/Ride Control Circuit Reducing Valve (OPT)

Standard measurement value MPa (kgf/cm2) (psi) Steering line main relief pressure (at maximum speed)

20.6±0.5 (210±5) (2,986±71)

Steering line overload relief pressure (at idling speed)

24.5 +1.0 0 (250 +100 ) (3,555 +1420 )

Pilot line

3.5 (36) (512)

Hydraulic oil temp : 50±5ºC (120±9ºF) Reference Releasing residual pressure from tank and pipes Keep the bottom surface of the bucket horizontal, and stop the engine when the bucket is approximately 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.

Push down on, then open the cap of the hydraulic tank to release the residual pressure.

Measuring steering circuit main relief pressure 1. Attach the pressure gauge to gauge port (1) or (2).

2. In case the pressure gauge is installed to (1), steer the machine to the left until the front and rear chassis contact each other.

Continue to hold the steering wheel fully turned.

Note Because the stop valve is installed into the steering line, oil pressure does not reach the set point when the steering is fully turned.

When measuring oil pressure, be sure to apply the articulation stopper or screw the stopper (bolt) in until the front and rear chassis contact each other.

WARNING If the machine begins to move with the articulation stopper applied, it may cause an accident resulting in injury or death.

After the measurement, be sure to disconnect and store the articulation stopper.

3. Increase the engine speed to high idle, and measure and record the pressure.

Steering cylinder

(2)

Note North America equipped M/c's have quick connectors at ports (1) and (2).

(1)

70ZV43007

Adjusting steering line main pressure Loosen the lock nut and adjust the pressure by the adjusting screw.

Turn clockwise the adjusting screw to raise the steering line main pressure.

43-12 92ZV-2 Check & Adjustment Hydraulic Group Loading/Steering Circuit Relief Valve/Ride Control Circuit Reducing Valve (OPT) Reducing valve

Main relief valve

Lock nut Adjusting screw

(A)

(3)

(B)

115ZV43006

Steering valve

Steering valve 70ZV43009

Overload relief valve

Main relief valve

70ZV43008

43-13 92ZV-2 Check & Adjustment Hydraulic Group Loading/Steering Circuit Relief Valve/Ride Control Circuit Reducing Valve (OPT)

Measuring steering circuit overload relief pressure

Stopper (bolt)

Port B To steering valve

Adjusting overload relief pressure

Port A From Orbitrol®

Lock nut

Spool

Adjusting screw Installed on front chassis

Check valve 70ZV43005

Installed on rear chassis 90V2U42003

1. Attach the pressure gauge to the port ((1) for the left turn, (2) for the right turn).

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.

3. Steer the machine until the front and rear chassis contact each other. Continue to hold the steering wheel fully turned.

Note Because the stop valve is installed into the steering line, oil pressure does not reach the set point when the steering is fully turned.

When measuring oil pressure, be sure to apply the articulation stopper or screw the stopper (bolt) in until the front and rear chassis contact each other.

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.

Loosen the lock nut and adjust the pressure by the adjusting screw.

Turn clockwise the adjusting screw to raise the set pressure, or turn counterclockwise the adjusting screw to lower the set pressure.

WARNING If the machine begins to move with the articulation stopper applied, it may cause an accident resulting in injury or death.

After the measurement, be sure to disconnect and store the articulation stopper.

IMPORTANT At the completion of check and adjustment of overload relief valve pressure, be sure to reset the main relief valve to the original condition.

43-14 92ZV-2 Check & Adjustment Hydraulic Group Loading/Steering Circuit Relief Valve/Ride Control Circuit Reducing Valve (OPT)

Measuring pilot circuit relief pressure (reducing pressure)

Adjusting screw

Adjusting pilot line pressure Loosen the lock nut and adjust the pressure by the adjusting screw.

Turn clockwise the adjusting screw to raise the pilot line pressure.

IMPORTANT

Lock nut

After the completion of the adjustment of the pilot line pressure, be sure to tighten the lock nut.

(T)

(A)

(3) (TS)

(B)

115ZV43007

1. Attach the pressure gauge to port (3).

Gauge port plug width across flat: 5 mm (0.2 in) 2. Keep the engine speed at low idle and record the pressure.

43-15 92ZV-2 Check & Adjustment Hydraulic Group Hydraulic Cylinder

Hydraulic Cylinder Cylinder natural drift

Measurement procedure 1. Unload the bucket.

WARNING Standing under the boom or bucket during service work is dangerous. An accident resulting in injury or death may be caused.

To prevent such an accident, be sure to lock the boom and bucket control levers in the cab, securely support the boom, and remove the starter key.

In addition, hang a "DO NOT OPERATE!" tag on the steering wheel.

2. Keep the boom and bucket horizontal.

3. Set the parking brake switch to the "ON" position.

4. Lock the boom and bucket control levers using the safety lock.

5. Stop the engine.

6. Mark the cylinder rod at a point 100~150 mm (4~6 in) away from the cylinder head cover.

Measurement instrument

7. Measure the accurate distance from the cylinder head cover to the vinyl tape. This is distance "A" mm (in). Measure the distance again 5 minutes later. This is distance "B" mm (in).

- Scale 150~300 mm (1 ft.)

- Stop watch

Cylinder drift (mm/min) A – B (mm) (in) = -------------(in/min) 5 (min)

- Black vinyl "electrician's" type Note Warm-up the hydraulic oil before measuring cylinder drift.

Standard measurement value (mm/min) (in/min) Boom cylinder

3 (1/8) or less

Bucket cylinder

4 (5/32) or less

43-16 92ZV-2 Check & Adjustment Hydraulic Group Hydraulic Cylinder Reference

Mark (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 cylinder rod, the tape may be caught by the rod seal. The tape will cause oil leakage from the rod seal. To prevent oil leakage, be sure to remove the vinyl tape.

43-17 92ZV-2 Check & Adjustment Hydraulic Group Stop Valve

Stop Valve Stop valve adjustment procedure

Reference dimension Front chassis

Stop valve (rear chassis)

Stopper (bolt)

38º 36º~

(L.H, R.H)

Front chassis Rear chassis

Reference dimension 31.7~36.3 mm (1.25~1.43 in)

Reference dimension 9.6~19.3 mm (0.38~0.76 in)

Stopper (bolt) length

Clearance between machine body and stopper

90ZVE43006

90ZVE43005

Articulation angle ( º)

WARNING When the machine turns, the clearance in the articulation area closes. As a result, people may be caught, leading to a severe accident. To prevent such an accident, observe the following items strictly when adjusting the steering stopper.

- Stop the engine before starting adjustment of the stopper bolt.

- When confirming the operation after setup, keep proper distance from the articulation area of the machine.

The stop valve works when the spool is pushed in 3 mm (0.118 in).

Adjust the stopper bolt by using the following procedure.

- Adjust the stopper (bolt) length so that the clearance between the machine body and the stopper becomes the reference dimension "9.6~19.3 mm (0.38~0.76 in)" shown in the table below.

38

37

36

Clearance between machine body and stopper (mm) (in)

9.6 (0.38)

14.5 (0.57)

19.3 (0.76)

Stopper (bolt) length (mm) (in)

31.7 (1.25)

34.0 (1.34)

36.3 (1.43)

*The target value should be the articulation angle "37º".

- After adjustment, turn the steering wheel slowly at a rate of 5 sec or more per turn, and confirm the clearance between the machine body and the stopper.

- When adjustment is completed, tighten the lock nut of the stopper (bolt). : 90 N-m (9.2 kgf-m) (67 lb-ft)

43-18 92ZV-2 Check & Adjustment Hydraulic Group

MEMO

53-1 92ZV-2 Check & Adjustment Brake Group

92ZV-2 Check & Adjustment Brake Group Brake Circuit Oil Pressure ....................................... 53-2 Service Brake .......................................................... 53-6 Parking Brake.......................................................... 53-9

53-2 92ZV-2 Check & Adjustment Brake Group Brake Circuit Oil Pressure

Brake Circuit Oil Pressure WARNING Unexpected movement of the machine may cause an accident resulting in injury or death. Therefore, to provide repair service with the engine running, be sure to observe the following items: - Park the machine on level ground.

- Apply the parking brake.

- Block the tires with chocks to prevent the tires from moving.

- Determine the signals between the service men.

Unloader valve setting pressure

(PPI)

(Z2)

(Z)

(Z1)

(PA) ACF

(ACCF)

(PARKING)

(ACCR) (PI)

(TA) (P) (T)

ACF port Valve assembly

92V2U53001

WARNING

Injection Hazard Depress brake pedal 80~100 times to completely discharge the brake accumulators prior to removing these test plugs.

135ZV52035

Brake line main pressure is regulated by the unloader valve.

53-3 92ZV-2 Check & Adjustment Brake Group Brake Circuit Oil Pressure Method 1 Refer to "Brake Main pressure 1" "Brake Main pressure 2" of MODM "Input/Output Monitor" section.

5. Keep the engine at low idle, and repeatedly depress and release the brake pedal to reduce the accumulator pressure. Measure and record the pressure when the pointer of the pressure gauge stops and then starts rising again (cut-in pressure).

Method 2 If the pressure gauge is not available as described "Method 2", apply the "Method 1".

Measurement instrument

Adjusting unloader valve setting pressure

21

22

Fan motor port

Hydraulic pressure gauge 20 MPa (200 kgf/cm2) (3,000 psi)

Gauge port ACF port on valve assembly Rc (PT) 1/8

Pump port Unloader valve

K115ZV53002

Standard measurement value Cut-out

11.8±0.5 MPa (120±5 kgf/cm2) (1,706±71 psi)

Cut-in

6.9±1.0 MPa (70±10 kgf/cm2) (995±142 psi)

Measurement procedure 1. Lower the boom to the lowest limit, and tilt the bucket down to the ground.

Then set the parking brake switch to the "ON" position.

2. Stop the engine. Repeatedly depress and release the brake pedal till you feel light brake to discharge accumulator pressure.

3. Remove one of the ACF port plug on the valve assembly and attach the pressure gauge to the port.

4. Start the engine, and keep the speed at low idle.

Measure and record the pressure when the pointer of the pressure gauge stops rising (cut-out pressure).

1. Loosen lock nut (22).

2. Adjust the pressure by adjusting screw (21). Turn the screw clockwise to raise the pressure.

Note In a case that the "ON" or "OFF" pressure does not match the standard setting pressure, set the "ON" (cutin) pressure to the standard setting pressure.

Tightening torque : ACF port plug: 11.3 N-m (1.15 kgf-m) (8.3 lb-ft) : Lock nut (22): 16.7 N-m (1.7 kgf-m) (12.3 lb-ft)

53-4 92ZV-2 Check & Adjustment Brake Group Brake Circuit Oil Pressure

Brake valve oil pressure

Gauge port

Force

Size of air bleeder port Rc (PT) 3/8

19

Pe

da

la ng

le

Remove air bleeder nipple fitting on the axle housing, and then install the pressure gauge to the bleeder position.

15

(In case of the bleeder valve M10 X 1.0)

0

45

m m

Air bleeder nipple fitting [59 N-m (6.0 kgf-m) (43 lb-ft)]

85V2E53002

Method 1 Refer to "Brake Pedal Output Oil Pressure" of MODM "Input/Output Monitor" section.

85ZVE53001

Method 2 If the pressure gauge is not available as described "Method 2", apply the "Method 1".

Measurement procedure Check to be sure the brake valve is fully released.

Measurement instrument

Press down the brake pedal to check that the oil pressure rises in proportion to the pedal angle.

Hydraulic pressure gauge 10 MPa (105 kgf/cm2) (1,500 psi)

Release the brake pedal to check that the oil pressure drops to zero in proportion to the pedal angle. In addition, visually check for brake oil leakage.

53-5 92ZV-2 Check & Adjustment Brake Group Brake Circuit Oil Pressure

Brake valve performance

Output oil pressure (brake port)

MPa (kgf/cm2) (psi) 4 (40) (580)

4.01 (41) (581)

2 (20) (290) 0.57 (6) (83) 0

10

3.9 5

15

18.5 19

(deg)

Pedal stroke

90V2E53001

Refer to the curve shown in the above figure.

When the measured value does not match the performance curve, check the following points.

Possible cause Malfunctioning brake valve

Solution Repair or replacement

Brake line oil pressure low (Pump, reducing valve malfunction)

Check and repair

IMPORTANT After measuring oil pressure, be sure to tighten the air bleeder valve. Also be sure to bleed air.

53-6 92ZV-2 Check & Adjustment Brake Group Service Brake

Service Brake Service brake performance check

Method 2

Method 1

If no test course available as described "Method 1", carry out the following method.

WARNING

IMPORTANT

Separate the test course by using rope etc. and keep persons away from the test course. In addition, post persons in several positions near the course to warn others and avoid an accident while checking the service brake performance.

The following method is easy and simple, however it is not an accurate way, because the braking force and rim-pull may vary on each machine. Confirm engine & transmission performance via using a stall test. See page 03-3.

Reconfirm the brake performance by the method 1 as soon as possible.

Condition

WARNING

1. Test course Level, straight, dry and the paved ground.

2. Run the machine and depress the brake pedal at 35 km/h (22 mph).

Measure and record the braking distance.

Unexpected movement of the machine may cause an accident resulting in injury or death.

Before starting brake performance check, be sure to observe the following items: - Place the machine on level ground.

- Check that there is enough clearance for brake performance check around the machine.

- During performance check, prohibit any person to walking near the machine.

Standard measurement value Braking distance 20 m (22 1/4 yd) or shorter

1. Lower the boom to the lowest limit, and roll back the bucket fully until the bucket contacts to the stopper.

Possible causes of extremely long braking distance

2. Set the parking brake switch to the "OFF" position.

Possible cause

Solution

Low brake line pressure

Check and repair

Friction plate wear

Check and repair

Brake valve malfunction

Check and repair

Note The brake performance check condition and standard measurement value are based on the law and the regulation in Japan.

When checking the service brake performance, follow the law and/or local regulation in your country, state, or province.

3. Set the declutch switch to OFF, and then depress the brake pedal all the way to the floor.

4. Set the shift lever to 2nd reverse speed.

5. Gradually increase the engine speed. The machine should not move at the maximum engine speed.

Possible cause of machine moving during brake performance check.

Possible cause

Solution

Low brake line pressure

Check and repair

Friction plate wear

Check and repair

Brake valve malfunction

Check and repair

53-7 92ZV-2 Check & Adjustment Brake Group Service Brake

Service brake friction plate wear measurement

A

Slide caliper

A

Steel plate Brake backing plate

Friction plate

85V2E53004

WARNING Upper Oil inlet port

10

10

Spring pin Internal gear

Inner steel plate teeth

Outer steel plate teeth 85ZVE53004

Unexpected movement of machine could cause serious injury or death. To prevent such an accident, observe the following items before checking the brake friction plate wear: - Park the machine on level ground.

- Apply the parking brake.

- Stop the engine.

- Determine the signals between the persons related to this work for engine starting to prevent an accident.

- Prohibit any person from walking into the dangerous area.

IMPORTANT After inserting calipers, do not rotate the wheels. If the wheels are rotated, the calipers may be caught and broken by the reduction gear. In this case, the reduction gear must be disassembled.

53-8 92ZV-2 Check & Adjustment Brake Group Service Brake

Measurement procedure Turn the planetary gear so that the oil supply plug is positioned at the place about 10º from the top. Check that the teeth of steel plate are as shown in the figure in page 53-7 (only one section of the plate circumference is as shown in the figure).

Cautions on installing brake discs

A B Wheel hub

Insert calipers to the inner steel plate to measure the dimension A. Note During measurement, be sure the service brake is applied.

The wear limit for dimension A is 25.1 mm (0.988 in).

Note that dimension A is 29.0 mm (1.142 in) when the plate is new and unused.

Note To aid quick measurement on the front axle-raise the front of the machine so the front tires clear the ground by about 25 mm (1 in). This allows easy rotation of the wheel to align the gear teeth.

Brake piston

85V2E53005

When only the friction plates or the steel plates are to be replaced, if the brake piston is installed as it is, the brake may drag and the brake discs may seize.

Push back the brake piston by loosening the air bleeder nipple before replacing a friction plate or a steel plate.

- After pushing back the piston, confirm dimension A from the piston end face to the wheel hub end face.

IMPORTANT Wheel bearings must be adjusted correctly to get an accurate measurement for dimension A. Dimension should be equal at top and bottom.

A: 158.05~159.55 mm (6.222~6.281 in) Note Piston stroke B 1.18~1.83 mm (0.046~0.072 in) - After finishing the installation work, bleed air completely from the brake line.

53-9 92ZV-2 Check & Adjustment Brake Group Parking Brake

Parking Brake Parking brake performance check

Method 2

Method 1

If no test course available as described "Method 1", carry out the following method.

WARNING

IMPORTANT

Unexpected movement of the machine may cause an accident resulting in injury or death.

Before starting brake performance check, be sure to observe the following items: - Check that there is enough clearance for brake performance check around the machine.

- During performance check, prohibit any person to walking near the machine.

The following method is easy and simple, however it is not an accurate way, because the braking force and rim-pull may vary on each machine.

Confirm engine & transmission performance via stall test. See page 03-3. Reconfirm the brake performance by the method 1 as soon as possible.

WARNING Unexpected movement of the machine may cause an accident resulting in injury or death.

Before starting brake performance check, be sure to observe the following items: - Place the machine on level ground.

- Check that there is enough clearance for brake performance check around the machine.

- During performance check, prohibit any person to walking near the machine.

Condition 1. Test course 1/5 slope (Approx. 11º 19') 2. Bucket empty 3. Parking switch ON

1. Set the parking brake switch to the "ON" position.

Standard measurement value

2. Disconnect the cable connector of parking brake solenoid valve.

No movement on 1/5 slope.

3. Place the shift lever to the 3rd reverse position.

Possible cause of machine moving during brake performance check

4. Gradually increase the engine speed. The machine should not move at the maximum speed.

Possible cause

Solution

Wear or breakage of brake disc

Check and repair

Parking brake switch malfunction

Check and repair

Parking brake solenoid valve malfunction

Check and repair

Note The brake performance check methods 1 and 2 are based on the law and the regulation in Japan.

When checking the service brake performance, follow the law and/or local regulation in your country, state, or province.

IMPORTANT If the machine begins to move with the parking brake applied, the brake discs are worn.

At the completion of parking brake test, be sure to connect the connector of electrical line to the solenoid valve again.

Possible cause Wear or breakage of brake disc

Solution Check and repair

Parking brake switch malfunction

Check and repair

Parking brake solenoid valve malfunction

Check and repair

Maintenance Log Date

Machine hours

Service performed

Date

Machine hours

Service performed

Date

Machine hours

Service performed

Date

Machine hours

Service performed

Notes