Professional Documents
Culture Documents
92ZV 2 (EU Trouble)
92ZV 2 (EU Trouble)
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 meth-
ods. Please read this manual to ensure correct troubleshooting and good repair service.
This manual will be periodically reviewed and revised for more satisfactory content. If you have any opinion or
requests, please inform us.
Safety 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 cool-
ant pipe.
- 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 crib-
bing under the unit to prevent unexpected dropping.
- 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.
- When working outdoors keep work areas, ladders, steps, decks and work platforms clear of snow, ice, and mud.
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.
Oil or
Shows the oil or water supply port and the refill
water
amount.
supply
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 dam-
aged 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 follow-
ing abbreviation list.
E/G ........... Engine RH ........... Right hand side 3rd ............3rd speed
T/C ........... Torque converter LH ........... Left hand side 4th ............4th speed
T/M ........... Transmission H ........... High M/C ............Machine
SOL ........... Solenoid valve L ........... Low min-1 ............RPM
SW ........... Switch GND ........... Ground ELS ............Efficient loading system
F ........... Front or Forward OPT ........... Option MODM ........Machine operation diag-
A/M ........... Auto/Manual Assy ........... Assembly nostic module
B ........... Battery 1st ........... 1st speed MCU............Machine control unit
R ........... Rear or Reverse 2nd ........... 2nd speed
CONTENTS
• TROUBLESHOOTING....................................................01-1
Troubleshooting
01
Cautions Regarding Troubleshooting ................................................................................................................ 01-3
How to Use Quick Troubleshooting Table ......................................................................................................... 01-4
Safety Precautions ............................................................................................................................................ 01-5
For instance, assume that the operator complains that This machine is controlled by electrical, hydraulic,
the boom power is low, and the rim-pull is also low. In and mechanical systems. The most easy-to-be-
this case, there are two possible causes ; low hydraulic repaired system is the electrical system. Check the
power and low rim-pull. The remedies against both electrical system first. If no problem is detected in
causes are much different from each other. the electrical system, check the hydraulic system,
and then the mechanical system.
If you hastily determine the wrong cause without check-
ing the actual condition of the problem, it will take too Note
much time and expense to solve the problem. As a Check the error code on the MODM at first !
result, you will not be trusted by the user.
01-4
92ZV-2 Troubleshooting
How to Use Quick Troubleshooting Table
Safety Precautions
DANGER WARNING
Entering the articulation area of the machine body Service work under the machine may cause an acci-
while the engine is running may cause severe acci- dent resulting in injury or death. To prevent such an
dents. accident, be sure to observe the following items.
Make sure to stop the engine, pull out the starter key, - Park the machine on level ground.
and attach a "DO NOT OPERATE!" tag to the cab - Apply the parking brake.
before entering the articulation area. - Block the tires with chocks to prevent the tires from
moving.
- Stop the engine.
WARNING - Give signals to the person in the cab during the
Unexpected movement of the machine may cause an work.
accident resulting in injury or death.
ler unit).
Low clutch oil pressure at all the shift lever positions.
Machine moves at a certain shift lever position, but hesitates to move at any other posi-
2. Machine dose not move at a cer-
Machine does not move at a certain shift lever position, but moves at all the other posi-
Clutch oil pressure is low at a certain position only. At all the other positions, the pres-
tain shift lever position.
Clutch can be engaged at a certain shift lever position, though the clutch will not be
(OR:Machine moves only in a cer-
tain shift lever position.)
F5 fuse blows.
tions.
tions.
When the lever is shifted to the reverse position, the machine does not move reverse
position.
(Example: Machine moves for-
When the lever is shifted to the forward position, the machine moves forward.
ward at the neutral position.)
Main oil pressure is too low at all the shift lever positions.
Large time lag at a certain shift lever position only.
Large time lag at all the shift lever positions.
Less difference in torque converter oil temperature between cooler inlet and outlet.
Thermometer in T/C out line indicates less than 250ºF/120ºC when gauge or light indicates overheat.
Check before starting work.
Machine does not move at a certain shift lever position (or dragging is felt).
1. Check the torque converter oil level.
2. Check the engine coolant for overheat.
Speed is fixed to a certain position, and automatic speed change is not possible.
Hydraulic Group
Boom and bucket do not move while the engine runs at idle rev. but they move while the
Check before starting work.
Boom and bucket move with no load, though they do not move when loaded.
1. Check the oil level.
Bucket moves if the overload relief valves are exchanged with each other. ∗
2. Check that the loading control lock lever is
Cylinder does not operate, though oil is discharged from the return port.
Main relief pressure is too low when the boom or bucket is operating.
fully released.
3. Check that the pilot valve inline filter is not
clogged.
4. Check the error code No. shown on the
Symptoms / check point
Either or both of the boom or/and bucket do(es) not move.
MODM.
Front wheels drift down when the front wheels are lifted off the ground by means of the
In the case that the overload relief valve is switched or replaced, excessive drift stops.
The maximum drift rate is measured according
When the piping for cylinder rod side is removed, pressurized oil spouts out. ∗
to instructions on "Measuring Cylinder Drift".
boom cylinder.
Boom and bucket are strong enough if the engine runs at the full speed while dumping
In case that the overload relief valves are switched ∗, the boom and bucket are strong
During digging operation, the bucket tilts back even though the lever is at the neutral
(Holding bucket against the
Bucket cannot support the lifted front wheels, or the lifted front wheels soon drop.
Boom cannot support the lifted front wheels, or the lifted front wheels soon drop.
ground is not possible-front
wheels off the ground.)
or lowering.
position.
LED lamp of the proximity switch does not light (starter switch ON & metal plate in front
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
Remove the connector of the proximity switch, and connect the wire harness (BrW),
Boom lift kickout and lower kick-
out does not work.
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
Check the relays and lines for lift kickout and lower kickout.
Symptoms / check point
If the overload relief valves are exchanged ∗, steering problem switches sides.
Check before starting work.
1. Check the oil level in the hydraulic tank.
2. Check that the stop bolts for the stop valves
Steering is not possible (or hard) in both the right and left directions.
While the machine is travelling straight, the machine sways even if the steering wheel is
during steering
12. Others
When the boom lever is switched from "DOWN" to "NEUTRAL", the boom will continue
When the bucket lever is set to "Roll-back" position, the bucket will be dumped slightly
When the boom lever is set to "UP" position, the boom will drop slightly first and then
Check before starting work.
1. Check the error code No. shown on the
MODM.
Brake Group
Measure the wear of the brake disk using calipers. The obtained wear value is less than
When the pedal is pressed, the brake oil pressure greatly differs between the front axle
(In the worst case, the brake does
not work at all.)
Buzzer sounds each time when the brake pedal is stepped on.
Check before starting work.
1. Check the accumulator Nitrogen gas pres-
Symptoms / check point
Turning on/off the parking brake switch causes a solenoid valve emitting noise.
Turning on/off the parking brake switch activates the link under the cylinder.
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.
Electrical Group
Energized T/M solenoid valve does not correspond with the shift lever position.
Check before starting work.
Two or more monitor lamps will not light after setting the starter key to ON.
One of the monitor lamps will not light after setting the starter key to ON.
1. Check the fuses.
2. Check if bulb(es) of monitor is / are burnt
out.
3. Check the error code No. shown on the
Parking brake remains unreleased regardless of the parking brake switch position.
Check before starting work.
1. Check the error code No. shown on the
MODM.
Please note that not all are used in the 92ZV-2 machine
application. Refer to Cummins Engine troubleshooting
fault codes list for more information.
QSK19 (115ZV-2)
QST30 (135ZV-2)
QSC8.3 (80ZV-2)
QSC8.3 (85ZV-2)
QSB4.5 (60ZV-2)
QSB6.7 (70ZV-2)
(70TMV-2)
QSM11 (90ZV-2)
QSM11 (92ZV-2)
QSX15 (95ZV-2)
FAULT
CODE/ DESCRIPTION
LAMP
EG111
Engine Control Module (ECM) - critical internal failure.
Red
EG113
Engine Timing Actuator Circuit - shorted high.
Yellow
EG114
Engine Timing Actuator Circuit - shorted low.
Yellow
EG115 Engine Speed / Camshaft Position Sensor Circuit - lost both of two signals from
Red the magnetic pickup sensor.
EG121 Engine Speed / Position Sensor Circuit - lost one of two signals from the
Yellow magnetic pickup sensor.
EG122
Intake Manifold Pressure Sensor #1 Circuit - shorted high.
Yellow
EG123
Intake Manifold Pressure Sensor #1 Circuit - shorted low.
Yellow
EG124
Intake Manifold Pressure - above normal operation.
Yellow
EG131
Accelerator Pedal Position Sensor Circuit - shorted high.
Red
EG132
Accelerator Pedal Position Sensor Circuit - shorted low.
Red
EG133
Remote Accelerator Pedal Position Sensor Circuit - shorted high.
Red
EG134
Remote Accelerator Pedal Position Sensor Circuit - shorted low.
Red
EG135
Engine Oil Pressure Sensor Circuit - shorted high.
Yellow
EG141
Engine Oil Pressure Sensor Circuit - shorted low.
Yellow
EG143
Engine Oil Pressure Low - warning.
Yellow
EG144 Engine Coolant Temperature Sensor Circuit - voltage above normal or shorted
Yellow high.
EG145 Engine Coolant Temperature Sensor Circuit - voltage below normal or shorted
Yellow low.
EG146
Engine Coolant Temperature High - warning.
Yellow
EG151
Engine Coolant Temperature High - critical.
Red
EG153 Intake Manifold Air Temperature Sensor Circuit - voltage above normal or
Yellow shorted high.
EG154 Intake Manifold Air Temperature Sensor Circuit - voltage below normal or
Yellow shorted low.
01-39
92ZV-2 Troubleshooting
Electrical Group
QST30 (135ZV-2)
QSK19 (115ZV-2)
QSC8.3 (80ZV-2)
QSC8.3 (85ZV-2)
QSB4.5 (60ZV-2)
QSB6.7 (70ZV-2)
(70TMV-2)
QSM11 (90ZV-2)
QSM11 (92ZV-2)
QSX15 (95ZV-2)
FAULT
CODE/ DESCRIPTION
LAMP
EG155
Intake Manifold Air Temperature Sensor High - critical.
Red
EG166
Rack Position Sensor #1 Circuit - shorted high.
Yellow
EG172
Rack Actuator Position #1 Circuit - grounded circuit.
Red
EG173
Rack Actuator - mechanically stuck open.
Yellow
EG184
Engine Control Module Identification Input State Error.
Yellow
EG185
Engine Control Module Network Communication Error.
Yellow
EG187
Sensor Supply Voltage #2 Circuit - shorted low.
Yellow
EG212
Engine Oil Temperature Sensor Circuit - shorted high.
Yellow
EG213
Engine Oil Temperature Sensor Circuit - shorted low.
Yellow
EG214
Engine Oil Temperature High - Critical.
Red
EG221
Ambient Air Pressure Sensor Circuit - shorted high.
Yellow
EG222
Ambient Air Pressure Sensor Circuit - shorted low.
Yellow
EG227
Sensor Supply Voltage #2 Circuit - shorted high.
Yellow
EG231
Engine Coolant Pressure Sensor Circuit - shorted high.
Yellow
EG232
Engine Coolant Pressure Sensor Circuit - shorted low.
Yellow
EG233
Engine Coolant Pressure Low - warning.
Yellow
EG234
Engine Speed High - critical.
Red
EG238
Sensor Supply Voltage #3 Circuit - shorted low.
Yellow
EG254
Fuel Shutoff Valve Circuit - shorted low.
Red
EG255
Fuel Shutoff Valve Circuit - shorted high.
Yellow
EG259
Fuel Shutoff Valve - stuck open.
Red
EG261
Fuel Temperature High - warning.
Yellow
EG263
Fuel Temperature Sensor Circuit - shorted high.
Yellow
EG265
Fuel Temperature Sensor Circuit - shorted low.
Yellow
EG266 Engine Fuel Temperature - data valid but above normal operational range - most
Red severe level.
EG271
Fuel Control Actuator Circuit - shorted low.
Yellow
EG272
Fuel Control Actuator Circuit - shorted high.
Yellow
01-40
92ZV-2 Troubleshooting
Electrical Group
QST30 (135ZV-2)
QSK19 (115ZV-2)
QSC8.3 (80ZV-2)
QSC8.3 (85ZV-2)
QSB4.5 (60ZV-2)
QSB6.7 (70ZV-2)
(70TMV-2)
QSM11 (90ZV-2)
QSM11 (92ZV-2)
QSX15 (95ZV-2)
FAULT
CODE/ DESCRIPTION
LAMP
EG281
Injection Pump Mechanical System - signal not in range from ECM.
Yellow
EG284 Engine Speed / Position Sensor #1 (Crankshaft) Supply Voltage Circuit - shorted
Yellow low.
EG285
SAE J1939 Data Link Multiplexing PGN Timeout Error.
Yellow
EG286
SAE J1939 Data Link Multiplexing Configuration Error.
Yellow
EG287
SAE J1939 Multiplexing Accelerator Pedal Sensor System Error.
Red
EG295
Ambient Air Pressure Sensor Circuit - data incorrect.
Yellow
EG299
Engine stopped not using Starter Switch.
Yellow
EG311
Injector Solenoid Valve Cylinder #1 Circuit - grounded circuit.
Yellow
EG312
Injector Solenoid Valve Cylinder #5 Circuit - grounded circuit.
Yellow
EG313
Injector Solenoid Valve Cylinder #3 Circuit - grounded circuit.
Yellow
EG314
Injector Solenoid Valve Cylinder #6 Circuit - grounded circuit.
Yellow
EG315
Injector Solenoid Valve Cylinder #2 Circuit - grounded circuit.
Yellow
EG319
Real Time Clock - power Interrupt.
Yellow
EG321
Injector Solenoid Valve Cylinder #4 Circuit - grounded circuit.
Yellow
EG322
Injector Solenoid Valve Cylinder #1 Circuit - open circuit.
Yellow
EG323
Injector Solenoid Valve Cylinder #5 Circuit - open circuit.
Yellow
EG324
Injector Solenoid Valve Cylinder #3 Circuit - open circuit.
Yellow
EG325
Injector Solenoid Valve Cylinder #6 Circuit - open circuit.
Yellow
EG331
Injector Solenoid Valve Cylinder #2 Circuit - open circuit.
Yellow
EG332
Injector Solenoid Valve Cylinder #4 Circuit - open circuit.
Yellow
EG334
Coolant Temperature Sensor Circuit - data erratic, intermittent, or incorrect.
Yellow
EG341
Engine Control Module - data lost.
Yellow
EG342
Engine Control Module - out of calibration.
Red
EG343
Engine Control Module - warning internal hardware failure.
Yellow
EG346
Engine Control Module - warning software error.
Yellow
EG351
Injector Power Supply.
Yellow
EG352
Sensor Supply Voltage #1 Circuit - shorted low.
Yellow
01-41
92ZV-2 Troubleshooting
Electrical Group
QST30 (135ZV-2)
QSK19 (115ZV-2)
QSC8.3 (80ZV-2)
QSC8.3 (85ZV-2)
QSB4.5 (60ZV-2)
QSB6.7 (70ZV-2)
(70TMV-2)
QSM11 (90ZV-2)
QSM11 (92ZV-2)
QSX15 (95ZV-2)
FAULT
CODE/ DESCRIPTION
LAMP
EG378
Fueling Actuator #1 Circuit - open circuit.
Yellow
EG379
Fueling Actuator #1 Circuit - grounded circuit.
Yellow
EG386
Sensor Supply Voltage #1 Circuit - shorted high.
Yellow
EG387
Accelerator Pedal Position Sensor Supply Voltage Circuit - shorted high.
Yellow
EG394
Timing Actuator #1 Circuit - open circuit.
Yellow
EG395
Timing Actuator #1 Circuit - grounded circuit.
Yellow
EG396
Fueling Actuator #2 Circuit - open circuit.
Yellow
EG397
Fueling Actuator #2 Circuit - grounded circuit.
Yellow
EG398
Timing Actuator #2 Circuit - open circuit.
Yellow
EG399
Timing Actuator #2 Circuit - grounded circuit.
Yellow
EG415
Engine Oil Pressure Low - critical.
Red
EG418
Water in Fuel Indicator High - maintenance.
Yellow
EG419
Intake Manifold Boost Pressure Imbalance.
Yellow
EG423
Fuel Timing Pressure or Timing Actuator Stuck.
Yellow
EG428
Water in Fuel Sensor Circuit - shorted high.
Yellow
EG429
Water in Fuel Sensor Circuit - shorted low.
Yellow
EG431
Accelerator Pedal Idle Validation Circuit - data incorrect.
Yellow
EG432
Accelerator Pedal Idle Validation Circuit - out of calibration.
Red
EG433
Intake Manifold Pressure Sensor Circuit - data incorrect.
Yellow
EG434
Voltage to ECM less than 6 V
Yellow
EG435
Engine Oil Pressure Switch Circuit - data incorrect.
Yellow
EG441
Battery #1 Voltage Low - warning.
Yellow
EG442
Battery #1 Voltage High - warning.
Yellow
EG443
Accelerator Pedal Position Sensor Supply Voltage Circuit - shorted low.
Yellow
EG449
Fuel Pump Delivery Pressure High - warning.
Yellow
EG451
Injector Metering Rail #1 Pressure Sensor Circuit - shorted high.
Yellow
EG452
Injector Metering Rail #1 Pressure Sensor Circuit - shorted low.
Yellow
01-42
92ZV-2 Troubleshooting
Electrical Group
QST30 (135ZV-2)
QSK19 (115ZV-2)
QSC8.3 (80ZV-2)
QSC8.3 (85ZV-2)
QSB4.5 (60ZV-2)
QSB6.7 (70ZV-2)
(70TMV-2)
QSM11 (90ZV-2)
QSM11 (92ZV-2)
QSX15 (95ZV-2)
FAULT
CODE/ DESCRIPTION
LAMP
EG465
Turbocharger #1 Wastegate Control Circuit - shorted high.
Yellow
EG466
Turbocharger #1 Wastegate Control Circuit - shorted low.
Yellow
EG482
Fuel Pressure Low - warning.
Yellow
EG483
Injector Metering Rail #2 Pressure Sensor Circuit - shorted high.
Yellow
EG484
Injector Metering Rail #2 Pressure Sensor Circuit - shorted low.
Yellow
EG485
Injector Metering Rail #2 Pressure High - warning.
Yellow
EG486
Injector Metering Rail #2 Pressure Low - warning.
Yellow
EG488
Intake Manifold Temperature High - warning.
Yellow
EG491
Turbocharger #2 Wastegate Control Circuit - shorted high.
Yellow
EG492
Turbocharger #2 Wastegate Control Circuit - shorted low.
Yellow
EG496
Engine Speed / Position Sensor #2 (Camshaft) Supply Voltage.
Yellow
EG524
OEM Alternate Droop Switch Validation - data incorrect.
Yellow
EG527
Auxiliary Input / Output #2 Circuit - shorted high.
Yellow
EG528
OEM Alternate torque validation switch - data incorrect.
Yellow
EG529
Auxiliary Input / Output #3 Circuit - shorted high.
Yellow
EG546
Fuel Delivery Pressure Sensor Circuit - shorted high.
Yellow
EG547
Fuel Delivery Pressure Sensor Circuit - shorted low.
Yellow
EG551
Accelerate Pedal Idle Validation Circuit - shorted low.
Yellow
EG553
Injector Metering Rail #1 Pressure High - warning level.
Yellow
EG554
Fuel Pressure Sensor Error.
Yellow
EG559 Injector Metering Rail #1 Pressure Low - data valid but below normal operational
Yellow range - moderately severe level.
EG596
Electrical Charging System Voltage High - warning level.
Yellow
EG598
Electrical Charging System Voltage Low - critical level.
Red
EG689
Crankshaft Engine Speed Signal Error.
Yellow
EG731
Mechanical Timing Misalignment.
Yellow
EG753 Crankshaft Position Sensor and Camshaft Position Sensor - data erratic,
Yellow intermittent, or in correct.
EG757
Electronic Control Module Data Lost.
Yellow
01-43
92ZV-2 Troubleshooting
Electrical Group
QST30 (135ZV-2)
QSK19 (115ZV-2)
QSC8.3 (80ZV-2)
QSC8.3 (85ZV-2)
QSB4.5 (60ZV-2)
QSB6.7 (70ZV-2)
(70TMV-2)
QSM11 (90ZV-2)
QSM11 (92ZV-2)
QSX15 (95ZV-2)
FAULT
CODE/ DESCRIPTION
LAMP
EG758
Injector Metering Rail #2 Pressure Malfunction.
Yellow
EG778
Engine Speed Sensor (Camshaft) - data erratic, intermittent, or incorrect.
Yellow
EG951
Cylinder Power Imbalance Detected.
None
EG1117
Power Lost with Ignition ON - data erratic, intermittent, or incorrect.
None
EG1358 Accelerator Pedal Position Sensor 1 Circuit - voltage above normal or shorted
Yellow high.
EG1359 Accelerator Pedal Position Sensor 1 Circuit - voltage below normal or shorted
Yellow low.
EG1361 Remote Accelerator Pedal Position Sensor 1 Circuit - voltage below normal or
Yellow shorted low.
EG1376 Engine Camshaft Speed / Position Sensor - data erratic, intermittent, or
Orange incorrect.
EG1595 Remote Accelerator Pedal Position Sensor 1 Circuit - voltage above normal or
Yellow shorted high.
EG1597 Engine Control Module Critical Internal Failure - bad intelligent device or
Orange component.
EG1845 Water in Fuel Indicator Sensor Circuit - voltage above normal or shorted to high
Orange source.
EG1846 Water in Fuel Indicator Sensor Circuit - voltage below normal or shorted to low
Orange source.
EG1852 Water in Fuel Indicator - data valid but above normal operational range -
Yellow moderately severe level.
EG1911
Injector Metering Rail 1 Pressure - above normal operating range.
Yellow
EG2185
Sensor Supply Voltage #4 Circuit - shorted high.
Yellow
EG2186
Sensor Supply Voltage #4 Circuit - shorted low.
Yellow
EG2215 Fuel Pump Delivery Pressure - data valid but below normal operational range -
Yellow moderately severe level.
EG2249
Fuel Pump Delivery Pressure Sensor Circuit - shorted low.
Yellow
EG2261 Fuel Pump Delivery Pressure - data valid but above normal operational range -
Orange least severe level.
EG2262 Fuel Pump Delivery Pressure - data valid but below normal operational range -
Orange least severe level.
EG2265
Fuel Priming Pump Control Signal Circuit - shorted high.
Yellow
EG2266
Fuel Priming Pump Control Signal Circuit - shorted low.
Yellow
EG2311
Fueling Actuator #1 Circuit Error - condition exists.
Yellow
EG2321
Engine Speed Sensor #1 - data erratic, intermittent, or incorrect.
None
EG2322
Engine Speed Sensor #2 - data erratic, intermittent, or incorrect.
None
EG2697 Accelerator Pedal Position Sensor Circuit and Idling Position Detection Switch
Orange Circuit - data erratic, intermittent, or incorrect.
EG2963
Engine Coolant Temperature High - warning.
None
01-44
92ZV-2 Troubleshooting
Electrical Group
QST30 (135ZV-2)
QSK19 (115ZV-2)
QSC8.3 (80ZV-2)
QSC8.3 (85ZV-2)
QSB4.5 (60ZV-2)
QSB6.7 (70ZV-2)
(70TMV-2)
QSM11 (90ZV-2)
QSM11 (92ZV-2)
QSX15 (95ZV-2)
FAULT
CODE/ DESCRIPTION
LAMP
EG2964
Intake Manifold Temperature High - warning.
None
EG2973
Intake Manifold Pressure Sensor Circuit - data erratic, intermittent, or incorrect.
Yellow
(09D20E)
01-45
92ZV-2 Troubleshooting
Operator Station Group
Repair/check
End
80V2E01012
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.
Sight glass
Receiver joint
Receiver drier
95ZVE01003
Cooling failure
Normal air High pressure both at high-pressure side and low-pressure side See C-5 .
flow rate Low pressure both at high-pressure side and low-pressure side Insufficient refrigerant.
80V2E01013
Operator Station Group
92ZV-2 Troubleshooting
01-47
01-48
Magnet clutch circuit failure Check the clutch circuit. Replace the clutch relay with a new one.
Voltage applied to Thermister(frosting sensor) wiring failure Check the short-circuit. Correction
magnet clutch
Thermister(frosting sensor) characteristic failure Check for characteristic. Replace the thermister(frosting sensor) with a new one.
Operator Station Group
92ZV-2 Troubleshooting
Adjustment failure of gap between the thermister(frosting sensor) and evaporator Adjust the gap(12 ± 5 mm).
A-1
12 ± 5 mm
80V2E01014
Unusually low outside air temperature
Limited refrigerant Limited amount of refrigerant filled Fill the refrigerant to proper level.
Gas leakage Perform the leak test and repair the location of
failure before filling the refrigerant.
C-3
Compressor failure Swash plate shoe seizure
Locked piston Replace the compressor with a new one.
Suction/discharge valve failure
Expansion valve failure Clogged valve(mixing of foreign matter) Replace the valve with a new one.
Relieved gas from pressure needle valve Replace the valve with a new one.
Clogging(mixing of moisture content) due to frozen valve Execute the evacuation fully after replacing the
valve and receiver with a new one respectively.
Gas leakage Perform the leak test and repair the location of
failure before filling the refrigerant.
Expansion valve failure Clogged valve(mixing of foreign matter) Replace the valve with a new one.
Relieved gas from pressure needle valve Replace the valve with a new one.
Temporary clogging(mixing of moisture content) Execute the evacuation fully after replacing the
due to frozen valve valve and receiver with a new one respectively.
Insufficiently cooled condenser Clogging of dust or mud, etc. in fin. Clean(washing with water) the fin.
C-5
Over-filled refrigerant Discharge the refrigerant to proper level.
80V2E01015
Operator Station Group
92ZV-2 Troubleshooting
01-49
01-50
Air conditioner switch failure Replace the control panel with a new one.
Blower switch failure Replace the control panel with a new one.
Compressor clutch relay failure Replacement
D-2
Thermo-sensor failure Replacement
High/low-pressure switch failure Replacement
High-pressure error Excessively high pressure [2452 kPa(25kgf/cm2)or over] C-1
2
Excessively low pressure [981 kPa(10kgf/cm )or lower] C-4
80V2E01016
Insufficient Same as "Cooling failure"
wind force
Heating failure
Low water temperature
Normal wind
force
Note: Do not fail to check that the pump pressure is normal, and that the heater hose is not connected with
IN side and OUT side reversed.
The temperature
controller LED is Disengaged temperature controller link Re-set the link.
operated properly. Foreign matter caught Remove the foreign matter.
The temperature
Wiring failure, disconnection, disconnected connector Check the wiring.
controller LED is not
operated properly. Servo motor failure Replacement
Leakage of water in
Clogged drain hole Cleaning
operator's cabin
80V2E01017
Operator Station Group
92ZV-2 Troubleshooting
01-51
01-52
Blow-off changeover Wiring failure, disconnection, disconnected connector Check the wiring.
failure
With diagnostic display: E43
Servo motor failure Replacement
(blow-off servo motor abnormal)
Outside air/inside air Wiring failure, disconnection, disconnected connector Re-check the wiring
changeover failure
With diagnostic display: E45
Servo motor failure Replacement
(inside air/outside air servo motor abnormal)
80V2E01018
03-1
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 CAUTION
Unexpected movement of the machine may cause an Touching the fan or the V belt of the engine or the hot
accident resulting in injury or death. area while the engine is running may cause severe
Therefore, to provide repair service with the engine accidents.
running, be sure to observe the following items: Make sure to stop the engine before opening the
- Park the machine on level ground. engine room access panel.
- Apply the parking brake.
- Block the tires with chocks to prevent the tires from
moving.
- Determine the signals between the service man.
- Prohibit any person from walking into dangerous
areas.
- Near articulation areas of the machine
- Under the machine
- Around the engine
- In front of or behind the machine
WARNING
Operation under the boom or the bucket may lead to
severe accidents.
Make sure to apply the safety lock of the boom and
the bucket control lever provided in the cab, remove
the starter key, and attach a "DO NOT OPERATE!"
tag to the cab.
CAUTION
Be careful not to be burnt by bursting high pressure
oil.
Release the pressure remaining inside the circuit and
open the cap of the hydraulic tank before removing
the plug from the pressure measurement port so that
the internal pressure of the hydraulic tank is released
and burst of the high pressure oil can be prevented.
WARNING
Entering the articulation area of the machine body
while the engine is running may cause severe acci-
dents.
Make sure to stop the engine, pull out the starter key,
and attach a "DO NOT OPERATE!" tag to the cab
before entering the articulation area.
03-3
92ZV-2 Measurement for Performance Check
Standard Measurement Values for Performance Check
Standard measurement
Item
values for performance check
Remarks
Fuel efficient
System Measurement item Normal
mode
Minimum no-load speed, Low Idle (LI) 800±50 725 in hibernate mode
Maximum no-load speed, High Idle (HI) 2,200±50 2,000±50
Maximum speed in torque converter stall mode 2,000±100
Engine
Engine speed
(min-1) (rpm) Maximum speed in multiple control valve relief mode 1,970±100
Engine speed
MPa (kgf/cm2) (psi) Maximum (HI) 1.9±0.15 (19±1.5) (270±21)
20.6±0.5 (210±5)
Loading line main relief pressure (HI)
(2,986±71)
Hydraulic line
11.8±0.5 (120±5)
Off (Cut-out)
Unloader valve (1,706±71)
Brake
setting pressure
Brake line setting (LI) 6.9±1.0 (70±10)
pressure On (Cut-in)
(995±142)
MPa (kgf/cm2) (psi)
Note
These are the standard measurement values for the
machines at the time when delivered from the factory.
03-6
92ZV-2 Measurement for Performance Check
Preparation for Performance Check
110ºC(230ºF)
97ºC(206ºF) 100ºC(212ºF)
100ºC(212ºF) 120ºC(248ºF)
35ºC(95ºF) 103ºC(217ºF)
50ºC(122ºF)
125ºC(257ºF)
Indication
Resistance
120~125 75~80
between S and E (Ω)
Resistance
120~125 85~90
between S and V (Ω)
Resistance
170~190 130~150
between E and V (Ω)
Engine
Measurement conditions
Temperature of torque converter oil :
WARNING 50~80ºC (120~180ºF)
Unexpected movement of the machine may cause an Temperature of hydraulic oil :
accident resulting in injury or death. 50~80ºC (120~180ºF)
Therefore, to provide repair service with the engine Temperature of engine coolant :
running, be sure to observe the following items: 50~80ºC (120~180ºF)
- Park the machine on level ground.
- Apply the parking brake. 1. Press the brake pedal.
- Block the tires with chocks to prevent the tires from Set and confirm the transmission shift lever is neu-
moving. tral position.
- Determine the signals between the service men.
- Prohibit any person from walking into dangerous 2. Set and confirm the parking brake to the "ON" posi-
areas. tion.
- Near articulation area of the machine
- Under the machine 3. Lower the bucket onto the ground.
- Around the engine
- In front of or behind the machine 4. Set the boom and bucket control lever to "Neutral
position".
2. Set and confirm the parking brake to the "ON" posi- 5. Place the bucket control lever in roll back position.
tion. Measure the engine speed.
6. Press the brake pedal all the way to the floor, and
then set the transmission shift lever to the forward
3rd speed position.
Maximum speed in torque converter stall plus multi- 1. Press the brake pedal.
ple control valve relief mode. Set and confirm the transmission shift lever is neu-
tral position.
WARNING 2. Set and confirm the parking brake to the "ON" posi-
Unexpected movement of the machine for abnormal tion.
brake performance may cause an accident resulting
in injury or death. 3. Lower the boom to the lowest limit. Roll back the
Before measuring, make sure that the machine has bucket fully until the bucket contacts to the stopper.
sufficient brake performance.
4. Set the parking brake to the "OFF" position.
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
Defective fuel pump Repair The engine speed is too low in multiple control valve relief mode.
Possible cause Solution The engine speed is too high in torque converter stall plus multiple
Slipping transmission clutch or defect Disassembly control valve relief mode.
inside of transmission & repair
Disassembly Possible cause Solution
Defect inside torque converter
& repair
Slipping transmission clutch or defect inside of Disassembly
transmission or T/C & repair
Relief pressure too low Adjustment
Disassembly
The engine speed is too low in torque converter stall mode. Defective pump / pump seals
& repair
Caused by reduction in engine power The engine speed is too low in torque converter stall plus multiple
control valve relief mode.
Possible cause Solution
Possible cause Solution
Clogged air cleaner element Cleaning
Inspection
Fuel Engine low power
Improper type of fuel & repair
replacement
Extremely high relief pressure of multiple control
Clean or Adjustment
Clogged fuel filter or suction strainer valve or steering valve
replace
Use antifreeze Malfunctioning torque converter Repair
Frozen fuel / wax build up
mixture
Inspection
Malfunctioning accelerator pedal or harness
& repair
Defective fuel pump Repair
92V2U33001
Hydraulic Cylinder
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
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
Measurement procedure increases the drift rate. Cold thick oil reduces the drift
rate.
1. Unload the bucket.
- Tachometer (MODM) 10. Set and confirm the transmission shift lever is neu-
tral.
Measurement procedure
5. Lower the boom to the lower limit, and roll back the
bucket.
Boom cylinder
To steering line
Multiple control
valve
Steering
valve
ELS valve
Hydraulic tank
95ZV03004
03-16
92ZV-2 Measurement for Performance Check
Full Steering Cycle Time
- Stop watch 4. Set and confirm the parking brake switch to the
"ON" position.
- Tachometer (MODM)
5. Lower the boom, and roll back the bucket.
(Bucket and boom are not on to ground for steer-
ing)
Warm-up the engine before measuring full
6. Set the parking brake switch to the "OFF" position
steering time. and release the brake pedal.
12. Measure and record the time required for full steer-
ing.
IMPORTANT
After measuring, return the stopper bolts.
(Refer to "Stop valve" in Check & Adjustment.)
97ZV03007
Full steering
MR
Pb Pa
Steering valve T
95ZV03005
03-18
92ZV-2 Measurement for Performance Check
Loading/Steering Circuit Relief Valve
CAUTION
Do not touch the fan or V-belt of the engine or a high-
temperature section if the engine is running. An acci-
dent resulting in injury may occur.
Be sure to stop the engine before you open the
access panel of the engine room. Keep all guards in
place.
Avoid high temperature components even when the
engine is stopped.
03-19
92ZV-2 Measurement for Performance Check
Loading/Steering Circuit Relief Valve
Standard measurement value MPa Measuring loading circuit main relief pres-
(kgf/cm2) (psi) sure
Cap
Lock nut
(2)
Note Adjusting
(1) North America equipped screw
M/c's have a quick connector
in port (3) for testing.
K97V2J43003 95ZV43004
Make-up valve
Overload relief
valve
Valve assembly
(4)
(PPI) (Z)
(Z2) (Z1)
(PA)
(PARKING) ACF (ACCF) (ACCR)
(TA)
(T) (P)
Reducing valve
(for pilot)
85V2E43006
03-21
92ZV-2 Measurement for Performance Check
Loading/Steering Circuit Relief Valve
2. Move the bucket control lever to the roll back posi- Overload relief valve
tion.
WARNING
Lock nut
Trapped pressure in brake circuit could cause serious
injury when the plug is removed.
Fully release all residual accumulator pressure
before servicing.
Note 90ZVE43004
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" posi-
tion, the engine coolant temperature is higher than
60ºC, and the engine speed is held at 950 min-1 or less
for 10 seconds.
IMPORTANT
After the completion of the adjustment of the pilot line
pressure, be sure to tighten the lock nut.
03-23
92ZV-2 Measurement for Performance Check
Loading/Steering Circuit Relief Valve
CAUTION
Do not touch the fan or V-belt of the engine or a high-
temperature section if the engine is running. An acci-
dent resulting in injury may occur.
Be sure to stop the engine before you open the
access panel of the engine room. Keep all guards in
place.
Avoid high temperature components even when the
engine is stopped.
03-24
92ZV-2 Measurement for Performance Check
Loading/Steering Circuit Relief Valve
Standard measurement value MPa Measuring steering circuit main relief pres-
(kgf/cm2) (psi) sure
Steer the machine in a straight position. 6. In case the pressure gauge is installed to (1), steer
Keep the bottom surface of the bucket horizontal, the machine to the left until the front and rear chas-
and stop the engine when the bucket is approxi- sis contact each other.
mately 30 cm (1 ft.) above the ground. 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.
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
Adjusting screw
Steering cylinder Lock nut
(2)
(A)
Note
(3)
North America equipped (1)
M/c's have quick
connectors at ports
(1) and (2).
70ZV43007 (B) 115ZV43006a
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
90V2U42003
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 artic-
ulation stopper or screw the stopper (bolt) in until the
front and rear chassis contact each other.
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" posi-
tion, the engine coolant temperature is higher than
60ºC, and the engine speed is held at 950 min-1 or less
for 10 seconds.
Adjusting screw
Lock nut
95ZV43008
(T)
Loosen the lock nut and adjust the pressure by the
adjusting screw.
(A)
Turn clockwise the adjusting screw to raise the set pres-
sure, or turn counterclockwise the adjusting screw to (3)
lower the set pressure.
(TS)
WARNING
(B)
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 115ZV43007
store the articulation stopper.
1. Attach the pressure gauge to the port (3).
IMPORTANT
Gauge port plug width across flat
At the completion of check and adjustment of over- 5 mm
load relief valve pressure, be sure to reset the main
relief valve to the original condition. 2. Move the bucket control lever to the roll back posi-
tion.
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" posi-
tion, the engine coolant temperature is higher than
60ºC, and the engine speed is held at 950 min-1 or less
for 10 seconds.
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
WARNING IMPORTANT
Separate the test course by using rope etc. and keep The following method is easy and simple, however it
persons away from the test course. In addition, post is not an accurate way, because the braking force
persons in several positions near the course to warn and rim-pull may vary on each machine. Confirm
others and avoid an accident while checking the ser- engine & transmission performance via using a stall
vice brake performance. test. See page 03-3.
Reconfirm the brake performance by the method 1 as
soon as possible.
Condition
WARNING
1. Test course
Level, straight, dry and the paved ground. Unexpected movement of the machine may cause an
accident resulting in injury or death.
2. Run the machine and depress the brake pedal at Before starting brake performance check, be sure to
35 km/h (22 mph). observe the following items:
Measure and record the braking distance. - 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
Standard measurement value walking near the machine.
Braking distance 1. Lower the boom to the lowest limit, and roll back
20 m (22 1/4 yd) or shorter the bucket fully until the bucket contacts to the stop-
per.
Possible causes of extremely long braking distance
2. Set the parking brake switch to the "OFF" position.
Possible cause Solution
3. Set the declutch switch to OFF, and then depress
Low brake line pressure Check and repair
the brake pedal all the way to the floor.
Friction plate wear Check and repair
4. Set the shift lever to 2nd reverse speed.
Brake valve malfunction Check and repair
Parking Brake
WARNING IMPORTANT
Unexpected movement of the machine may cause an The following method is easy and simple, however it
accident resulting in injury or death. is not an accurate way, because the braking force
Before starting brake performance check, be sure to and rim-pull may vary on each machine.
observe the following items: Confirm engine & transmission performance via stall
- Check that there is enough clearance for brake test. See page 03-3. Reconfirm the brake perfor-
performance check around the machine. mance by the method 1 as soon as possible.
- During performance check, prohibit any person to
walking near the machine.
WARNING
Unexpected movement of the machine may cause an
Condition accident resulting in injury or death.
Before starting brake performance check, be sure to
1. Test course observe the following items:
1/5 slope (Approx. 11º 19') - Place the machine on level ground.
- Check that there is enough clearance for brake
2. Bucket empty performance check around the machine.
- During performance check, prohibit any person to
3. Parking switch ON walking near the machine.
(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
If the pressure gauge is not available as described 2. Stop the engine. Repeatedly depress and release
"Method 2", apply the "Method 1". the brake pedal till you feel light brake to discharge
accumulator pressure.
21 22
Fan motor port
Pump port
Unloader valve
K115ZV53002
Note
In a case that the "ON" or "OFF" pressure does not
match the standard setting pressure, set the "ON" (cut-
in) 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
19
Rc (PT) 3/8
Pe
M10 X 1.0)
m
m
45
85V2E53002
Method 1
Method 2
Press down the brake pedal to check that the oil pres-
Measurement instrument
sure rises in proportion to the pedal angle.
Hydraulic pressure gauge Release the brake pedal to check that the oil pressure
10 MPa (105 kgf/cm2) (1,500 psi) drops to zero in proportion to the pedal angle. In addi-
tion, visually check for brake oil leakage.
03-35
92ZV-2 Measurement for Performance Check
Brake Circuit Oil Pressure
MPa
(kgf/cm2)
(psi) 4.01
(41)
(581)
Output oil pressure (brake port)
4
(40)
(580)
2
(20)
(290)
0.57
(6)
(83)
0 3.9 5 10 15 18.5 19
(deg)
Pedal stroke
90V2E53001
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
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: (PPI) (Z)
- Park the machine on level ground.
- Apply the parking brake. (PA) (Z2) (Z1)
- Block the tires with chocks to prevent the tires from
moving. (ACCF) (ACCR)
(PI)
- Determine the signals between the service men. (TA)
- Prohibit any person from walking into dangerous (P)
(T)
areas.
- Near articulation areas of the machine
- Under the machine
- Around the engine
- In front of or behind the machine
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 Valve assembly
open the cap of the hydraulic tank before removing
95V2E03003
the plug and hose from the pressure measurement
port.
Measurement instrument
- Stop watch
Measurement procedure
1. Lower the boom to the lowest limit, and tilt down the
bucket to the ground.
Declutch Engagement
Standard measurement value
WARNING
1/5 slope (approx. 11º19'), unloaded bucket, engine
Brake performance check on a slope is dangerous 15 cm (6 in)
maximum speed at 1st speed position, quickly
or less
work. An accident resulting in injury or death may released inching pedal
occur.
Before starting declutch engagement test observe
the following: Cause of extremely high measurement
- Check that the slope is smooth. value and solution
- Check that the brake works well.
- Prohibit any person from walking into the danger-
Possible cause Solution
ous.
Too much delay in resetting declutch Check and replace
- Determine the signs between the service men. switch declutch switch
- Do not enter the area near the moving machine. Refer to "Time lag mea-
Too much time lag in engaging clutch
surement procedure".
Measurement procedure
MEMO
Check & Adjustment
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
Linkage Pin
WARNING CAUTION
Unexpected movement of the machine may cause an Unexpectedly dropped parts may cause an accident
accident resulting in injury or death. resulting in injury.
Before starting adjustment work, be sure to observe - Before liner insertion, be sure to lift the cylinder
the following items: using a crane to prevent the cylinder from unex-
- Park the machine on level ground. pectedly dropping during liner insertion.
- Apply the parking brake. - Wear protective clothes like work gloves and steel
- Remove the starter key, and hang a "DO NOT toed shoes.
OPERATE!" tag on the steering wheel.
- Block the tires with chocks to prevent the tires from
moving.
Liner
4 5
92V2U13001
Adjustment portion 1 2 3 4 5 6 7
Liner hole diameter 110 71 101 81 111 Adjustment 51
mm (in) (4.33) (2.79) (3.98) (3.19) (4.37) unnecessary (2.01)
13-3
92ZV-2 Check & Adjustment Chassis Group
Linkage Pin
Adjustment
* *
95ZV12005
Boom Bucket
Bushing A Bushing B
Hinge pin
Bolt
Dust seal
How to assemble
2. Align the pin holes in the bucket and the boom then
insert the pin.
1 mm.
Center Pin
4
7
9
Front
10 3
5
6 3
Rear chassis
11 Install bearing cover (3) so that the grease nipple
1
8 2 mounting hole is positioned at the specified angle as
Upper 92V2U12004 shown in the figure.
5
7 8
6
4
2
Rear chassis
Front chassis
Lower
92V2U12005
Front
3
Split of outer
20º bearing
Grease nipple
installation position
90ZVE12013
Engine
Measuring engine oil pressure
WARNING
Measurement instrument
Unexpected movement of the machine may cause an
accident resulting in injury or death.
Therefore, to provide repair service with the engine - Pressure gauge
running, be sure to observe the following items:
- Park the machine on level ground.
- Apply the parking brake.
- Block the tires with chocks to prevent the tires from Install position
moving.
- Determine the signals between the service men. 1. Location (A)
- Prohibit any person from walking into dangerous
areas. 2. Measuring port: NPTF 1/4
- Near articulation area of the machine
- Under the machine 3. Oil pressure gauge: 1.0 MPa (10 kgf/cm2) (142 psi)
- Around the engine
- In front of or behind the machine
- Tachometer
Propeller Shaft
95ZV22007
Top view
Side view
95ZV22008
Tightening torque
2nd propeller shaft Pillow block (Center bearing) 3rd propeller shaft
7
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.
Axle
6 9 8 7
A
PT3/8
Brake oil inlet
4
1
10
5
3
92V2U23002
1. Tighten axle nut (6) with 2,300 N-m (235 kgf-m) Note
(1,696 lb-ft) tightening torque to install taper roller Use jig to install the floating seal to the axle assembly.
bearings (7)(8).
Adjust the clearance between axle nut and axle exten-
2. Loosen the axle nut. sion to A (1.14~2.26 mm) (0.05~0.09 in).
3. Tighten the axle nut again with 2,300 N-m (235 kgf- :
m) (1,696 lb-ft) tightening torque. 1. 89.7 N-m (9.15 kgf-m) (66 lb-ft)
2. 216 N-m (22.0 kgf-m) (159 lb-ft)
4. Turn wheel hub (9) 2~3 turns back and forth, and 3. 33.3 N-m (3.40 kgf-m) (25 lb-ft)
measure the preload applied to section (∗ part). 4. 53.0 N-m (5.40 kgf-m) (39 lb-ft)
5. 86.3 N-m (8.80 kgf-m) (64 lb-ft)
Preload of section (∗ part)
226~265 N (23~27 kgf) (51~59 lbf) ∗∗
#1, 2, 4: Screw lock agent (Loctite® 262)
∗∗This is "breakaway" force. The force required to #10: Liquid gasket
start the wheel turning. (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
9
7 2
3
90V2U23001
Bearing installation
Pinion gear
Snap ring
Bearing (8)
K85ZV23003
Note
A snap ring is set to bearing (8) as shown above. Incor-
rect installation of bearing (8) may cause the snap ring
to drop, resulting in a serious mechanical trouble.
Apply grease
when
assembling.
K85ZV23004
23-8
92ZV-2 Check & Adjustment Power Group
Axle
A Correct
2
Ring gear is too far from the
C Do the reverse adjusting as B.
drive pinion
10
1 5 4
Pattern TOP HEEL
A
Pitch line 4~5 10
TOE
BOTTOM
10
2 4 4
Pattern TOP HEEL
B Pitch line 4~5 10
TOE
BOTTOM
10
3 4 3
Pattern TOP HEEL
C TOE 4~5 10
Pitch line
BOTTOM
Service parts
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
92V2U33001
CAUTION
Do not touch the fan or V-belt of the engine or a high-
temperature section if the engine is running. An acci-
dent resulting in injury may occur.
Be sure to stop the engine before you open the
access panel of the engine room. Keep all guards in
place.
Avoid high temperature components even when the
engine is stopped.
43-3
92ZV-2 Check & Adjustment Hydraulic Group
Loading/Steering Circuit Relief Valve/Ride Control Circuit Reducing Valve (OPT)
Standard measurement value MPa Measuring loading circuit main relief pres-
(kgf/cm2) (psi) sure
Adjusting
screw
Tank port
K90V2J43001 90ZVE43002
(3)
90ZVE43001
Valve assembly
(5)
(PPI) (Z)
(Z2) (Z1)
(4) (PA)
ACF (ACCF) (ACCR)
(PARKING)
(TA)
(T) (P)
Reducing valve
(for pilot)
85V2E43001
43-5
92ZV-2 Check & Adjustment Hydraulic Group
Loading/Steering Circuit Relief Valve/Ride Control Circuit Reducing Valve (OPT)
IMPORTANT
At the completion of check and adjustment of over-
load relief valve pressure, be sure to reset the main
relief valve to the original condition.
43-6
92ZV-2 Check & Adjustment Hydraulic Group
Loading/Steering Circuit Relief Valve/Ride Control Circuit Reducing Valve (OPT)
WARNING
Lock nut
Trapped pressure in brake circuit could cause serious
injury when the plug is removed.
Fully release all residual accumulator pressure
before servicing.
WARNING 90ZVE43004
Injection Hazard
Depress brake pedal 80~100
times to completely discharge
the brake accumulators prior to
removing these plugs.
K65ZV42022
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)
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 high-
temperature section if the engine is running. An acci-
dent resulting in injury may occur.
Be sure to stop the engine before you open the
access panel of the engine room. Keep all guards in
place.
Avoid high temperature components even when the
engine is stopped.
43-8
92ZV-2 Check & Adjustment Hydraulic Group
Loading/Steering Circuit Relief Valve/Ride Control Circuit Reducing Valve (OPT)
23
Hydraulic oil temp : 50±5ºC (120±9ºF)
(18)
Reference
From pump
1
P (11)
Depressure valve section
(12) 85V2E43003
TOKYO JAPAN
KAYABA INDUSTRY CO,LTD
(18) 1. Loosen the lock nut (23) and depressure valve (18)
for releasing internal pressure from accumulator
B
T
B circuit.
SP2
Boom cylinder Boom cylinder : Plug SP2: 165 N-m (16.8 kgf-m) (121 lb-ft)
bottom side rod side 85V2E43002
3. Keep the engine speed at low idle and then mea-
sure and record the pressure.
Releasing residual pressure from tank and pipes
1
21
22
Loosen the lock nut (21) and adjust the pressure by the
adjusting screw (22).
IMPORTANT
At the completion of check and adjustment of reduc-
ing 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)
CAUTION
Do not touch the fan or V-belt of the engine or a high-
temperature section if the engine is running. An acci-
dent resulting in injury may occur.
Be sure to stop the engine before you open the
access panel of the engine room. Keep all guards in
place.
Avoid high temperature components even when the
engine is stopped.
43-11
92ZV-2 Check & Adjustment Hydraulic Group
Loading/Steering Circuit Relief Valve/Ride Control Circuit Reducing Valve (OPT)
Standard measurement value MPa Measuring steering circuit main relief pres-
(kgf/cm2) (psi) sure
Steering line main relief pressure 20.6±0.5 1. Attach the pressure gauge to gauge port (1) or (2).
(at maximum speed) (210±5) (2,986±71)
2. In case the pressure gauge is installed to (1), steer
Steering line overload relief pressure 24.5 +1.0
(at idling speed)
0
(250 +100 ) (3,555 +1420 )
the machine to the left until the front and rear chas-
sis contact each other.
Pilot line
3.5 Continue to hold the steering wheel fully turned.
(36) (512)
Note
Hydraulic oil temp : 50±5ºC (120±9ºF) Because the stop valve is installed into the steering line,
oil pressure does not reach the set point when the
Reference steering is fully turned.
Releasing residual pressure from tank and pipes When measuring oil pressure, be sure to apply the artic-
ulation stopper or screw the stopper (bolt) in until the
Keep the bottom surface of the bucket horizontal, front and rear chassis contact each other.
and stop the engine when the bucket is approxi-
mately 30 cm (1 ft.) above the ground. WARNING
Tilt down the bucket until it comes in contact with If the machine begins to move with the articulation
the ground. Place the bucket control lever in the stopper applied, it may cause an accident resulting in
roll back position, and then lower the boom. injury or death.
After the measurement, be sure to disconnect and
Push down on, then open the cap of the hydraulic store the articulation stopper.
tank to release the residual pressure.
3. Increase the engine speed to high idle, and mea-
sure and record the pressure.
Steering cylinder
(2)
Note
North America equipped (1)
M/c's have quick
connectors at ports (1)
and (2). 70ZV43007
Lock nut
Adjusting
screw
(A)
(3)
(B) 115ZV43006
Steering valve
Steering valve
70ZV43009
Overload relief
valve
Port B Port A
Lock nut
To From
steering valve Orbitrol®
Stopper
(bolt) Spool
Adjusting screw
90V2U42003
Loosen the lock nut and adjust the pressure by the
adjusting screw.
1. Attach the pressure gauge to the port ((1) for the
left turn, (2) for the right turn).
Turn clockwise the adjusting screw to raise the set pres-
sure, or turn counterclockwise the adjusting screw to
2. Adjust the main relief valve pressure to 25.5 MPa
lower the set pressure.
(260 kgf/cm2) (3,697 psi) + 1/4 additional turn, so
the pressure is above the overload relief pressure.
WARNING
3. Steer the machine until the front and rear chassis
If the machine begins to move with the articulation
contact each other. Continue to hold the steering
stopper applied, it may cause an accident resulting in
wheel fully turned.
injury or death.
After the measurement, be sure to disconnect and
Note
store the articulation stopper.
Because the stop valve is installed into the steering line,
oil pressure does not reach the set point when the
steering is fully turned. IMPORTANT
When measuring oil pressure, be sure to apply the artic-
ulation stopper or screw the stopper (bolt) in until the At the completion of check and adjustment of over-
front and rear chassis contact each other. load relief valve pressure, be sure to reset the main
relief valve to the original condition.
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.
43-14
92ZV-2 Check & Adjustment Hydraulic Group
Loading/Steering Circuit Relief Valve/Ride Control Circuit Reducing Valve (OPT)
Lock nut
IMPORTANT
After the completion of the adjustment of the pilot line
pressure, be sure to tighten the lock nut.
(T)
(A)
(3)
(TS)
(B)
115ZV43007
Hydraulic Cylinder
Note
Warm-up the hydraulic oil before measuring cylinder
drift.
Reference
Mark
(Vinyl tape)
Scale
70ZV43012
IMPORTANT
At the completion of measurement, if the vinyl tape
used for measurement is not removed from the cylin-
der rod, the tape may be caught by the rod seal. The
tape will cause oil leakage from the rod seal. To pre-
vent oil leakage, be sure to remove the vinyl tape.
43-17
92ZV-2 Check & Adjustment Hydraulic Group
Stop Valve
Stop Valve
Front chassis
Stop valve
Stopper (rear chassis)
(bolt) (L.H, R.H)
38º
36º~
Front chassis
Articulation angle ( º) 38 37 36
WARNING Clearance between machine body and 9.6 14.5 19.3
stopper (mm) (in) (0.38) (0.57) (0.76)
When the machine turns, the clearance in the articu- 31.7 34.0 36.3
Stopper (bolt) length (mm) (in)
lation area closes. As a result, people may be caught, (1.25) (1.34) (1.43)
leading to a severe accident. To prevent such an
accident, observe the following items strictly when *The target value should be the articulation angle "37º".
adjusting the steering stopper.
- Stop the engine before starting adjustment of the - After adjustment, turn the steering wheel slowly at a
stopper bolt. rate of 5 sec or more per turn, and confirm the clear-
- When confirming the operation after setup, keep ance between the machine body and the stopper.
proper distance from the articulation area of the
machine. - When adjustment is completed, tighten the lock nut
of the stopper (bolt).
The stop valve works when the spool is pushed in 3 mm
(0.118 in). : 90 N-m (9.2 kgf-m) (67 lb-ft)
MEMO
53-1
92ZV-2 Check & Adjustment Brake Group
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
If the pressure gauge is not available as described Adjusting unloader valve setting pressure
"Method 2", apply the "Method 1".
21 22
Measurement instrument Fan motor port
Gauge port
Unloader valve
K115ZV53002
Note
In a case that the "ON" or "OFF" pressure does not
Measurement procedure match the standard setting pressure, set the "ON" (cut-
in) pressure to the standard setting pressure.
1. Lower the boom to the lowest limit, and tilt the
bucket down to the ground. Tightening torque
Then set the parking brake switch to the "ON" posi- : ACF port plug: 11.3 N-m (1.15 kgf-m) (8.3 lb-ft)
tion. : Lock nut (22): 16.7 N-m (1.7 kgf-m) (12.3 lb-ft)
19
Rc (PT) 3/8
Pe
M10 X 1.0)
m
m
45
85V2E53002
Method 1
Method 2
Press down the brake pedal to check that the oil pres-
Measurement instrument
sure rises in proportion to the pedal angle.
Hydraulic pressure gauge Release the brake pedal to check that the oil pressure
10 MPa (105 kgf/cm2) (1,500 psi) drops to zero in proportion to the pedal angle. In addi-
tion, visually check for brake oil leakage.
53-5
92ZV-2 Check & Adjustment Brake Group
Brake Circuit Oil Pressure
MPa
(kgf/cm2)
(psi) 4.01
(41)
(581)
Output oil pressure (brake port)
4
(40)
(580)
2
(20)
(290)
0.57
(6)
(83)
0 3.9 5 10 15 18.5 19
(deg)
Pedal stroke
90V2E53001
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
WARNING IMPORTANT
Separate the test course by using rope etc. and keep The following method is easy and simple, however it
persons away from the test course. In addition, post is not an accurate way, because the braking force
persons in several positions near the course to warn and rim-pull may vary on each machine. Confirm
others and avoid an accident while checking the ser- engine & transmission performance via using a stall
vice brake performance. test. See page 03-3.
Reconfirm the brake performance by the method 1 as
soon as possible.
Condition
WARNING
1. Test course Unexpected movement of the machine may cause an
Level, straight, dry and the paved ground. accident resulting in injury or death.
Before starting brake performance check, be sure to
2. Run the machine and depress the brake pedal at observe the following items:
35 km/h (22 mph). - Place the machine on level ground.
Measure and record the braking distance. - Check that there is enough clearance for brake
performance check around the machine.
- During performance check, prohibit any person to
walking near the machine.
Standard measurement value
1. Lower the boom to the lowest limit, and roll back
Braking distance the bucket fully until the bucket contacts to the stop-
20 m (22 1/4 yd) or shorter per.
Possible causes of extremely long braking distance 2. Set the parking brake switch to the "OFF" position.
Possible cause Solution 3. Set the declutch switch to OFF, and then depress
Low brake line pressure Check and repair the brake pedal all the way to the floor.
Friction plate wear Check and repair
Brake valve malfunction Check and repair 4. Set the shift lever to 2nd reverse speed.
Slide caliper
Steel plate
Brake
backing
plate Friction plate
85V2E53004
WARNING
Upper Unexpected movement of machine could cause seri-
Spring pin
Oil inlet port 10 10 ous injury or death. To prevent such an accident,
Internal gear 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
Inner steel Outer steel to this work for engine starting to prevent an acci-
plate teeth plate teeth
dent.
85ZVE53004 - Prohibit any person from walking into the danger-
ous 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
IMPORTANT
Wheel bearings must be adjusted correctly to get an
accurate measurement for dimension A. Dimension
should be equal at top and bottom.
Note
Piston stroke B
1.18~1.83 mm (0.046~0.072 in)
Parking Brake
WARNING IMPORTANT
Unexpected movement of the machine may cause an The following method is easy and simple, however it
accident resulting in injury or death. is not an accurate way, because the braking force
Before starting brake performance check, be sure to and rim-pull may vary on each machine.
observe the following items: Confirm engine & transmission performance via stall
- Check that there is enough clearance for brake test. See page 03-3. Reconfirm the brake perfor-
performance check around the machine. mance by the method 1 as soon as possible.
- During performance check, prohibit any person to
walking near the machine.
WARNING
Unexpected movement of the machine may cause an
accident resulting in injury or death.
Condition Before starting brake performance check, be sure to
observe the following items:
1. Test course - Place the machine on level ground.
1/5 slope (Approx. 11º 19') - Check that there is enough clearance for brake
performance check around the machine.
2. Bucket empty - During performance check, prohibit any person to
walking near the machine.
3. Parking switch ON
1. Set the parking brake switch to the "ON" position.
No movement on 1/5 slope. 3. Place the shift lever to the 3rd reverse position.
Possible cause of machine moving during brake 4. Gradually increase the engine speed. The machine
performance check should not move at the maximum speed.