Professional Documents
Culture Documents
80Z5 (Ex F&S)
80Z5 (Ex F&S)
80Z5
April 2019
SHOP MANUAL
SHOP MANUAL
WHEEL LOADER
Troubleshooting
80Z5
Troubleshooting
Measurement for Performance
Check
Check & Adjustment
93209-00571
©2019 Hitachi Construction Machinery Co., Ltd. All rights reserved. Printed in Japan (K)
( 輸出一般用 )
93209-00571
April 2019
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
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 kg (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
F ........... Front or Forward OPT ........... Option
A/M ........... Auto/Manual Assy ........... Assembly
B ........... Battery 1st ........... 1st speed
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
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 (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
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 (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. Abnormal noise in hydraulic system. .................................................................................................... 01-23
9. Others ................................................................................................................................................... 01-24
01-2
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
much time and expense to solve the problem. As a
result, you will not be trusted by the user.
01-4
80Z5 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.
Even if the breaker of the controller is turned ON, the breaker will be immediately
Check before starting work.
1. Check that the parking brake is released.
2. Check the torque converter oil level.
3. Check the fuse of the controller system.
Defective controller
Clutch oil leaks internally.
Possible cause
cable
cable
Repair
Repair
Controller
Shift lever
Shift lever
replacement
replacement
replacement
replacement
replacement
replacement
replacement
Solution
Solenoid valve
Solenoid valve
Solenoid valve
Solenoid valve
Disassembly &
Disassembly &
Disassembly &
80Z5 Troubleshooting
01-7
When the lever is shifted to the reverse position, the machine does not move reverse
Controller output LED “F” will go out when shifted to reverse (output LED “R” will not
position.
(Example: Machine moves for-
When the lever is shifted to the forward position, the machine moves forward.
ward at the neutral position.)
turn on)
Even if the solenoid valve for trimmer is pressed, the solenoid valve does not work.
ing speed / direction
Main oil pressure rises too quickly at all the shift lever positions.
Clutch oil pressure is too low or rises too slowly at a certain shift lever position only.
changing speed / direction
Time lag just after using the inching brake (check setting condition).
Main oil pressure rises too slowly at all the shift lever positions.
Controller output LED “DC” indicator does not light properly
Symptoms / check point
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.
6. Low power
(Defective torque converter or
transmission)
Machine moves even if the shift lever is set to the neutral position. ∗
1. Check the parking brake and service brake
for dragging.
2. Check the torque converter oil level.
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.
Machine does not move at a certain shift lever position (or dragging is felt).
Check before starting work.
1. Check the torque converter oil level.
After pedal release, too much time is required to turn off the controller LED “I” indicator
starting to climb up on a slope
using inching brake.
Controller LED for machine speed does not change even if machine speed is changed.
9. Automatic speed change is not
possible.
Speed is fixed to 2nd speed, and automatic speed change is not possible.
Actual speed increase or reduction does not correspond to the set speed.
1. Manually change the speed from 1st speed
to 3rd speed. If manual speed change is
impossible, refer to "Machine does not
Controller input LED “S” indicator does not light when the QUAD switch is turned on
Check before starting work.
1. Check that the downshift button (QUAD
Controller input LED “S” indicator light when the QUAD switch is turned on
switch) is being used at the 2nd forward/
reverse speed position.
At the other positions, shifting down is not
possible.
Hydraulic Group
Boom and bucket do not move normally while the engine runs idle but appears to move
1. Boom and/or bucket do not move.
Boom and bucket move with no load, though they do not move when loaded.
Bucket moves if the overload relief valves are exchanged with each other. ∗
1. Check the oil level.
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.
Disassembly &
Internally damaged main pump.
repair
Disassembly &
Internally damaged pilot pump.
repair
Disassembly &
Multiple control valve
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
5. Bucket leveler (kickout) does not
Remove the connector of the proximity switch, and connect the wire harness (brown/
white), from the pilot valve to the ground (blue). Check that the lever is held properly.
work.
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
7. Machine sways, or has a shock
during steering
9. 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
Symptoms / check point
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 deffers between the front axle
1. Brake does not work well.
Machine turns when the brake is applied suddenly (the steering wheel slips from our
(In the worst case, the brake does
not work at all.)
Both the right and left pedals have low braking resistance when pressed.
Check before starting work.
1. Check the Nitrogen gas pressure in the
accumulator.
2. Check the brake piping for leakage.
hands)
Turning the manual release knob of the solenoid valve counterclockwise releases the
(or: Releasing the parking brake
is not possible.)
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.
parking brake.
Electrical Group
T/M (transmission) solenoid valve does not operate based on the speed set by the shift
1. Instrument panel does not indi-
Speed indicated on the instrument panel does not correspond to the speed set by the
cate properly.
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. Lamp test
Turn the starter switch key to "ON" position
shift lever.
lever.
Possible cause Solution
Bulb of monitor lamp burnt out Bulb replacement
Defective sensor or improper wiring Sensor replacement
Disconnected or defective electrical circuit Repairing cable
Connector check &
Loose connector
re-connection
T/M controller breaker turned off Inspection & repair
T/M controller failure alarm turned on Inspection & repair
Controller replace-
Defective T/M controller
ment
Defective inside mechanism of gauge or meter Replacement
Defective board of instrument panel Replacement
T/M solenoid valve improperly connected. Properly connect
Gauge circuit grounded improperly. Inspection & repair
∗ If the gauge and warning lamps do not agree there probably is a defect in the wiring. Stop immediately and diagnose the defect.
Remarks
01-31
80Z5 Troubleshooting
Electrical Group
In the solenoid valve continuity test, change the positive and negative sides to each
troller is turned off
Parking brake remains unreleased regardless of the parking brake switch position.
Both the forward and reverse shift lever position enable the engine to start.
Repair/check
End
95ZVE01002
01-33
80Z5 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
Examine the cause before taking the corrective measure. See A-1 .
Operator Station Group
Blower motor Adhesion of dust to surface of evaporator Clean the surface of evaporator.
rotation
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
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.
Adjustment failure of gap between the thermister(frosting sensor) and evaporator Adjust the gap(12 ± 5 mm).
A-1
12 ± 5 mm
80V2E01014
80Z5 Troubleshooting
Operator Station Group
01-35
01-36
Gas leakage Perform the leak test and repair the location of
Operator Station Group
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
Disconnected stator coil Replacement
Excessive air gap between rotor and stator Repair or replacement
Slipped clutch Slippage due to broken key or key insertion failure Replace the key with a new one.
Stained clutch surface due to oil Remove the oil.
D-1
Rare-short in coil Replacement
Battery voltage drop Re-charging
Foreign matter caught between rotor and stator Disassembling/repair
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
80Z5 Troubleshooting
Operator Station Group
01-37
01-38
Insufficient Same as "Cooling failure"
wind force
Heating failure
80Z5 Troubleshooting
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
Without diagnostic display
Disengaged link Re-set the link.
(blow-off servo motor normal)
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
80Z5 Troubleshooting
Operator Station Group
01-39
01-40
80Z5 Troubleshooting
MEMO
03-1
03
Cautions on Safety ............................................................................................................................................ 03-3
Standard Measurement Values for Performance Check ................................................................................... 03-4
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
Clutch Time Lag .............................................................................................................................................. 03-15
Measuring clutch time lag ......................................................................................................................... 03-15
Hydraulic Cylinder ........................................................................................................................................... 03-16
Cylinder natural drift .................................................................................................................................. 03-16
Boom Rising Time ........................................................................................................................................... 03-17
Full Steering Time ........................................................................................................................................... 03-20
Loading/Steering Circuit Relief Valve .............................................................................................................. 03-22
Loading circuit relief valve setting pressures ............................................................................................ 03-22
Steering circuit relief valve setting pressures ............................................................................................ 03-28
Stop Valve ....................................................................................................................................................... 03-33
Stop valve adjustment procedure ............................................................................................................. 03-33
Fan Revolution ................................................................................................................................................ 03-34
Service Brake .................................................................................................................................................. 03-35
Service brake performance check ............................................................................................................ 03-35
Service brake friction plate wear measurement ........................................................................................ 03-36
Cautions on installing brake discs ............................................................................................................. 03-37
Parking Brake ................................................................................................................................................. 03-38
Parking brake performance check ............................................................................................................ 03-38
Parking brake clearance adjustment ......................................................................................................... 03-40
03-2
Cautions on Safety
WARNING CAUTION
Unexpected movement of the machine may cause an Touching the fan or the V belt of the engine or the hot
accident resulting in injury or death. area while the engine is running may cause severe
Therefore, to provide repair service with the engine accidents.
running, be sure to observe the following items: Make sure to stop the engine before opening the
- Park the machine on level ground. engine room side cover.
- Apply the parking brake.
- Block the tires with chocks to prevent the tires from
moving.
- Determine the signals between the service man.
- Prohibit any person from walking into dangerous
areas.
- Near articulation areas of the machine
- Under the machine
- Around the engine
- In front of or behind the machine
WARNING
Operation under the boom or the bucket may lead to
severe accidents.
Make sure to apply the safety lock of the boom and
the bucket control lever provided in the cab, remove
the starter key, and attach a "DO NOT OPERATE!"
tag to the cab.
CAUTION
Be careful not to be burnt by bursting high pressure
oil.
Release the pressure remaining inside the circuit and
open the cap of the hydraulic tank before removing
the plug from the pressure measurement port so that
the internal pressure of the hydraulic tank is released
and burst of the high pressure oil can be prevented.
WARNING
Entering the articulation area of the machine body
while the engine is running may cause severe acci-
dents.
Make sure to stop the engine, pull out the starter key,
and attach a "DO NOT OPERATE!" tag to the cab
before entering the articulation area.
03-4
80Z5 Measurement for Performance Check
Standard Measurement Values for Performance Check
Engine speed
MPa (kgf/cm2) (psi) Maximum (HI) 1.5±0.2 (15±2) (213±28)
20.0±0.5 (204±5)
Loading line main relief pressure (HI)
(2,900±71)
11.8±0.5 (120±5)
Off (Cut-out)
(1,706±71)
Unloader valve
Brake
Note
These are the standard measurement values for the
machines at the time when delivered from the factory.
03-6
80Z5 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
Measuring engine speed
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 - Tachometer (Provided on the instrument panel)
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 Standard measurement value
moving.
- Determine the signals between the service men. min-1 (rpm)
- Prohibit any person from walking into dangerous Minimum no-load speed (LI) 800±50
areas.
- Near articulation area of the machine Maximum no-load speed (HI) 2,355±70
- Under the machine Maximum speed in torque converter stall mode 2,255±100
- Around the engine Maximum speed in multiple control valve relief
- In front of or behind the machine 2,250±100
mode
Maximum speed in torque converter stall plus
1,730+150
-100
multiple control valve relief mode
CAUTION
Do not touch the fan or V-belt of the engine or high- Measurement conditions
temperature section if the engine is running.
An accident resulting in injury may occur. Warm-up the engine before measuring the engine
Be sure to stop the engine before you open the side speed.
cover 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 revo-
lution.
03-9
80Z5 Measurement for Performance Check
Engine
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
4th speed position.
Note
97ZV03002
Cancel the auto shift mode.
As a result the transmission shift lever “A” position
works as “4” 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.
97ZV03002
03-11
80Z5 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
Frozen fuel / wax build up
mixture
Inspection
Malfunctioning accelerator pedal
& repair
Defective fuel pump Repair
Measurement instrument
- Pressure gauge
5 MPa (50 kgf/cm2) (1,000 psi)
with 2~3 m (6~10 ft.) hose
c
Pressure measurement port
PF1/4
- Tachometer
Note
Warm-up the engine before measuring the clutch oil
pressure.
90ZV03001J
80Z533001
Measuring clutch time lag Possible causes for clutch time lag
Measurement instrument
Solenoid valve
for trimmer
- Stop watch
Note
Warm-up the engine before measuring time lag. From torque To torque
converter pump converter
1. Lower the boom to the lowest limit, and fully roll Clutch oil regulator valve in transmission control valve
back the bucket until the bucket contacts to the
stopper.
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.
11. Measure the time required for the boom from the
lowest to the highest limit.
Measurement instrument
12. Adjust the engine speed to high idle (HI).
- Stop watch
13. Measure the time required for the boom from the
- Tachometer (Provided on the instrument panel) lowest to the highest limit.
Note
Even if the boom kick out system is installed, the boom
Warm-up the engine before measuring control lever should be held in the UP position until the
boom rising time. boom rises to the highest limit.
Measurement procedure
97ZV03005
5. Lower the boom to the lower limit, and roll back the
bucket.
Possible causes of excessive cylinder drift: Possible causes of excessive cylinder drift:
Bucket cylinder Boom cylinder
Bucket cylinder
Boom cylinder
90ZV03003 90ZV03004
Bucket cylinder rod side flange Boom cylinder rod side flange
Note
If only a few drops come out per minute it is considered
normal.
03-19
80Z5 Measurement for Performance Check
Boom Rising Time
Boom cylinder
To steering line
Multiple control
valve
Steering
valve
Hydraulic tank
K90Z503001
03-20
80Z5 Measurement for Performance Check
Full Steering Time
- Stop watch 4. Set and confirm the parking brake switch to the
"ON" position.
- Tachometer (Provided on the instrument panel)
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. Confirm the parking brake switch is in the “ON”
steering time. position and release the brake pedal.
Standard measurement value 8. Adjust the engine speed to low idle (LI) speed.
Idling (LI) 5.0±0.5 9. Measure and record the time required for full steer-
Engine speed (sec) 1,500 min-1 (rpm) 2.1±0.3 ing.
Maximum (HI) 2.0±0.3
10. Set and confirm the transmission shift lever is neu-
tral.
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
Steering valve
T
90ZV03005
03-22
80Z5 Measurement for Performance Check
Loading/Steering Circuit Relief Valve
Loading circuit relief valve setting Releasing residual pressure from tank and pipes
pressures Keep the bottom surface of the bucket horizontal,
and stop the engine when the bucket is approxi-
mately 30 cm (1 ft.) above the ground.
WARNING
Unexpected movement of the machine may cause an Tilt down the bucket until it comes in contact with
accident resulting in injury or death. the ground. Place the bucket control lever in the
Therefore, to provide repair service with the engine roll back position, and then lower the boom.
running, be sure to observe the following items :
- Park the machine on level ground. Push down on, then open the cap of the hydraulic
- Apply the parking brake. tank to release the residual pressure.
- 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 Measurement instruments
areas.
- Near articulation areas of the machine Pressure gauge
- Under the machine
- Around the engine 30 MPa (300 kgf/cm2) (5,000 psi)
- In front of or behind the machine (for loading line with 3 m (10 ft.) hose and steering line
with 1.5~3 m (4~10 ft.) hose)
CAUTION 5 MPa (50 kgf/cm2) (1,000 psi)
Do not touch the fan or V-belt of the engine or a high- (for pilot line) with 2~3 m (6~10 ft.) hose
temperature section if the engine is running. An acci-
dent resulting in injury may occur. Note
Be sure to stop the engine before you open the For safety, route the gauge to an area where it may be
access panel of the engine room. Keep all guards in safely read by the person doing the test.
place.
Avoid high temperature components even when the
engine is stopped.
Gauge port
CAUTION Gauge port location Port size
Be careful, you may get burned if the high pressure Main relief
(1), (3)
oil spouts out. To prevent such an accident, be sure pressure
(1), (3)
to release the residual pressure from the pipe, and G (PF) 1/4 with O-ring
Overload relief
open the cap of the hydraulic tank before removing pressure
(1), (3)
the plug from the pressure measurement port.
(4)
Pilot line pressure G (PF) 3/8 with O-ring
(4), (5)
(Reducing valve) (5)
G (PF) 1/4 with O-ring
03-23
80Z5 Measurement for Performance Check
Loading/Steering Circuit Relief Valve
K85V2J43001
Overload
relief valve
70ZVE43002
Valve assembly
(5)
(PPI) (Z)
(Z2) (Z1)
(4) (PA)
ACF (ACCF) (ACCR)
(PARKING)
(TA)
(T) (P)
Reducing valve
(for pilot)
85Z543001
03-24
80Z5 Measurement for Performance Check
Loading/Steering Circuit Relief Valve
Method 1: Using gauge port (3) Method 2: Using gauge port (1)
2. Press the brake pedal, and set and confirm the 2. Press the brake pedal, and set and confirm the
transmission shift lever is at the neutral position. transmission shift lever is at the neutral position.
3. Set and confirm the parking brake is at the "ON" 3. Set and confirm the parking brake is at the "ON"
position. position.
4. Press the brake pedal, and lower the boom to the 4. Press the brake pedal, and lower the boom to the
lowest limit. lowest limit.
5. Attach the pressure gauge 30 MPa (300 kgf/cm2) 5. Attach the pressure gauge 30 MPa (300 kgf/cm2)
(5,000 psi) to the gauge (3). (5,000 psi) to the bucket cylinder rod side (1).
6. Set the declutch ON/OFF switch to ON. 6. Raise the boom horizontal.
7. Move the bucket control lever to the roll back posi- 7. Set the declutch ON/OFF switch to ON.
tion. Hold the lever at that position.
8. Move the bucket control lever to the dump position.
8. Increase the engine speed to the maximum, and Hold the lever at that position.
measure and record the pressure using the pres-
sure gauge. 9. Increase the engine speed to the maximum, and
measure and record the pressure using the pres-
sure gauge.
03-25
80Z5 Measurement for Performance Check
Loading/Steering Circuit Relief Valve
Adjusting
screw
Tank port
Lock nut
Main relief valve
85ZVE43004
IMPORTANT
At the completion of check and adjustment of main
relief valve pressure, be sure to tighten the lock nut.
03-26
80Z5 Measurement for Performance Check
Loading/Steering Circuit Relief Valve
4. Keep the engine speed at low idle. Turn clockwise the adjusting screw to raise the set pres-
sure, or turn counterclockwise the adjusting screw to
5. Hold the bucket control lever at the roll back posi- lower the set pressure.
tion and record the pressure.
WARNING
Trapped pressure in brake circuit could cause serious Lock nut
injury when the plug is removed.
Fully release all residual accumulator pressure
before servicing.
Injection Hazard
IMPORTANT
Depress brake pedal 80~100 After the completion of the adjustment of the pilot line
times to completely discharge pressure, be sure to tighten the lock nut.
the brake accumulators prior to
removing these plugs.
K65ZV42022
3.5
Pilot line
(36) (512)
Gauge port
Reducing valve
(A)
(3)
(B) 115ZV43006
Steering valve
Overload relief
valve
2. Press the brake pedal, and set and confirm the Adjusting steering line main pressure
transmission shift lever is at the neutral position.
Steering cylinder
(2)
Steering valve
Note
North America equipped (1)
Main relief valve
M/c's have quick 70ZV43009
connectors at ports (1)
and (2).
70ZV43007
Loosen the lock nut and adjust the pressure by the
adjusting screw.
5. Attach the pressure gauge to the gauge port ((1) or
(2)). Turn clockwise the adjusting screw to raise the steering
line main pressure.
6. Set the declutch ON/OFF switch to ON.
Press down the brake pedal all the way to the floor
to avoid the “fuel saving mode at idle time”.
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.
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.
03-31
80Z5 Measurement for Performance Check
Loading/Steering Circuit Relief Valve
Port B Port A
To From Lock nut
steering valve Orbitrol®
Stopper
(bolt) Spool
Adjusting screw
90V2U42003
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
Stop Valve
Front chassis
Stop valve
Stopper (rear chassis)
(bolt) (L.H, R.H)
Front chassis
Articulation angle ( º) 38 37 36
WARNING Clearance between machine body and 13.7 20.6 27.5
stopper (mm) (in) (0.54) (0.81) (1.08)
When the machine turns, the clearance in the articu- 33.8 36.2 38.7
Stopper (bolt) length (mm) (in)
lation area closes. As a result, people may be caught, (1.33) (1.42) (1.52)
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)
Fan Revolution
Hydraulic circuit diagram
CAUTION
Do not touch the fan or V-belt of the engine or a high- Cooling fan
temperature section if the engine is running. An acci-
dent resulting in injury may occur.
Be sure to stop the engine before you open the side
T 44 P
cover of the engine room. Keep all guards in place. cm3/rev
Avoid high temperature components even when the
engine is stopped. DR
10.4MPa(106 kgf/cm2)
K90Z503002
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 03-4.
Reconfirm the brake performance by the method 1 as
soon as possible.
Condition
WARNING
1. Test course Unexpected movement of the machine may cause an
Level, straight, dry and the paved ground. accident resulting in injury or death.
Before starting brake performance check, be sure to
2. Run the machine and depress the brake pedal at observe the following items:
20 km/h (12.5 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-
8 m (8 3/4 yard) 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
A
Brake
backing
plate
Steel plate
Friction plate
80ZVE53002
WARNING
Oil inlet port Unexpected movement of machine could cause seri-
Internal gear ous 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
Brake backing
Steel plate plate to this work for engine starting to prevent an acci-
dent.
70V2U53001 - 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.
03-37
80Z5 Measurement for Performance Check
Service Brake
Note
During measurement, be sure the service brake is Brake piston
applied.
80V2E53003
The wear limit for dimension A is 15.1 mm (0.59 in).
Note that dimension A is 17.4 mm (0.69 in) when the
plate is new and unused. When only the friction plate or the steel plate is to be
replaced, if the brake piston is installed as it is, the
Note brake may drag and the brake disc may seize.
To aid quick measurement on the front axle-raise the
front of the machine so the front tires clear the ground Push back the brake piston by loosening the air bleeder
by about 25 mm (1 in). This allows easy rotation of the nipple before replacing a friction plate or a steel plate.
wheel to align the gear teeth.
- 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.
Note
Piston stroke B
1.55~3.40 mm (0.061~0.134 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 03-4. 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
Condition Unexpected movement of the machine may cause an
accident resulting in injury or death.
1. Test course Before starting brake performance check, be sure to
1/5 slope (Approx. 11º 19') observe the following items:
- Place the machine on level ground.
2. Bucket empty - Check that there is enough clearance for brake
performance check around the machine.
3. Parking switch ON - During performance check, prohibit any person to
walking near the machine.
Standard measurement value
1. Set the parking brake switch to the "ON" position.
No movement on 1/5 slope.
2. Disconnect the cable connector of parking brake
Possible cause of machine moving during brake solenoid valve.
performance check
3. Set the parking brake switch to the "OFF" position.
Possible cause Solution
Clearance between brake drum and shoe 4. Place the shift lever to the 3rd reverse position.
Clearance adjustment
too large
Improperly adjusted spring chamber link Check and adjustment 5. Gradually increase the engine speed. The machine
Broken spring chamber spring Check and repair should not move at the maximum speed.
Parking brake solenoid valve malfunction Check and repair
Note
IMPORTANT
The brake performance check condition and standard If the machine begins to move with the parking brake
measurement value are based on the law and the regu- applied, the brake shoes are burnt or misadjusted.
lation in Japan. At the completion of parking brake test, be sure to
When checking the service brake performance, follow connect the connector of electrical line to the sole-
the law and/or local regulation in your country, state, or noid valve again.
province.
03-39
80Z5 Measurement for Performance Check
Parking Brake
B B
Brake lining
Brake shoe
Position of
Inspection hole adjusting Approx. 8º
A screw
2nd propeller shaft
D D
A
Adjusting screw rotational
direction for brake shoe
expansion
Rivet Brake shoe
A-A
Adjusting screw
D-D 80ZV53002
A
Adjustment range
0.10~0.25 mm (0.004~0.010 in)
Shoe Rivet
B Abrasion limit
Lining
80ZV53004
(T) (P)
ACF port
ACCR is to be connected
to accumulator circuit front.
ACCF is to be connected
to accumulator circuit rear.
Valve assembly
85Z553001
WARNING
Injection Hazard
Depress brake pedal 80~100 times
to completely discharge the brake
accumulators prior to removing
these test plugs.
135ZV52035
Unloader valve setting pressure measure- Unloader valve setting pressure adjustment
ment
Measurement instrument 21 22
Fan motor port
Hydraulic pressure gauge
20 MPa (200 kgf/cm2) (3,000 psi)
Gauge port
1. Lower the boom to the lowest limit, and tilt the : Lock nut (22): 16.7 N-m (1.7 kgf-m) (12.3 lb-ft)
bucket down to the ground.
Then set the parking brake switch to the "ON" posi- 2. Adjust the pressure by adjusting screw (21). Turn
tion. the screw clockwise to raise the pressure.
:
ACF port plug: 11.3 N-m (1.15 kgf-m) (8.3 lb-ft)
Measurement instrument
Force
la
da
19
Pe
Gauge port
15
0
85V2E53002
Air bleeder nipple fitting
[59 N-m (6.0 kgf-m) (43 lb-ft)]
85ZVE53001
Measurement procedure
MPa
(kgf/cm2)
(psi) 4.06
(41)
(589)
Output oil pressure (brake port)
4
(40)
(580)
2
(20)
(290)
0 3.9 5 10 15 18.5 19
( )
Pedal stroke
K80V2U53001
IMPORTANT
After measuring oil pressure, be sure to tighten the
air bleeder valve. Also be sure to bleed air.
03-46
80Z5 Measurement for Performance Check
Accumulator Circuit Charging Time
WARNING
Unexpected movement of the machine may cause an
accident resulting in injury or death. (PPI) (Z)
Therefore, to provide repair service with the engine
running, be sure to observe the following items:
(Z2) (Z1)
- Park the machine on level ground.
(PA)
- Apply the parking brake. ACF (ACCF) (ACCR)
- Block the tires with chocks to prevent the tires from (PARKING)
moving. (TA)
ACCR is to be connected
CAUTION to accumulator circuit front.
ACCF is to be connected
Be careful, you may get burned if the high pressure to accumulator circuit rear.
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
85Z553001
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