AAA-S11C3V01-012 (93216-00081)
WHEEL LOADER SHOP MANUAL
115 Z
Powered by CUMMINS QSK19-C Engine. SERIAL NUMBERS 11C3-5501 and up.
Troubleshooting Measurement for Performance Check
FOREWORD To ensure good machine performance, reduce failures or problems, and prolong the service life of each component, it is necessary to operate the machine as is directed in the Operator and Maintenance Manual. To effectively diagnose and repair the machine, it is important to follow the guidelines laid out in this Shop Manual. Troubleshooting Measurement for Performance Check Note: ① For General Information and Functions and structure, refer to the 115ZⅣ -2 Shop Manual AAA-S11C3V00-012 (93216-00071). ② For Disassembly and reassembly and Service standard, refer to the 115ZⅣ -2 Shop Manual AAA-S11C3V14-012 (93216-00091) ③ For the engine, refer to the engine Shop Manual provided by the engine manufacturer. The purpose of this manual is to provide information on the product and the correct maintenance and repair methods. Please read this manual to ensure correct troubleshooting and good repair service. This manual will be periodically reviewed and revised for more satisfactory content. If you have any opinions or requests, please inform us.
（1）
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 a level and solid ground, and place chocks against the wheels to prevent movement. ・ Remove the cable from the battery before starting the service work, and attach a "DO NOT OPERATE!" tag to the steering wheel. ・ Be sure to release the internal pressure before you remove a pipe, such as the hydraulic oil, air, or engine coolant pipe. ・ Be sure to apply the articulation stopper before starting work. ・ While supporting the bottom of the chassis using a jack, be sure to support the chassis using the blocks. ・ When the boom or bucket is raised or when a unit is lifted by a crane, be sure to place a stand or adequate cribbing under the unit to prevent unexpected dropping. ・ Do not start to work in an enclosed area if adequate ventilation is not provided. ・ To remove a heavy unit (20kg (40 lbs) or more), be sure to use a crane or other lifting tool. ・ Just after stopping operation, be careful not to directly touch a hot component. You may get burned. ・ Contact tire manufacturer's local dealer for tire servicing and changing. ・ Always store the tools in good condition, and use them properly. ・ Keep the work area clean. Clean up spills immediately. ・ Avoid the use of flammable solvents and cleaners. ・ When working outdoors keep work areas, ladders, steps, decks and work platforms clear of snow, ice, and mud. ・ Use safe work platforms to reach higher areas of the machine.
（2）
Safety Symbols An accident may occur if you disregard safety rules. In this manual, several expressions are used according to levels of danger for inspection and repair work as shown below. Read the work procedures and cautions described in this manual, and take preventive measures against possible problems before starting service work.
DANGER This danger symbol identifies special warnings or procedures which, if not strictly observed, will result in death or serious injury.
WARNING This warning symbol identifies special warnings or procedures which, if not strictly observed, could result in death or serious injury.
CAUTION This caution symbol identifies special instructions or procedures which, if not strictly observed, may result in minor or moderate injury.
IMPORTANT This important symbol identifies special instructions or procedures which, if not correctly followed, may result in serious machine damage. We cannot predict all possible accidents or incidents that may occur during service work. Therefore, an accident that is not specifically mentioned in this manual may occur. To protect yourself from all accidents, be careful when doing service work.
（3）
Symbols For safe and effective service work, the following symbols are used for notes and useful information in this manual. Symbol
Item Reference
Description Shows the condition or procedure that will be useful or efficient in doing service work. Shows the weight of a part or unit. The weight
Weight
should be considered in selecting wire rope or cable for slinging work or determining the working posture.
Shows the tightening torque of a section that Tightening should be carefully tightened during assembly torque work.
Coating
l
Oil or water supply
Drainage
Shows the type of coating or adhesive and the coating section.
Shows the oil or water supply port and the refill amount.
Shows the oil or water drain port and the drain amount.
IMPORTANT If the specified conditions are not satisfied or the specified procedure is not observed, there is a strong possibility that the product will be damaged or the performance of the product will be reduced. The message shows the preventive measures.
（4）
Troubleshooting ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 01-1 Measurement for performance check ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 03-1
Troubleshooting 01 Cautions Regarding Troubleshooting ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 01-3 How to Use Quick Troubleshooting Table ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 01-4 Safety Precautions ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 01-5 Quick Troubleshooting Table Torque Converter and Transmission Group 1.
Machine does not move in any shift lever position ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 01-6
2.
Machine does not move at a certain shift lever position ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 01-7 (or: Machine moves only in a certain shift lever position)
3.
Machine moves at the neutral position ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 01-8 (Example: Machine moves forward at the neutral position)
4.
Large shock at starting or changing speeds / direction ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 01-9
5.
Large time lag at starting or changing speed / direction ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 01-10
6.
Low power ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 01-11 (Defective torque converter or transmission)
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.
QUAD (PUS) switch does not work ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 01-15
Hydraulic Group 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 ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 01-19
4.
Boom and/or bucket are spongy ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 01-21 (Holding bucket against the ground is not possible)
5.
Bucket positioner (kick-out) does not work ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 01-22
6.
Steering is not possible or hard to steer ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 01-23
7.
Machine sways, or has a shock during steering ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 01-24
8.
Abnormal noise in hydraulic system ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 01-25
9.
Others ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 01-26
01-1
Brake Group 1.
Brake does not work well (In the worst case, the brake does not work at all) ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 01-27
2.
Brake is dragging when released ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 01-28
3.
Brake oil level lowers too much ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 01-29
4.
Stepping on the brake pedal sounds the buzzer ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 01-30
5.
Accumulator pressure does not rise, or too slow in rising ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 01-31
6.
Parking brake does not work ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 01-32 (or: Releasing the brake is not possible)
7.
Auto brake does not work ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 01-33
Electrical Group 1.
Engine hard to start or will not start ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 01-34
2.
Engine will not stop even if the starter switch is turned to "OFF" (or: Starting the engine is not possible) ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 01-35
3.
Instrument panel does not indicate properly ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 01-36
4.
Breaker of the transmission controller is turned off ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 01-37
01-2
Cautions Regarding Troubleshooting ・ Important points
The
following
questions
will
be
helpful
in
The important points for troubleshooting is to
determining of the cause. Answer the questions to
carefully read the operation manual and shop
prevent an incorrect diagnosis.
manual to get enough information on the operation,
1. Did the problem occur suddenly?
circuits, structure, and function of each component.
2. When did the operator notice the problem?
If you have enough knowledge of each component
3. Is there any past problem that may be the cause
and system, you can easily determine the cause of
of this problem?
the problem.
4. When the problem occurred, what kind of work
There may be various causes for each problem,
was the operator doing?
therefore experience will be needed to determine
5. Has the machine had the same kind of problem
which is the actual cause of the problem.
before?
It is necessary to know the normal operation of
6. Has the machine been repaired or inspected
each component. In addition, it is also important to
recently?
know the abnormal condition when a problem
7. Does the machine have any other problem?
occurs. This chapter shows various examples of past problems, and describes possible causes and
・ Troubleshooting
remedies for each problem.
・ Check before determination of cause A
・ Before starting troubleshooting
problem
may
be
caused
by
poor
daily
maintenance, such as lack of grease, low or
To prevent incorrect diagnosis, talk with the
improper oil or a clogged filter. Be sure to check
persons concerned, particularly with the operator,
the machine for oil level, appearance, unpleasant
to get enough information on the problem.
odor, etc. to prevent time loss due to other
If
unnecessary tests.
possible, check the machine by repeating the
・ Inspection procedure
symptom. If the problem cannot be repeated, do not provide
As a rule, check the easy-to-be-repaired system
any repair service.
first (excluding the cases where the cause can be
For instance, assume that the operator complains
easily determined based on the past experiences).
that the boom power is low, and the rim-pull is also
This machine is controlled by electrical, hydraulic,
low. In this case, there are two possible causes;
and mechanical systems.
low hydraulic power and low rim-pull.
The
be-repaired system is the electrical system. Check
remedies against both causes are much different
the electrical system first. If no problem is detected
from each other.
in the electrical system, check the hydraulic
If you hastily determine the wrong cause without
system, and then the mechanical system.
checking the actual condition of the problem, it will take too much time and expense to solve the problem. As a result, you will not be trusted by the user.
01-3
The most easy-to-
How to Use Quick Troubleshooting Table To immediately determine the cause of the problem without
disassembling
parts,
use
the
quick
troubleshooting table. From the problem explained by the user and the check points written in the table, you can immediately determine the cause of the problem.
・ How to use quick troubleshooting table
(4) Generally, the possible cause that has many
(1) According to the problem explained by the user,
check marks will be the actual cause. If two or
open the quick troubleshooting table to the page
more possible causes have several check marks,
where the corresponding problem is described.
check each possible cause to prevent an
(2) Check
the
machine
according
to
the
incorrect diagnosis.
"Symptoms/check point" field in the table. Start
In this case, start from the most easily checked
from the most easily checked point.
item.
(3) Operate the machine, and write the check marks "
" in the corresponding circles " ○ " if the
problem occurs.
01-4
Safety Precautions WARNING
WARNING
Unexpected operation of the machine may cause an accident resulting in injury or death. Therefore, to provide repair service during engine running, be sure to observe the following items: ・Park the machine on level ground. ・Apply the parking brake. ・Brace the tires with chocks to prevent accidental movement. ・Determine the signals between the service technicians. ・Prohibit any person from entering into dangerous areas. ・ Near articulation area of the machine ・ Under the machine ・ Around the engine ・ In front of or behind the machine
Do not enter the articulation area of the machine if the engine is operating. An accident resulting in injury or death may occur. To enter the articulation area, be sure to stop the engine, and remove the starter key. In addition, hang a "DO NOT START THE ENGINE!" tag on the steering wheel.
WARNING Unexpected operation of the machine may cause an accident resulting in injury or death. To crawl under the machine, be sure to stop the engine, and brace the tires with the chocks to prevent them from rotation. Give signals to the person in the cab during the work.
WARNING CAUTION
Standing under the boom or bucket during service work is dangerous. An accident resulting in injury or death may be caused. To prevent such an accident: ・Lock the boom and bucket control levers in the cab. ・Remove the starter key. ・Hang a "DO NOT OPERATE!" tag on the steering wheel. ・Securely brace the boom / attachment in the raised position.
Do not touch the fan or V-belt of the engine or a high-temperature section if the engine is running. An accident resulting in injury may occur. Be sure to stop the engine before you open the side cover of the engine room. Avoid high temperature components even when the engine is stopped.
CAUTION Be careful, injury may occur if high pressure oil sprays out. To prevent such an accident, before removing the plug from the pressure measurement port, be sure to: ・Release the residual pressure from the pipe. ・Open the cap of the hydraulic oil tank.
01-5
115Z Ⅳ -2
Machine does not move in any shift lever position
QUICK TROUBLESHOOTING TABLE 01
will operate except horn circuit and hazard flasher [opt.].)
Ｐｏｓｓ ｉ ｂ ｌ ｅ ｃａｕｓｅ
Pump produces an abnormal(shrieking)noise
(If the 70A fusible link is off, no electrical circuits
Controller LED "I" indicator is ON
ON. (6) Check the 70A fusible link.
Filter of the torque converter is clogged
(5) Check that the circuit protector of the controller is
Temperature of the torque converter oil is too high
(4) Check the fuse of the controller system.
Torque converter oil becomes milky and cloudy in color
(3) Check the torque converter oil level.
Low clutch oil pressure at all the shift lever positions
released.
Ｓｙｍｐ ｔ ｏｍｓ／ｃｈｅｃｋ ｐｏ ｉ ｎ ｔ
(2) Check that the solenoid valve for auto brake is
Pump is extremely heated
(1) Check that the parking brake is released.
Even if the breaker of the controller is turned ON, the breaker will be immediately turned OFF
Check before starting work
The controller LED "X" indicator is OFF
1. Machine does not move in any shift lever position
Setting the T/M(transmission)cut-off switch to OFF allows normal operation
Torque Converter and Transmission Group
Ｓ ｏ ｌ ｕ ｔｉｏ ｎ
Air drawn into suction line of the torque converter pump
○ ○ ○
○ ○
Tightening hose band
Defective torque converter pump
○
○
Pump replacement
○ ○
Damaged torque converter Sticking clutch pressure modulator valve (1)
Disassembly&repair
○
Disassembly&repair
○ ○
Malfunctioning inching switch Defective controller
○
○
Switch replacement
○
Controller replacement
○
Short circuited clutch solenoid valve or wiring Restricted suction line-pinched, plugged, or internally defective
Repairing wiring
○ ○
01-6
Replace hose
Machine does not move at a certain shift lever 115Z Ⅳ -2 position
QUICK TROUBLESHOOTING TABLE 01
Clutch slipping
○
Machine may move even when shift lever is in "NEUTRAL"
Controller IN and OUT LED do not correspond with each other, controller failure light on dash is ON
Controller input LED will not light at a certain shift lever position
Breaker of the controller will be turned off at a certain shift lever position
Disassembly
○ &repair
Disassembly &repair
○
○
Coil of clutch solenoid valve is defective
○
Harness of clutch solenoid valve disconnected
○
○ ○
Clutch solenoid valve sticking in OFF position
○
○
○
Solenoid valve replacement
○
○
Repair cable Solenoid valve replacement Solenoid valve replacement
○
Shift lever replacement
○ ○
Shift lever switch sticking in ON (regardless of position) ○
○
○ ○
***
○
Solenoid valve replacement
○
Defective controller ** Refer to "operation error preventive function". *** If "F" or "R" switch is stuck in the "ON" position.
01-7
Shift lever
○ replacement ○
Damaged clutch solenoid valve diode
＊ Ｒｅｍａｒｋｓ
At a certain shift lever position, the controller input LED is turned on and will not go out
○
Clutch oil leaks internally
Clutch solenoid valve sticking in ON position
Ｓｏｌｕｔ ｉｏｎ Disassembly &repair
○ ○
Seized clutch
Shift lever switch sticking in OFF (regardless of position)
Clutch oil pressure is always high despite shift lever position and output LED
Even when pressing solenoid valve, machine does not move
Resistance of the solenoid valve coil is too high (more than 14 Ω )
24V power is not supplied to the solenoid valve (output LED OK)
Ｐｏｓｓ ｉ ｂ ｌ ｅ ｃａｕｓｅ
Clutch oil pressure is low at a certain position only. At all the other positions, the pressure is normal
Machine may move unexpectedly during testing causing injury or death. ・ Block the machine securely. ・ Always stay clear of the articulation area and wheels when the engine is running.
Torque converter oil looks and smells as if it was scorched (black)
WARNING
Ｓｙｍｐ ｔ ｏｍｓ／ｃｈｅｃｋ ｐｏ ｉ ｎ ｔ
lever position)
Machine moves at a certain shift lever position, but hesitates to move at any other positions
(OR : Machine moves only in a certain shift
Machine does not move at a certain shift lever position, but moves at all the other positions
2. Machine does not move at a certain shift lever position
Clutch can be engaged at a certain shift lever position, though the clutch will not be engaged at any other position**
Torque Converter and Transmission Group
Controller replacement
115Z Ⅳ -2
Machine moves at the neutral position
QUICK TROUBLESHOOTING TABLE 01
Seized clutch on forward side *
○
○
Malfunctioning forward solenoid valve (sticking at ON position)*
○
○
○
Ｓ ｏ ｌ ｕ ｔｉｏ ｎ T/M disassembly and repair
○
Solenoid valve replacement
○
Defective controller(malfunctioned after outputting "F")* Defective shift lever(switch stuck in "F" position)*
Controller output LED "F" will go out when shifted to reverse (output LED "R" will not turn on). Machine feels like its neutral.
Ｐｏｓｓ ｉ ｂ ｌ ｅ ｃａｕｓｅ
Controller input LED "F" indicator is on and will not go out
Ｓｙｍｐ ｔ ｏｍｓ／ｃｈｅｃｋ ｐｏ ｉ ｎ ｔ
(1) Check that the ground is level
Oil is black and smells scorched
Check before starting work
Controller output LED "F" indicator is on and will not go out
neutral position)
When the lever is shifted to the reverse position, the machine does not move reverse (as if the brake is applied)
3. Machine moves at the neutral position (Example: Machine moves forward at the
When the lever is shifted to the forward position, the machine moves forward
Torque Converter and Transmission Group
○ ○
Controller replacement
○
Shift lever replacement
＊ Ｒｅｍａｒｋｓ
* The same possible cause but involving the reverse clutch or circuit could occur with the opposite symptoms.
01-8
Large shock at starting or changing speeds / 115Z Ⅳ -2 direction
QUICK TROUBLESHOOTING TABLE 01
Torque Converter and Transmission Group
Resistance of the modulator valve (2) coil is infinite Ω
Temperature of the torque converter oil is too high
Foreign material is on the line filter
Controller output LED "DC" indicator does not light properly
Main oil pressure rises too quickly at all the shift lever positions
Large shock at a certain shift lever position only
Ｐｏｓｓ ｉ ｂ ｌ ｅ ｃａｕｓｅ
Large shock at all the shift lever positions
Ｓｙｍｐ ｔ ｏｍｓ／ｃｈｅｃｋ ｐｏ ｉ ｎ ｔ
4. Large shock at starting or changing speeds / direction
Ｓ ｏ ｌ ｕ ｔｉｏ ｎ
Modulator valve (1) sticking in ON position
○
○
Disassembly&repair
Harness of modulator valve disconnected
○
○
Repair
Modulator valve (2) sticking in OFF position
○
○
Defective controller
○
○ ○
Damaged or worn clutch disk
○
01-9
○
Disassembly&repair Controller replacement
○ ○
T/M disassembly and repair
Large time lag at starting or changing speed / 115Z Ⅳ -2 direction
QUICK TROUBLESHOOTING TABLE 01
Charge pump extremely heated
Abnormal noise from charge pump (shrieking)
Torque converter oil overheats
Time lag just after using the inching brake
Large time lag at a certain shift lever position only
Main oil pressure is too low at all the shift lever positions
Controller output LED "DC" indicator does not light properly
Main oil pressure rises too slowly at all the shift lever positions
Ｐｏｓｓ ｉ ｂ ｌ ｅ ｃａｕｓｅ
Large time lag at all the shift lever positions
Ｓｙｍｐ ｔ ｏｍｓ／ｃｈｅｃｋ ｐｏ ｉ ｎ ｔ
5. Large time lag at starting or changing speed / direction
Clutch oil pressure is too low or rises too slowly at a certain shift lever position only
Torque Converter and Transmission Group
Ｓ ｏ ｌ ｕ ｔｉｏ ｎ
Defective torque converter pump
○ ○
○
Disassembly&repair
Harness of modulator valve (1) disconnected (or sticking in OFF position)
○
○
Disassembly&repair
Malfunctioning pressure difference sensor
○ ○
Disassembly&repair
Defective controller
○ ○ ○
Controller replacement
○
Internally leaked clutch oil
○
Malfunctioning inching proximity switch Restricted suction line-pinched, internally defective
T/M disassembly and repair
○
○ ○
01-10
Switch replacement
○ ○ ○
Replace hose
115Z Ⅳ -2
Low power
QUICK TROUBLESHOOTING TABLE 01
Torque Converter and Transmission Group 6. Low power (Defective torque converter or
Air drawn into suction line of torque converter
○
Broken torque converter turbine and pump
○
Torque converter internal pressure too low
○
○
○
Pump produces an abnormal(shrieking)noise
○ ○
Iron and/or fiber material in line filter and strainer
Pump is extremely heated
Clutch oil pressure is too low at a certain shift lever position
Silver powder (Aluminum) is on the line filter and strainer
Ｐｏｓｓ ｉ ｂ ｌ ｅ ｃａｕｓｅ
Torque converter oil is milky and cloudy in color
link of the engine governor operates at full stroke.
Temperature of the torque converter oil is too high
hydraulic line(like excessive pilot pressure). (4) Step on the accelerator pedal, and check that the
Torque converter oil is discolored or emits nasty smell
(3) Check that no unusual load is applied to the
Output power is low at a certain shift lever position only
(2) Check the torque converter oil level.
Output power is low at all the shift lever positions
dragging.
Ｓｙｍｐ ｔ ｏｍｓ／ｃｈｅｃｋ ｐｏ ｉ ｎ ｔ
(1) Check the parking brake and foot brake for
Large time lag at a certain shift lever position only
Check before starting work
Machine moves even if the shift lever is set to the neutral position*
transmission)
Ｓ ｏ ｌ ｕ ｔｉｏ ｎ Tightening suction hose band T/M disassembly and repair
○
Regulator valve check
Seized clutch
○ ○
○ ○
Clutch slipping
○
○
Internally leaking clutch oil
○
○
T/M disassembly and
○ repair
T/M disassembly and repair T/M disassembly and repair
○
Restricted suction line-pinched, internally defective
○
○
Harness of modulator valve (1) disconnected (or sticking in OFF position)
○
○ ○
Disassembly&repair
Defective controller
○
○ ○
Controller replacement
＊ Ｒｅｍａｒｋｓ
* If the seized clutch is Forward or Reverse clutch.
01-11
○ ○
Replace hose
115Z Ⅳ -2
Torque converter oil is overheating
QUICK TROUBLESHOOTING TABLE 01
Torque Converter and Transmission Group
Air drawn into suction line of torque converter Internally torque converter leakage
Engine RPM at no load or during stall test is too low
Installing thermometer in T / C out line indicates less then 250 °F / 120 ℃ when gauge or light indicates overheat
One or more planetaries are hotter than others
Parking brake is excessively hot / discolored
T/C disassembly and repair
○ ○
T/C disassembly and repair
○
T/M disassembly and repair
○ ○
T/M disassembly and repair
○ ○ ○
T/C disassembly and repair
○ ○ ○
Clutch slipping
○
Scale deposited in water line of torque converter cooler ○ ○
Cooler cleaning
○ ○ ○
Wrong oil viscosity is used
Ｓｏｌｕｔ ｉｏｎ Tightening hose band
○
Seized clutch
Restricted suction line-pinched, internally defective
Less difference in torque converter oil temperature between cooler inlet and outlet
Pump produces an abnormal(shrieking)noise
Pump is extremely heated
○
Damaged torque converter Torque converter pump discharge amount too small
Output power is too small at a certain shift lever position
Torque converter inlet pressure is too low
Clutch oil pressure is too low
Ｐｏｓｓ ｉ ｂ ｌ ｅ ｃａｕｓｅ
Torque converter oil is milky and cloudy in color
(3) Check tire pressures-adjust to specification.
Ｓｙｍｐ ｔ ｏｍｓ／ｃｈｅｃｋ ｐｏ ｉ ｎ ｔ
Oil level too high. (2) Check the engine coolant for overheat.
Torque converter oil is discolored or emits nasty smell
(1) Check the torque converter oil level.
Foreign material is on the filter-especially silver powder (Aluminum)
Check before starting work
Machine does not move at a certain shift lever position (or dragging is felt)
7. Torque converter oil is overheating
Replace hose Replace w/proper oil
○
Test/repair brake circuit
○ ○
Service or parking brake dragging Operator is using too high gear for load
Train operator
Incorrect indication of gauge (no alarm) Alarm switch defective (gauge in green zone)
○
Test/replace gauge or sender
○
Replace switch
○
Contamination in oil cooler (oil side)
Replace cooler
○
Engine RPM too low / Engine power too low
01-12
Machine moves reverse when climbing
115Z Ⅳ -2
QUICK TROUBLESHOOTING TABLE 01
Ｓｙｍｐ ｔ ｏｍｓ／ｃｈｅｃｋ ｐｏ ｉ ｎ ｔ
8. Machine moves reverse when starting to climb up on a slope using inching brake
Ｐｏｓｓ ｉ ｂ ｌ ｅ ｃａｕｓｅ
After pedal release, too much time is required to turn off the controller LED "I" indicator
Torque Converter and Transmission Group
Large time lag in clutch engagement Delay in resetting inching proximity switch
Ｓ ｏ ｌ ｕ ｔｉｏ ｎ Refer to description of time lag
○
01-13
Switch replacement
115Z Ⅳ -2
Automatic speed change is not possible
QUICK TROUBLESHOOTING TABLE 01
Ｓ ｏ ｌ ｕ ｔｉｏ ｎ Shift lever replacement or repairing wire
○
Damaged speed sensor or disconnected sensor
○
Speed sensor signal output error or improperly adjusted speed sensor
○ ○
○
Defective controller
○
○
○
Sensor replacement or repairing wire
○
Sensor replacement or readjustment Controller replacement
○ ○
Low speed(engine output power too low) Parking or service brakes dragging
One or more planetaries are excessively hot/parking brake is hot or discolored
Ｐｏｓｓ ｉ ｂ ｌ ｅ ｃａｕｓｅ
Defective shift lever "A" position or defective wiring to controller
Actual speed increase or reduction does not correspond with the set speed
lever position."
Controller input LED "A" indicator does not light
refer to "Machine does not move at a certain shift
Ｓｙｍｐ ｔ ｏｍｓ／ｃｈｅｃｋ ｐｏ ｉ ｎ ｔ
speed. If manual speed change is impossible,
Speed is properly increased on a downward slope
(1) Manually change the speed from 1st speed to 3rd
Speed is fixed to 3rd speed, and is not increased to 4th speed
Check before starting work
Speed is fixed to 2nd speed, and automatic speed change is not possible
9. Automatic speed change is not possible
Controller LED for machine speed does not change even if machine speed is changed
Torque Converter and Transmission Group
○ ○ ○
01-14
Inspection&repair
○
Repair brake circuit
QUAD switch does not work
115Z Ⅳ -2
QUICK TROUBLESHOOTING TABLE 01
Check before starting work (1) Check that the QUAD (PUS) switch is being used At other positions, shifting down is not possible. (2) Check the fuses.
Ｐｏｓｓ ｉ ｂ ｌ ｅ ｃａｕｓｅ
Ｓｙｍｐ ｔ ｏｍｓ／ｃｈｅｃｋ ｐｏ ｉ ｎ ｔ
only at the 2nd forward/reverse speed position.
Controller input LED "S" indicator lights when the QUAD (PUS) switch is turned on
10. QUAD (PUS) switch does not work
Controller input LED "S" indicator does not light when the QUAD (PUS) switch is turned on
Torque Converter and Transmission Group
Ｓ ｏ ｌ ｕ ｔｉｏ ｎ
Defective switch
○
Switch replacement
Disconnected switch or wiring
○
Repair wire
○
Defective controller
01-15
Controller replacement
115Z Ⅳ -2
Boom and/or bucket do not move
QUICK TROUBLESHOOTING TABLE 01
Broken pump drive shaft
○
Internally damaged steering pump
○
○
Internally damaged main pump
○
○
Internally damaged pilot pump
○ ○
○
Oil leakage from overload relief valve (Bucket)
○
○
Multiple control valve plunger sticking
Pump is extremely heated
Disassembly
○ &repair ○
○
Disassembly &readjustment Disassembly &readjustment
○ ○
○
Main relief valve produces a noise
Cylinder does not operate, though oil is discharged from the return port
○ &repair
○
Plunger replacement Disassembly &readjustment
○ ○ ○
Bucket moves if the overload relief valves are exchanged with each other *
After warm-up, it is possible to operate the bucket and boom
Pilot relief pressure is too low
No pilot relief pressure built
Disassembly
○
○
Defective pilot relief valve Internally damaged cylinder
Disassembly
○ &repair
○ ○
Oil leakage from main relief valve
Ｓｏｌｕｔ ｉｏｎ Pump replacement
○
○ ○
Multiple control valve
Pump
Ｐｏｓｓ ｉ ｂ ｌ ｅ ｃａｕｓｅ
Either the boom or bucket does not move
(3) Check that the pilot valve filter is not clogged.
Steering is not possible either
released.
Ｓｙｍｐ ｔ ｏｍｓ／ｃｈｅｃｋ ｐｏ ｉ ｎ ｔ
(2) Check that the loading control lock lever is fully
Main relief pressure is too low when the boom or bucket is operating
(1) Check the oil level.
Boom and bucket move with no load, though they do not move when loaded
Check before starting work
No main relief pressure built
1. Boom and/or bucket do not move
Boom and bucket do not move normally while the engine runs idle but appears to move normally while it runs at full speed
Hydraulic Group
○
Disassembly &repair
* Remarks
* Exchange of the overload relief valve means that the valves should be changed between the rod and bottom sides.
01-16
115Z Ⅳ -2
Boom and/or bucket have low power or slow
QUICK TROUBLESHOOTING TABLE 01
If the brakes, service or parking, drag it reduces the power available to hydraulics when the machine is moving.(Static testing will show normal hydraulic power and speed.) (6) Check that the pilot valve filter is not clogged.
Ｐｏｓｓ ｉ ｂ ｌ ｅ ｃａｕｓｅ
Internally damaged steering pump
○
Internally damaged main pump
○ ○
Oil leakage from main relief valve
○ ○
Oil leakage from overload relief valve for bucket bottom side
○
Internally damaged cylinder
○
Oil leakage from reducing valve of pilot relief valve
○
Ｓｏｌｕｔ ｉｏｎ
○
Disassembly &repair
○
Disassembly &repair Disassembly &readjustment
○ ○
Disassembly &readjustment
○
Disassembly &repair
○ ○
Disassembly &repair
○
Warm up hydraulics Replace oil w/proper oil
Oil is cold, wrong oil viscosity (too thick)
○
○
Suction side air leak-clamp, hose, o-rings
○
○
○
Suction line pinched or internally defective
○
○
○
01-17
Pump makes noise (shrieking)
(5) Check that the machine rolls freely in neutral.
Oil is foamy or milky looking after operation, but normal after stopping engine and letting the oil sit for 1 hour
to hydraulics.
Only bucket operation is abnormal
Dragging/seized clutches reduce power available
Only boom lifting operation is abnormal
lever of the transmission is at the neutral position.
Either the boom and bucket does not operate properly
(4) Check that the machine does not move if the shift
Both the boom and bucket do not operate properly
lever of the engine governor operates at full stroke. Measure/Adjust High Idle (HI) Speed.
Steering system operates properly
(3) Step on the accelerator pedal, and check that the
Steering system does not operate properly
released.
Ｓｙｍｐ ｔ ｏｍｓ／ｃｈｅｃｋ ｐｏ ｉ ｎ ｔ
(2) Check that the loading control lock lever is fully
Bucket drifts down when full
(1) Check the oil level.
Pump is extremely heated
Check before starting work
Main relief valve produces a noise
2. Boom and/or bucket have low power, or move too slowly
Stop the engine when the boom is on its way up(or down). Holding the boom at that position is not possible
Hydraulic Group (S/N 11C3-5501〜5700)
○
Check & repair
○ suction line
Check & repair
○ suction line
115Z Ⅳ -2
Boom and/or bucket have low power or slow
QUICK TROUBLESHOOTING TABLE 01
Check before starting work (1) Check the oil level.
If the brakes, service or parking, drag it reduces the power available to hydraulics when the machine is moving.(Static testing will show normal hydraulic power and speed.) (6) Check that the pilot valve filter is not clogged.
Ｐｏｓｓ ｉ ｂ ｌ ｅ ｃａｕｓｅ
Internally damaged steering pump
○
Internally damaged main pump
○ ○
Oil leakage from main relief valve
○ ○
Oil leakage from overload relief valve for bucket bottom side
○
Internally damaged cylinder
○
Ｓ ｏ ｌ ｕ ｔｉｏ ｎ
○
Disassembly&repair
○
Disassembly&repair Disassembly &readjustment
○ ○
Disassembly &readjustment
○
○
Disassembly&repair Warm up hydraulics Replace oil w/proper oil
Oil is cold, wrong oil viscosity (too thick)
○
○
Suction side air leak-clamp, hose, o-rings
○
○
○
Suction line pinched or internally defective
○
○
○
01-18
Bucket drifts down when full
(5) Check that the machine rolls freely in neutral.
Pump is extremely heated
to hydraulics.
Only bucket operation is abnormal
Dragging/seized clutches reduce power available
Main relief valve produces a noise
lever of the transmission is at the neutral position.
Either the boom and bucket does not operate properly
(4) Check that the machine does not move if the shift
Both the boom and bucket do not operate properly
lever of the engine governor operates at full stroke. Measure/Adjust High Idle (HI) Speed.
Steering system operates properly
(3) Step on the accelerator pedal, and check that the
Steering system does not operate properly
released.
Ｓｙｍｐ ｔ ｏｍｓ／ｃｈｅｃｋ ｐｏ ｉ ｎ ｔ
(2) Check that the loading control lock lever is fully
Pump makes noise (shrieking)
2. Boom and/or bucket have low power, or move too slowly
Oil is foamy or milky looking after operation, but normal after stopping engine and letting the oil sit for 1 hour
Hydraulic Group (S/N 11C3-5701〜)
○
○
Check & repair suction line
○
Check & repair suction line
115Z Ⅳ -2
Excessive cylinder drift
QUICK TROUBLESHOOTING TABLE 01
Ｐｏｓｓ ｉ ｂ ｌ ｅ ｃａｕｓｅ
Internal boom cylinder piston seal oil leakage Internal bucket cylinder piston seal oil leakage Oil leakage from multiple control valve main spool Oil leakage from multiple control valve overload relief valve
Excessive drift of bucket
Trapped oil under pressure can spray out causing injury. ・ Always release tank and trapped cylinder pressure before removing any lines, plugs or components.
Excessive drift of boom
WARNING
Ｓｙｍｐ ｔ ｏｍｓ／ｃｈｅｃｋ ｐｏ ｉ ｎ ｔ
instructions on "Measuring Cylinder Drift".
○
Front wheels drift down when the front wheels are lifted off the ground by means of the boom cylinder
The maximum drift rate is measured according to
There is a hose that connects the pilot relief valve to the boom cylinder bottom. Remove the hose from the pilot relief valve, and attach a blank plug to the valve side. Check that the drift is stopped
3. Excessive cylinder drift
In the case that the overload relief valve is switched or replaced, excessive drift stops
Hydraulic Group (S/N 11C3-5501〜5700)
○ ○ ○ ○
01-19
Disassembly&repair Disassembly&repair
○
Oil leakage from reducing valve of pilot relief valve
Seal replacement Seal replacement
○ ○ ○
Ｓ ｏ ｌ ｕ ｔｉｏ ｎ
Disassembly&repair
115Z Ⅳ -2
Excessive cylinder drift
QUICK TROUBLESHOOTING TABLE 01
The maximum drift rate is measured according to
Ｐｏｓｓ ｉ ｂ ｌ ｅ ｃａｕｓｅ
Internal boom cylinder piston seal oil leakage Internal bucket cylinder piston seal oil leakage Oil leakage from multiple control valve main spool Oil leakage from multiple control valve overload relief valve
Excessive drift of bucket
Trapped oil under pressure can spray out causing injury. ・ Always release tank and trapped cylinder pressure before removing any lines, plugs or components.
Excessive drift of boom
WARNING
Ｓｙｍｐ ｔ ｏｍｓ／ｃｈｅｃｋ ｐｏ ｉ ｎ ｔ
instructions on "Measuring Cylinder Drift".
○
Front wheels drift down when the front wheels are lifted off the ground by means of the boom cylinder
3. Excessive cylinder drift
In the case that the overload relief valve is switched or replaced, excessive drift stops
Hydraulic Group (S/N 11C3-5701〜)
○ ○
01-20
Seal replacement Seal replacement
○ ○ ○
Ｓ ｏ ｌ ｕ ｔｉｏ ｎ
○ ○
Disassembly&repair Disassembly&repair
115Z Ⅳ -2
The boom or bucket is spongy
QUICK TROUBLESHOOTING TABLE 01
○
○
Disassembly&repair
Oil leakage from make-up valve for bucket rod side
○
○
○
○
Disassembly&repair
○
Ｓｙｍｐ ｔ ｏｍｓ／ｃｈｅｃｋ ｐｏ ｉ ｎ ｔ
Make-up valve does not open on bucket rod side
○ ○
Make-up valve opening impossible on boom rod side
Ｓｏｌｕｔｉｏｎ
Disassembly&repair
○
Oil leakage from make-up valve for boom rod side
Boom is spongy just after quick lowering
Overload relief pressure is too low
○
Ｐｏｓｓ ｉ ｂ ｌ ｅ ｃａｕｓｅ
Boom cannot support the lifted front wheels, or the lifted front wheels soon drop
In case that the overload relief valves are switched*, the boom and bucket are strong enough to support the front wheels.
○
possible-front wheels off the ground)
Boom and bucket are strong enough if the engine runs at the full speed while dumping or lowering
Bucket cannot support the lifted front wheels, or the lifted front wheels soon drop
Oil leakage from overload relief valve for bucket rod side
4. Boom and/or bucket are spongy (Holding bucket against the ground is not
Bucket is spongy just after dumping
During digging operation, the bucket tilts back even though the lever is at the neutral position
Hydraulic Group
Disassembly&repair
○ Disassembly&repair
* Regarding check point above, switching the overload relief valves means that the valves should be changed between the
＊ Ｒｅｍａｒｋｓ
rod and bottom sides of the bucket circuit.
01-21
Bucket positioner(kick-out) doesn't work
115Z Ⅳ -2
QUICK TROUBLESHOOTING TABLE 01
switch and detection bar is properly adjusted. (5mm ± 2[1/8 ″〜1/4 ″]) (3) Check all the connectors of the electrical power line to be sure they are properly connected.
Ｐｏｓｓ ｉ ｂ ｌ ｅ ｃａｕｓｅ
Defective proximity switch
Ｓｙｍｐ ｔ ｏｍｓ／ｃｈｅｃｋ ｐｏ ｉ ｎ ｔ
(2) Check that the distance between the proximity
○
○
01-22
Ｓ ｏ ｌ ｕ ｔｉｏ ｎ Proximity switch replacement
○ ○
Broken magnet coil inside pilot valve Disconnected electrical power line
Magnet coil resistance value is indicated as infinity or 0 Ω
(1) Check the fuses.
Remove the connector of the proximity switch, and connect the red and white wires of the connector to each other on the chassis side. Check that the lever is held properly.
Check before starting work
sw. face)
5. Bucket positioner (kick-out) does not work
LED lamp of the proximity switch does not light (key on & metal plate in front of
Hydraulic Group
Magnet replacement Repair
Steering is not possible or hard to steer
115Z Ⅳ -2
QUICK TROUBLESHOOTING TABLE 01
Hydraulic Group
Internally damaged orbitroll
○ ○
Sticking stop valve plunger
○
Internal damage of steering pump (deteriorated performance)
Boom slow, steering hard both directions, pump heated
Main relief pressure is too low in one direction only
If the overload relief valves are exchanged*, steering problem switches sides
Pump is extremely heated
Ｓｏｌｕｔ ｉｏｎ Disassembly &repair
○
○
Disassembly &repair
○ ○
Malfunctioning steering valve or flow control plunger
○
Defective main relief valve
○
○ ○
○
Disassembly
○
○ &repair
Disassembly &repair
○ ○
Disassembly &repair
○
○ ○
Defective overload relief valve Defective steering cylinder
Overload relief pressure is too low
Ｐｏｓｓ ｉ ｂ ｌ ｅ ｃａｕｓｅ
Steering relief pressure is too low
than normal.
Increasing the engine speed enables smooth operation
(4) Measure steering wheel force to see if it is greater
Steering is not possible at both the idling and full speeds
steering system is normal.
Boom is too slow in rising
& heavy loading can prevent steering even when
Steering wheel is too loose
(3) Check operating conditions. Full brake application
Steering wheel does not rotate
properly adjusted.
Ｓｙｍｐ ｔ ｏｍｓ／ｃｈｅｃｋ ｐｏ ｉ ｎ ｔ
(2) Check that the stop bolts for the stop valves are
Steering is possible in either the right or left direction
(1) Check the oil level in the hydraulic tank.
Steering relief valve produces a noise
Check before starting work
Steering is not possible (or hard) in both the right and left directions
6. Steering is not possible or hard to steer
○ ○ ○
○
Disassembly &repair Disassembly &repair
Suction line is pinched or internally defective
○ Check &repair
Cold oil / viscosity too thick for weather
Warm up hydraulics ○ Replace oil w/proper oil
* Regarding check point above, exchange of the overload relief valve means that the valves should be changed between the ＊ Ｒｅｍａｒｋｓ
left and right sides. The problem will switch sides also (weak steering to the left will, after exchange, become weak steering to the right).
01-23
Machine sways, or a has shock during steering
115Z Ⅳ -2
QUICK TROUBLESHOOTING TABLE 01
Tire having different diameter
○
Large difference in air pressure of tires
○
Steering cylinders or circuit recently repaired
Shock is noticed only when steering fully to right or left
Use of equal diameter tires
○
Air pressure adjustment
○
Steering stopper bolt or bolts misadjusted or missing
Adjust stopper bolts
○
Roading the machine at too high speed ○
Ｓ ｏ ｌ ｕ ｔｉｏ ｎ Pin replacement or shim add
○ ○
Loose steering cylinder pin *
Air trapped in cylinders
Complaint is only while roading the machine
Shock is applied to the machine after quick steering
Ｐｏｓｓ ｉ ｂ ｌ ｅ ｃａｕｓｅ
Machine sways after quick steering
Ｓｙｍｐ ｔ ｏｍｓ／ｃｈｅｃｋ ｐｏ ｉ ｎ ｔ
7. Machine sways, or has a shock during steering
While the machine is travelling straight, the machine sways even if the steering wheel is held steady
Hydraulic Group
○
Reduce speed
○
Steer full L & R several times to purge air
* Have an operator quickly move the steering wheel right and left a few degrees. If the cylinder pin moves back & forth
＊ Ｒｅｍａｒｋｓ
replace the pin & bushings. If the cylinders jump up & down add shims.
01-24
115Z Ⅳ -2
Abnormal noise in hydraulic system
QUICK TROUBLESHOOTING TABLE 01
Hydraulic Group
Air drawn into pump suction line Internally broken pump
○
Noise may vary with engine speed or circuit being used
Increasing the engine speed emits a whining sound-Hydraulics slow
Ｐｏｓｓ ｉ ｂ ｌ ｅ ｃａｕｓｅ
Pump emits a shrieking sound
Ｓｙｍｐ ｔ ｏｍｓ／ｃｈｅｃｋ ｐｏ ｉ ｎ ｔ
8. Abnormal noise in hydraulic system
○ ○
High-pressure hose contact with chassis-loose sheet metal
Ｓ ｏ ｌ ｕ ｔｉｏ ｎ Hose band tightening and inspection Disassembly&repair
○
Hose clamp check and repair
Suction hose pinched or internally defective
○ ○
Inspect or replace hose
Suction line restricted
○ ○
Drain & inspect tank
01-25
115Z Ⅳ -2
Others
QUICK TROUBLESHOOTING TABLE 01
○
Disassembly&repair
○
Malfunctioning multiple control valve or pilot valve are sticking
Disassembly&repair
○
Disassembly&repair Tightening hose band
○
Air drawn into pump suction line
Pump disassembly and repair
○
Damaged hydraulic oil pump Pilot relief valve defective or misadjusted(pilot pressure too low) Excessive hydraulic oil temp, due to cooler problems or improper operation
Adjust or repair pilot relief
○
Cooler bypass valve stuck open
Ｓｏｌｕｔｉｏｎ Disassembly&repair
○
Clogged orifice of slow return check valve in boom line*
Oil milky white
Hydraulic cylinder packings leak repeatedly
When boom lever is set to "FLOAT" the boom goes only into power down. (Engine may stall)
Hydraulic oil is mixed with the torque converter oil
Hydraulic oil is foaming
Boom or bucket control lever is too tight or too loose
When the boom lever is switched from "DOWN" to "NEUTRAL", the boom will continue to lower*
Ｐｏｓｓ ｉ ｂ ｌ ｅ ｃａｕｓｅ
Defective (incompletely closed) load check valve in multiple control valve boom line Defective(incompletely closed)load check valve in multiple control valve bucket line
When the bucket lever is set to "Roll-back" position, the bucket will be dumped slightly down first and then tilt back
Ｓｙｍｐ ｔ ｏｍｓ／ｃｈｅｃｋ ｐｏ ｉ ｎ ｔ
9. Others
When the boom lever is set to "UP" position, the boom will drop slightly first and then rise
Hydraulic Group
○
Test cooling Change operation
○
Remove & clean or replace
○ Drain & replace oil
Water in hydraulic oil
* Very cold or thick oil will also cause this symptom. If the problem stops when the oil warms up or the proper viscosity oil is ＊ Ｒｅｍａｒｋｓ
used the orifice is normal. Clogged slow return orifice will cause slow boom response in both up and down directions. (S/N 11C3-5701〜)
01-26
115Z Ⅳ -2
Brake does not work well
QUICK TROUBLESHOOTING TABLE 01
(2) Check the brake oil level. (3) Check the brake piping for leakage
Ｐｏｓｓ ｉ ｂ ｌ ｅ ｃａｕｓｅ
Worn brake disk
Machine turns when the brake is applied suddenly (the steering wheel slips from your hands)
accumulator.
Ｓｙｍｐ ｔ ｏｍｓ／ｃｈｅｃｋ ｐｏ ｉ ｎ ｔ
(1) Check the Nitrogen gas pressure in the
When the brake pedal is pressed, the brake oil pressure of the front axle greatly differs from that of the rear axle.
Check before starting work
Both the right and left pedals have low braking resistance when pressed
at all)
The brake oil pressure from the right hand side of the auto adjuster valve greatly differs from the left hand side of that.
1. Brake does not work well (In the worst case, the brake does not work
Measure the wear of the brake disk using calipers. The obtained wear value is less than the specified limit value.
Brake Group
○
Disassembly&repair
Defective hydro-master (S/N 11C3-5501〜5600)
○
Damaged brake oil pipe
○
○
Damaged brake piston seals one wheel
○
○
Disassembly&repair
○
○
Insufficient Nitrogen gas pressure in accumulator ○
01-27
Pipe replacement Test leakage
○
Improperly aligned oil passages inside wheel hub Defective auto adjuster valve
Ｓ ｏ ｌ ｕ ｔｉｏ ｎ
Remove & realign Disassembly&repair
○
Disassembly&repair
115Z Ⅳ -2
Brake is dragging when released
QUICK TROUBLESHOOTING TABLE 01
Brake Group 2. Brake is dragging when released
Check before starting work (1) Check that the solenoid valve for auto brake is
Use of fluids other than those recommended will cause premature brake failure or inadequate braking.
Ｐｏｓｓ ｉ ｂ ｌ ｅ ｃａｕｓｅ Stepping on brake pedal during traveling (Riding the brakes)
Manual rotation of the tire is not possible
WARNING
Either the left or right wheel causes dragging
hot(more than 100 ° C [212 °F]). (2) Jack up the tires, and check that manual rotation of
Either the front or rear axle causes dragging
(1) Check that the cover of the planetary gear is too
Manual rotation of the tire is possible
How to check dragging:
Ｓｙｍｐ ｔ ｏｍｓ／ｃｈｅｃｋ ｐｏ ｉ ｎ ｔ
released. (2) Check the type of the brake oil
○
Ｓ ｏ ｌ ｕ ｔｉｏ ｎ Instruction for operator
Insufficient return of brake pedal
○
Disassembly&repair
Incomplete air bleeding from the brake oil circuit (hydro master section) (S/N 11C3-5501〜5600) Incomplete air bleeding from the brake circuit (axle shaft end) Insufficient brake oil return due to defective hydro master check valve (S/N 11C3-5501〜5600) Insufficient return of hydro master piston (S/N 11C3-5501〜5600)
○
Disassembly, repair, and air bleeding Disassembly, repair, and air bleeding
○ ○
Disassembly&repair
○
Disassembly&repair
Distorted brake disk due to seizure
○
Disassembly&repair
Non-returned brake piston after replacement of brake disk
○
Disassembly&repair
Insufficient brake oil return due to defective auto adjuster valve
○
Disassembly&repair
○
Insufficient return of brake piston
01-28
Disassembly&repair
Brake oil level lowers too much
115Z Ⅳ -2
QUICK TROUBLESHOOTING TABLE 01
Brake Group (S/N 11C3-5501〜5600)
Check before starting work (1) Check the type of the brake oil.
Oil is leaking from the air bleeder screw
Ｐｏｓｓ ｉ ｂ ｌ ｅ ｃａｕｓｅ
Oil leakage from front brake piston seal (flaw or swelling) Oil leakage from rear brake piston seal (flaw or swelling) Oil leakage from front axle end "O" ring seal (flaw or swelling) Oil leakage from rear axle end "O" ring seal (flaw or swelling)
Oil level of the brake oil tank lowers
Use of fluids other than those recommended will cause premature brake failure or inadequate braking.
Oil level of the brake oil tank lowers
WARNING
Ｓｙｍｐ ｔ ｏｍｓ／ｃｈｅｃｋ ｐｏ ｉ ｎ ｔ
(2) Check for brake oil leakage (External).
Oil tank level drops to, or below, "MIN" when brake is applied. It returns to "MAX" when brake is released.
3. Brake oil level lowers too much
○
Ｓ ｏ ｌ ｕ ｔｉｏ ｎ Disassembly&repair
○
Disassembly&repair
○
Disassembly&repair
○
Disassembly&repair Re-bleeding air, tighten
○
Loose bleeder screw
○
Brake plates warped in one or more wheels
01-29
Disassembly & repair
115Z Ⅳ -2
Stepping on brake pedal sounds buzzer
QUICK TROUBLESHOOTING TABLE 01
Ｐｏｓｓ ｉ ｂ ｌ ｅ ｃａｕｓｅ
Parking brake is not released
(S/N 11C3-5501〜5600) (3) Step on the pedal, and check that oil is not leaking.
Auto brake does not work well
(2) Check the oil level of the brake oil tank.
the normal area when pedal is released.
(1) Check the accumulator Nitrogen gas pressure
External pipe is oily, leaking
Check before starting work:
Oil level of the brake oil tank lowers too rapidly
(S/N 11C3-5501〜5600)
Unloader valve on-load pressure is too low
[1.5MPa (15kgf/cm2) (213 psi) or more].
Too much time is required for accumulator gas charging
seconds or more).(S/N 11C3-5501〜5600) (3) Hydro master pressure difference
Buzzer sounds each time the brake pedal is stepped on
(2) Low oil level of brake oil tank (buzzer sounds for 3
Ｓｙｍｐ ｔ ｏｍｓ／ｃｈｅｃｋ ｐｏ ｉ ｎ ｔ
[3.9MPa (40kgf/cm2) (568 psi) or less].
Buzzer sounds when the pedal is repeatedly depressed
(1) Low accumulator pressure
Pedal resistance is too low when depressed
Conditions for buzzer sounding:
Pressure difference switch of either the front or rear axle is actuated
4. Stepping on the brake pedal sounds the buzzer
Oil tank level drops to, or below, "MIN" mark when pedal is applied. It returns to
Brake Group
Ｓ ｏ ｌ ｕ ｔｉｏ ｎ
Insufficient Nitrogen gas pressure in main accumulator
○ ○
○ ○ Adjust gas pressure
Insufficient Nitrogen gas pressure in accumulator for F/R axle
○ ○
Adjust gas pressure
Defective unloader valve
○ ○ ○
Inspection & readjustment
Large amount of oil leakage due to defective seal around ○ ○ ○ brake piston
○
Disassembly&repair
Brake oil piping damaged or loose
○ ○
Repair / tighten
○
Brake plates warped in one or more wheels ○
Defective low oil pressure warning switch Defective pressure difference switch
Replace switch
○ ○
Replace switch
○
Defective pilot pump
01-30
Disassembly&repair
Replace pump
Accumulator pressure does not rise, or too slow
115Z Ⅳ -2
QUICK TROUBLESHOOTING TABLE 01
Brake Group
Defective unloader valve
Ｓｏｌｕｔ ｉｏｎ Inspection & readjustment
○ ○
Internally damaged accumulator Defective pilot pump
Low accumulator pressure in a certain accumulator only
Ｐｏｓｓ ｉ ｂ ｌ ｅ ｃａｕｓｅ
Low accumulator pressure in all three accumulators
Ｓｙｍｐ ｔ ｏｍｓ／ｃｈｅｃｋ ｐｏ ｉ ｎ ｔ
5. Accumulator pressure does not rise, or too slow in rising.
○
01-31
Disassembly &repair Replace pump
115Z Ⅳ -2
Parking brake does not work
QUICK TROUBLESHOOTING TABLE 01
Defective coil of parking solenoid valve
○
Sticking spool of parking solenoid valve
○ ○
Oil leaking from line between solenoid valve and hydraulic cylinder Defective parking brake switch
Accumulator pressure in main accumulator is low
Even if the manual release knob of solenoid valve for auto brake is pushed in, the auto brake does not work
○
Solenoid valve replacement
○
Inspection&repair
○ ○
○
Switch replacement
○
○
Repair cable
○ ○
Defective link between hydraulic cylinder and brake drum ○ ○ Worn brake lining
Ｓ ｏ ｌ ｕ ｔｉｏ ｎ Solenoid valve replacement
○
○
Disconnected or defective electrical line Sticking hydraulic cylinder
○
Heavy movement of solenoid valve manual release knob
Ｐｏｓｓ ｉ ｂ ｌ ｅ ｃａｕｓｅ
Coil of the solenoid valve has extremely high or zero resistance
Unexpected movement of the machine may cause an accident resulting in injury or death. To prevent such an accident, observe the following caution when manually releasing the parking brake : ・ Apply the foot brake, and the machine will not move even if the parking brake is manually released. ・ If the foot brake cannot be applied chock the wheels to prevent the machine from moving.
Turning off the parking brake switch causes a solenoid valve emitting noise
WARNING
Ｓｙｍｐ ｔ ｏｍｓ／ｃｈｅｃｋ ｐｏ ｉ ｎ ｔ
(2) Check the main accumulator pressure.
Turning off the parking brake switch activates the link under the cylinder
(1) Check the fuses of the electrical system.
Parking brake remains unreleased
Check before starting work:
Brake does not work even if the parking switch is turned to "ON" position
6. Parking brake does not work (or: Releasing the brake is not possible)
Setting the manual release knob of the solenoid valve to ON releases the parking brake (see "WARNING")
Brake Group
○ ○
01-32
○
Inspection&repair
○ ○
Inspection&repair
○ ○
Readjustment
○
○
Inspection&repair
115Z Ⅳ -2
Auto brake does not work
QUICK TROUBLESHOOTING TABLE 01
Defective controller
○
Defective machine speed sensor
○
Disconnected or defective electrical line
○
Defective coil of auto brake solenoid valve
○
○
○
Defective service brake system
01-33
Controller output LED "BRK" will not light even when shifted to reverse/forward with machine high speed
Ｓ ｏ ｌ ｕ ｔｉｏ ｎ
○
Replacement
○
Replacement Inspection&repair
○
Sticking spool of auto brake solenoid valve Accumulator pressure in main accumulator is low
Coil of the solenoid valve has extremely high resistance
Ｐｏｓｓ ｉ ｂ ｌ ｅ ｃａｕｓｅ
Automatic speed change is unstable
Ｓｙｍｐ ｔ ｏｍｓ／ｃｈｅｃｋ ｐｏ ｉ ｎ ｔ
(2) Check the main accumulator pressure.
Heavy movement of the manual release knob of solenoid valve for auto brake
(1) Check the fuses of the electrical system.
Brake does not work well even when the brake pedal is pressed
Check before starting work
It is not possible to release the parking brake
7. Auto brake does not work
Auto brake works when the manual release knob of solenoid valve for auto brake is pushed in
Brake Group
Replacement Inspection&repair
○ ○
Inspection&repair
○
Inspection&repair
115Z Ⅳ -2
Engine hard to start or will not start
QUICK TROUBLESHOOTING TABLE 01
1. Engine hard to start or will not start
Before testing: Transmission shift lever must be in "NEUTRAL"
Ｅ ｌ ｅｃ ｔ ｒ ｉ ｃａ ｌ ｓｙｓ ｔ ｅｍ
Ｐｏｓｓ ｉ ｂ ｌ ｅ ｃａｕｓｅ
Cranking speed too low (100 rpm or less)
Machine may start & move suddenly during testing causing serious injury or death. ・ Never attempt to start the machine from the ground. ・ Securely chock the wheels to prevent movement.
Starter motor does not operate
WARNING
Ｓｙｍｐ ｔ ｏｍｓ／ｃｈｅｃｋ ｐｏ ｉ ｎ ｔ
position.
When the starter switch is set to ON, the magnetic switch emits a chattering or clicking sound
Electrical Group
Ｓ ｏ ｌ ｕ ｔｉｏ ｎ
Fusible link is blown / removed
○
Inspection&repair
Diode pack (Cummins) blown / removed
○
Inspection&repair
Battery relay is defective
○
Inspection&repair
Neutral relay is defective
○
Inspection&repair
Battery charge low
○ ○
Starting circuit connections loose or corroded
○
Inspection&repair
Disconnected electrical wiring
○
Inspection&repair
Defective starter motor
○ ○
Inspection&repair
Defective starter switch or starter relay
○
Inspection&repair
Engine oil is too thick for cold weather
○
01-34
○
Battery charge
Change oil&viscosity
115Z Ⅳ -2
Engine will not stop
QUICK TROUBLESHOOTING TABLE 01
(or: Starting the engine is not possible.) Check before starting work: (If the fusible link (30A) is failed, the engine can not be started.)
Ｓｙｍｐ ｔ ｏｍｓ／ｃｈｅｃｋ ｐｏ ｉ ｎ ｔ
(1) Check the fusible link (30A) for failed condition.
Ｐｏｓｓ ｉ ｂ ｌ ｅ ｃａｕｓｅ
Defective starter switch
Once stopped the engine will not start
2. Engine will not stop even if the starter switch is turned to "OFF".
Power will be continuously supplied to the starter switch B-BR terminal even if the starter switch is turned off
Electrical Group
○
Ｓ ｏ ｌ ｕ ｔｉｏ ｎ Switch replacement
Wiring error between units
Inspection&repair
○
Defective diode unit (shortcircuited diode) at battery relay
01-35
Diode replacement
Instrument panel does not indicate properly
115Z Ⅳ -2
QUICK TROUBLESHOOTING TABLE 01
Bulb of monitor lamp burnt out
Speed indicated on the instrument panel does not correspond with the speed set by the shift lever
T/M(transmission) solenoid valve does not operate based on the speed set by the shift lever
Hour meter does not operate
Pointers of all the gauges are deflected to their limits
○
Ｓ ｏ ｌ ｕ ｔｉｏ ｎ Bulb replacement
○
Defective sensor or improper wiring Disconnected or defective electrical circuit
One of the gauges does not indicate properly *
Ｐｏｓｓ ｉ ｂ ｌ ｅ ｃａｕｓｅ
All the gauge pointers do not move
controlled by rocker or toggle switches.
Pointer of the tachometer does not move
lamps-not green or amber lamps which are
One of the gauge pointers does not move
The lamp test circuit tests only the red warning
Ｓｙｍｐ ｔ ｏｍｓ／ｃｈｅｃｋ ｐｏ ｉ ｎ ｔ
(2) Lamp test
During operation, two or more monitor lamps light improperly *
(1) Check the fuses.
During operation, one of the monitor lamps lights improperly *
Check before starting work
One of the monitor lamps will not light after setting the starter key to ON
3. Instrument panel does not indicate properly
Two or more monitor lamps will not light after setting the starter key to ON
Electrical Group
○ ○
○ ○
○
Sensor replacement
○ ○ ○
○ ○ ○
Repairing cable
○
○ ○
Connector check and re-connection
Loose connector
○
○
T/M controller breaker turned off
○
Inspection&repair
T/M controller failure alarm turned on
○
Inspection&repair
Defective T/M controller
○ ○ ○
○ ○ ○
Defective inside mechanism of gauge or meter
○ ○ ○ ○
Defective board of instrument panel
Controller replacement Replacement Replacement
○ ○ Properly connect
T/M solenoid valves improperly connected
＊ Ｒｅｍａｒｋｓ
* If the gauge and warning lamps do not agree there probably is a defect in the wiring. Stop immediately and diagnose the defect.
01-36
115Z Ⅳ -2
Breaker of the transmission controller
QUICK TROUBLESHOOTING TABLE 01
Clutch solenoid valve power line contact with chassis (Wire chaffed or pinched by other components, etc.) Clutch solenoid valve power line occasional contact with chassis
○
Clutch solenoid valve coil shortcircuited
○
Clutch solenoid valve diode failed
○
Neutral relay power line contact with chassis
○
Monitor controller power line occasional contact with chassis Parking brake solenoid valve power line contact with chassis Parking brake solenoid valve power line occasional contact with chassis
Parking brake remains unreleased regardless of the parking brake switch position
Breaker is turned off when a certain speed or direction is selected
Both the forward and reverse shift lever position enable the engine to start
Coil of the solenoid valve has extremely low resistance
○
Ｓ ｏ ｌ ｕ ｔｉｏ ｎ Inspection&repair
○
Inspection&repair
○
Solenoid valve replacement
○
Solenoid valve replacement
○ ○
Inspection&repair
○
Neutral relay power line occasional contact with chassis Monitor controller power line contact with chassis
Breaker is turned off if the machine sways during travelling
Ｐｏｓｓ ｉ ｂ ｌ ｅ ｃａｕｓｅ
Breaker is turned off immediately after turning on
Ｓｙｍｐ ｔ ｏｍｓ／ｃｈｅｃｋ ｐｏ ｉ ｎ ｔ
4. Breaker of the transmission controller is turned off
In the solenoid valve continuity test, change the positive and negative sides to each other. After that, power is still supplied to the solenoid valve
Electrical Group
Inspection&repair
○
Inspection&repair
○ ○
Inspection&repair
○ ○
01-37
Inspection&repair Inspection&repair
MEASUREMENT FOR PERFORMANCE CHECK 03 Standard Measurement Values for Performance Check ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 03-2 Preparation for Performance Check ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 03-8 Measuring Engine Speed ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 03-10 Oil Pressure Gauge Port with Quick Coupler ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 03-14 Measuring Clutch Oil Pressure and Time Lag ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 03-15 Measuring Cylinder Drift ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 03-17 Measuring Boom Cycle Time ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 03-19 Measuring Full Steering Cycle Time ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 03-20 Measuring Relief Valve Setting Pressures ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 03-21 Checking Brake Performance ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 03-25 Measuring Brake Line Setting Pressure ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 03-27 Measuring Brake Pressure Difference Switch Setting Pressure ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 03-29 Measuring Accumulator Charging Time ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 03-30 Measuring Number of Brake Pedal Applications ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 03-32 Measuring Declutch Engagement ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 03-33 Measuring Radiator Cooling Capability ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 03-34
03-1
115Z Ⅳ -2
Standard Measurement Values
MEASUREMENT FOR PERFORMANCE CHECK 03
Standard Measurement Values for Performance Check (S/N 11C3-5501〜5600) Measurement conditions : Temperature of torque converter oil : 50 to 80 ° C (120〜180 ° F) Temperature of hydraulic oil : 50 to 80 ° C (120〜180 ° F) Temperature of engine coolant : 50 to 80 ° C (120〜180 ° F) Item Measurement item
Standard measurement values for performance check
Minimum no-load speed, Low Idle (LI)
800 ± 50
Maximum no-load speed, High Idle (HI)
2,250 ± 50
Maximum speed in torque converter stall mode
2,070 ± 100
Maximum speed in multiple control valve relief mode
2,000 ± 100
Maximum speed in torque converter stall plus multiple control valve relief mode Maximum speed in torque converter stall plus steering valve relief mode
1,510 ±150 100
Engine
System
Engine speed ( min-1)(rpm)
Remarks
1,790 ±150 100
1st speed
2.2-2.3 (22-23) (313-327)
Except 1st speed
2.5-2.6 (25-26) (356-370)
1st speed
2.5-2.6 (25-26) (356-370)
Except 1st speed
2.7-2.9 (27-30) (384-427)
Transmission
Low idle Clutch pressure MPa (kgf/cm2) (psi)
Engine speed High idle
Clutch time lag (sec)
Neutral → Forward 1st speed (engine speed: 1500 min-1(rpm))
Cylinder drift (when boom and bucket are Boom cylinder horizontal and with no load) (mm/min) Bucket cylinder (in/min)
Hydraulic pressure
Boom rising time (no load) (sec)
Full steering time (sec)
Engine speed
4 (5/32) or less 23 ± 3.0
-1
1500 min (rpm)
10.5 ± 1.0
Maximum (HI)
8.1 ± 0.5
Idling (LI)
5 ± 0.5
1500 min-1(rpm)
3.9 ± 0.3
Maximum (HI)
3.9 ± 0.3 20.6 ± 1.0 (210 ± 10) (2,990 ± 142)
Loading line main relief pressure (HI)
Loading line overload relief pressure (LI)
Relief valve setting pressure MPa (kgf/cm2 ) (psi)
Before wheels move
3 (1/8) or less
Idling (LI) Engine speed
0.3 ± 0.1
Steering line main relief pressure (HI)
+ 0.5 23.5-1.0 (240 -1+05 ) (3,410 -1+4271 )
Run engine at lowest possible speed while setting
20.6 ± 1.0 (210 ± 10) (2,990 ± 142) +5
Steering line overload relief pressure (LI)
+ 0.5 24.5-1.0 (250-10 ) (3,560 -1+4271 )
Relief valve (LI)
4.0 ± 0.3 (41 ± 3) (583 ± 43)
Reducing valve (engine stop)
1.5 ± 0.3 (15 ± 3.5) (213 ± 50)
Pilot line
03-2
Run engine at lowest possible speed while setting
115Z Ⅳ -2
Standard Measurement Values
MEASUREMENT FOR PERFORMANCE CHECK 03
Item System
Standard measurement values for performance check
Measurement item Performance of service brake
Performance of parking brake
Shift lever position 2nd speed reverse Engine speed
Maximum (HI)
↑ Maximum (HI) Off
11.8 ± 0.5 (120 ± 5) (1,710 ± 71)
On
6.9 ± 1.0 (70 ± 10) (995 ± 142)
Brake
Unloader valve setting pressure Brake line setting pressure 2 MPa (kgf/cm )(psi)
Accumulator charge time (sec)
Number of brake pedal applications
Declutch engagement (cm) (in)
Hydro-master switch pressure difference
1.5 ± 0.3 (15 ± 3) (210 ± 40)
Low-pressure alarm switch setting pressure
3.9 ± 0.3 (40 ± 3) (569 ± 43)
Engine speed (LI)
Hydraulic oil
Radiator
The time from the low-pressure alarm is turned off till the unloading valve cuts off pressure
Before brake check, be sure to disconnect the cable connector of parking brake solenoid valve
22 ± 5
Run engine 1 minute high idle, then stop the engine. Step on the brake pedal and release, and check the number of times until the low-pressure alarm is turned on.
10 times or more
Repeat stepping on the brake pedal as follows: On : 5 sec. Off : 5 sec.
Engine: Maximum speed / Inching pedal: Quick release
15 (6) or less
1/5 slope (approx. 11°), unladen, 1st speed
Engine cooling water
Torque converter oil
Slowly increase the engine speed, and check that the machine does not move at the maximum engine speed.
Shift lever position 2nd speed forward Engine speed
Remarks
Balanced temperature when engine is at HI speed
Engine outlet temperature ( ℃ )
40〜45 ° C above air temperature F) above air temperature (72〜81 °
Temperature difference between radiator inlet and outlet ( ℃ )
10〜15
Temperature difference between radiator inlet and outlet ( ℃ )
3〜5
03-3
115Z Ⅳ -2
Standard Measurement Values
MEASUREMENT FOR PERFORMANCE CHECK 03
Standard Measurement Values for Performance Check (S/N 11C3-5601〜5700) Measurement conditions : Temperature of torque converter oil : 50 to 80 ° C (120〜180 ° F) Temperature of hydraulic oil : 50 to 80 ° C (120〜180 ° F) Temperature of engine coolant : 50 to 80 ° C (120〜180 ° F) Item Measurement item
Standard measurement values for performance check
Minimum no-load speed, Low Idle (LI)
800 ± 50
Maximum no-load speed, High Idle (HI)
2,250 ± 50
Maximum speed in torque converter stall mode
2,070 ± 100
Maximum speed in multiple control valve relief mode
2,000 ± 100
Maximum speed in torque converter stall plus multiple control valve relief mode Maximum speed in torque converter stall plus steering valve relief mode
1,510 ±150 100
Engine
System
Engine speed ( min-1)(rpm)
Remarks
1,790 ±150 100
1st speed
2.2-2.3 (22-23) (313-327)
Except 1st speed
2.5-2.6 (25-26) (356-370)
1st speed
2.5-2.6 (25-26) (356-370)
Except 1st speed
2.7-2.9 (27-30) (384-427)
Transmission
Low idle Clutch pressure MPa (kgf/cm2) (psi)
Engine speed High idle
Clutch time lag (sec)
Neutral → Forward 1st speed (engine speed: 1500 min-1(rpm))
Cylinder drift (when boom and bucket are Boom cylinder horizontal and with no load) (mm/min) Bucket cylinder (in/min)
Hydraulic pressure
Boom rising time (no load) (sec)
Full steering time (sec)
Engine speed
4 (5/32) or less 23 ± 3.0
-1
1500 min (rpm)
10.5 ± 1.0
Maximum (HI)
8.1 ± 0.5
Idling (LI)
5 ± 0.5
1500 min-1(rpm)
3.9 ± 0.3
Maximum (HI)
3.9 ± 0.3 20.6 ± 1.0 (210 ± 10) (2,990 ± 142)
Loading line main relief pressure (HI)
Loading line overload relief pressure (LI)
Relief valve setting pressure MPa (kgf/cm2 ) (psi)
Before wheels move
3 (1/8) or less
Idling (LI) Engine speed
0.3 ± 0.1
Steering line main relief pressure (HI)
Steering line overload relief pressure (LI)
+ 0.5 23.5 -1.0 (240 -1+05 ) (3,410 -1+4271 )
20.6 ± 1.0 (210 ± 10) (2,990 ± 142) + 0.5 24.5 -1.0 (250 -1+05 ) (3,560 -1+4271 )
Relief valve (LI)
4.0 ± 0.3 (41 ± 3) (583 ± 43)
Reducing valve (engine stop)
1.5 ± 0.3 (15 ± 3.5) (213 ± 50)
Pilot line
03-4
Run engine at lowest possible speed while setting
Run engine at lowest possible speed while setting
115Z Ⅳ -2
Standard Measurement Values
MEASUREMENT FOR PERFORMANCE CHECK 03
Item System
Standard measurement values for performance check
Measurement item Performance of service brake
Performance of parking brake
Brake
Brake line setting pressure MPa (kgf/cm2)(psi)
Shift lever position 2nd speed reverse Engine speed
Maximum (HI)
↑ Maximum (HI) Off
11.8 ± 0.5 (120 ± 5) (1,710 ± 71)
On
6.9 ± 1.0 (70 ± 10) (995 ± 142)
Unloader valve setting pressure
Low-pressure alarm switch setting pressure Accumulator charge time (sec)
Engine speed (LI)
The time from the low-pressure alarm is turned off till the unloading valve cuts off pressure
Brake valve pressure difference at brake Differential pressure between front wheel and rear wheel valve MPa (kgf/c m 2 ) (psi)
Number of brake pedal applications
Declutch engagement (cm) (in)
Hydraulic oil
Radiator
Before brake check, be sure to disconnect the cable connector of parking brake solenoid valve
3.9 ± 0.3 (40 ± 3) (569 ± 43) 22 ± 5
1.5 ± 0.3 (15 ± 3) (213 ± 43) or more
Run engine 1 minute high idle, then stop the engine. Step on the brake pedal and release, and check the number of times until the low-pressure alarm is turned on.
10 times or more
Repeat stepping on the brake pedal as follows: On : 5 sec. Off : 5 sec.
Engine: Maximum speed / Inching pedal: Quick release
15 (6) or less
1/5 slope (approx. 11°), unladen, 1st speed
Engine cooling water
Torque converter oil
Slowly increase the engine speed, and check that the machine does not move at the maximum engine speed.
Shift lever position 2nd speed forward Engine speed
Remarks
Balanced temperature when engine is at HI speed
Engine outlet temperature ( ℃ )
C above air temperature 40〜45 ° F) above air temperature (72〜81 °
Temperature difference between radiator inlet and outlet ( ℃ )
10〜15
Temperature difference between radiator inlet and outlet ( ℃ )
3〜5
03-5
115Z Ⅳ -2
Standard Measurement Values
MEASUREMENT FOR PERFORMANCE CHECK 03
Standard Measurement Values for Performance Check (S/N 11C3-5701〜) Measurement conditions : Temperature of torque converter oil : 50 to 80 ° C (120〜180 ° F) Temperature of hydraulic oil : 50 to 80 ° C (120〜180 ° F) Temperature of engine coolant : 50 to 80 ° C (120〜180 ° F) Item Measurement item
Standard measurement values for performance check
Minimum no-load speed, Low Idle (LI)
800 ± 50
Maximum no-load speed, High Idle (HI)
2,250 ± 50
Maximum speed in torque converter stall mode
2,070 ± 100
Maximum speed in multiple control valve relief mode
2,000 ± 100
Maximum speed in torque converter stall plus multiple control valve relief mode Maximum speed in torque converter stall plus steering valve relief mode
1,510 ±150 100
Engine
System
Engine speed ( min-1)(rpm)
Remarks
1,790 ±150 100
1st speed
2.2-2.3 (22-23) (313-327)
Except 1st speed
2.5-2.6 (25-26) (356-370)
1st speed
2.5-2.6 (25-26) (356-370)
Except 1st speed
2.7-2.9 (27-30) (384-427)
Transmission
Low idle Clutch pressure MPa (kgf/cm2) (psi)
Engine speed High idle
Clutch time lag (sec)
Neutral → Forward 1st speed (engine speed: 1500 min-1(rpm))
Cylinder drift (when boom and bucket are Boom cylinder horizontal and with no load) (mm/min) Bucket cylinder (in/min)
Hydraulic pressure
Boom rising time (no load) (sec)
Full steering time (sec)
Engine speed
4 (5/32) or less 23 ± 3.0
-1
1500 min (rpm)
10.5 ± 1.0
Maximum (HI)
8.1 ± 0.5
Idling (LI)
5 ± 0.5
1500 min-1(rpm)
3.9 ± 0.3
Maximum (HI)
3.9 ± 0.3 20.6 ± 1.0 (210 ± 10) (2,990 ± 142)
Loading line main relief pressure (HI)
Loading line overload relief pressure (LI) Relief valve setting pressure MPa (kgf/cm2 ) (psi)
Steering line main relief pressure (HI)
Steering line overload relief pressure (LI)
Pilot line
Before wheels move
3 (1/8) or less
Idling (LI) Engine speed
0.3 ± 0.1
+ 0.5 23.5-1.0 (240-1+05 ) (3,410 -1+4271 )
20.6 ± 1.0 (210 ± 10) (2,990 ± 142) + 0.5 24.5-1.0 (250 -1+05 ) (3,560 -1+4271 )
4.0 ± 0.3 (41 ± 3) (583 ± 43)
Relief valve (LI)
03-6
Run engine at lowest possible speed while setting
Run engine at lowest possible speed while setting
115Z Ⅳ -2
Standard Measurement Values
MEASUREMENT FOR PERFORMANCE CHECK 03
Item System
Measurement item Performance of service brake
Performance of parking brake
Brake
Standard measurement values for performance check
Brake line setting pressure 2 MPa (kgf/cm )(psi)
Shift lever position 2nd speed reverse Engine speed
Maximum (HI)
↑ Maximum (HI) Off
11.8 ± 0.5 (120 ± 5) (1,710 ± 71)
On
6.9 ± 1.0 (70 ± 10) (995 ± 142)
Unloader valve setting pressure
Low-pressure alarm switch setting pressure Accumulator charge time (sec)
Number of brake pedal applications
Declutch engagement (cm) (in)
Engine speed (LI)
Hydraulic oil
Radiator
The time from the low-pressure alarm is turned off till the unloading valve cuts off pressure
Before brake check, be sure to disconnect the cable connector of parking brake solenoid valve
3.9 ± 0.3 (40 ± 3) (569 ± 43) 22 ± 5
Run engine 1 minute high idle, then stop the engine. Step on the brake pedal and release, and check the number of times until the low-pressure alarm is turned on.
10 times or more
Repeat stepping on the brake pedal as follows: On : 5 sec. Off : 5 sec.
Engine: Maximum speed / Inching pedal: Quick release
15 (6) or less
1/5 slope (approx. 11°), unladen, 1st speed
Engine cooling water
Torque converter oil
Slowly increase the engine speed, and check that the machine does not move at the maximum engine speed.
Shift lever position 2nd speed forward Engine speed
Remarks
Balanced temperature when engine is at HI speed
Engine outlet temperature ( ℃ )
40〜45 ° C above air temperature F) above air temperature (72〜81 °
Temperature difference between radiator inlet and outlet ( ℃ )
10〜15
Temperature difference between radiator inlet and outlet ( ℃ )
3〜5
03-7
Preparation for Performance Check
115Z Ⅳ -2
MEASUREMENT FOR PERFORMANCE CHECK 03
Preparation for Performance Check WARNING
CAUTION
Unexpected movement of the machine may cause an accident resulting in injury or death. Therefore, to provide repair service with the engine running, be sure to observe the following items: ・ Park the machine on level ground. ・ Apply the parking brake. ・ Block the tires with chocks to prevent the tires from moving. ・ Determine the signals between the service men. ・ Prohibit any person from walking into dangerous areas. ・ Near articulation area of the machine ・ Under the machine ・ Around the engine ・ In front of or behind the machine
Do not touch the fan or V-belt of the engine or a high-temperature section if the engine is running. An accident resulting in injury may occur. Be sure to stop the engine before you open the side cover of the engine room. Keep all guards in place. Avoid high temperature components even when the engine is stopped.
・Preparation of measurement units ・ To measure pressure, be sure to prepare the hose, adapter, and wrench for pressure port plug in addition to the measurement instruments.
・Cautions regarding measurement ・ Take safety precautions before starting measurement work, and carefully measure and record the values. ・ Measure a value three times or more. If the obtained values greatly differs from each other, an error has been made in measuring the value. Measure the value again. Calculate the average value from the various readings.
・ Check operation of the measurement instruments. Carefully handle the instruments. If something comes in contact with an instrument or large shock is applied to an instrument, the instrument may be damaged. In addition, periodic inspection of the instruments is also important. If the zero point of an instrument is not properly adjusted, the value indicated by the instrument may be wrong.
・Warm-up If the machine is too cold, measured values may be wrong. To prevent incorrect readings, be sure to warm up the machine until the torque converter oil, hydraulic oil, and engine coolant are heated to the specified temperature.
03-8
Preparation for Performance Check
115Z Ⅳ -2
・Procedure for warm-up
MEASUREMENT FOR PERFORMANCE CHECK 03
(140 ° F) (176 ° F) F) 60 ℃ 80 ℃ 100 ℃ (212 °
・ Torque converter oil temperature Perform torque converter stall operation by referring to "Stall speed measurement procedure". Check the approximate temperature using the temperature gauge in the instrument panel.
・ Hydraulic oil temperature Perform multiple control valve relief operation by referring to "Engine speed measurement procedure in multiple control valve relief mode". Check the approximate temperature using the contact thermometer attached to the outside surface of the hydraulic tank.
・ Engine coolant temperature Warming up the torque converter oil and hydraulic oil also warms up the engine. Check the engine coolant temperature using the temperature gauge in the instrument panel.
03-9
F) 110 ℃ (230 °
Torque converter oil temperature gauge
(140 ° F) (176 ° F) 60 ℃ 80 ℃ F) 90 ℃ (194 ° F) 110 ℃ (230 °
Engine coolant temperature gauge
115Z Ⅳ -2
Measuring Engine Speed
MEASUREMENT FOR PERFORMANCE CHECK 03
Measuring Engine Speed WARNING
CAUTION
Unexpected movement of the machine may cause an accident resulting in injury or death. Therefore, to provide repair service with the engine running, be sure to observe the following items: ・ Park the machine on level ground. ・ Apply the parking brake. ・ Block the tires with chocks to prevent the tires from moving. ・ Determine the signals between the service men. ・ Prohibit any person from walking into dangerous areas. ・ Near articulation area of the machine ・ Under the machine ・ Around the engine ・ In front of or behind the machine
Do not touch the fan or V-belt of the engine or a high-temperature section if the engine is running. An accident resulting in injury may occur. Be sure to stop the engine before you open the side cover of the engine room. Keep all guards in place. Avoid high temperature components even after the engine is stopped.
・Measurement instrument ・ Tachometer drive port Note : A tachometer is already provided on the instrument panel. ・Warm-up the engine before measuring the engine speed
・Standard measurement value (min-1) (rpm) Minimum no-load speed (LI)
800 ± 50
Maximum no-load speed (HI)
2,250 ± 50
Maximum speed in torque converter stall mode
2,070 ± 100
Maximum speed in multiple control valve relief mode
2,000 ± 100
Maximum speed in torque converter stall plus multiple control valve relief mode
1,510 ±150 100
Maximum speed in torque converter stall plus steering valve relief mode
1,790 ±150 100
03-10
Measuring Engine Speed
115Z Ⅳ -2
MEASUREMENT FOR PERFORMANCE CHECK 03
・Stall speed measurement procedure 1. Lower the boom to the lowest limit. Roll back the bucket fully until the bucket contacts to the stopper. 2. Record the High Idle (HI) engine speed. 3. Set the parking brake to the "OFF" position. 4. Press the right brake pedal all the way to the floor, and then set the transmission shift lever to the maximum forward speed position ("4"). Note : Cancel the auto shift mode. As a result the transmission shift lever"A" position works as "4" position. 5. Gradually increase the engine speed. Measure the engine speed when the accelerator pedal is fully pressed down.
IMPORTANT In the stall mode, the torque converter oil temperature rises rapidly. Therefore, long stall operation may damage the seals, and the damaged seal may cause oil leakage. This is why stall operation should be limited to 5 seconds. To repeat the stall operation, be sure to wait more than 5 seconds before next stall operation so that the torque converter oil is cooled enough. Using this cycle safely warms up cold oil.
6. Record the engine RPM at T/C stall. (During stall speed measurement, do not operate the steering system, boom, bucket, etc.) 7. Subtract T/C stall speed from HI speed.
・Engine speed measurement procedure in multiple control valve relief mode 1. Lower the boom to the lowest limit. Roll back the bucket fully until the bucket contacts to the stopper. 2. Set the parking brake to the "ON" position. 3. Set the engine speed to HI. 4. Place the bucket control lever in roll back position. Measure the engine speed.
IMPORTANT When the relief valve is activated, the oil temperature rises rapidly. Therefore, long relief operation may damage the seals or cause the plunger to stick inside the valve. This is why relief operation should be limited to 5 seconds. To repeat the relief operation, be sure to wait more than 5 seconds before next relief operation, and cool the inside of the valve. Using this cycle safely warms up cold oil.
03-11
115Z Ⅳ -2
Measuring Engine Speed
MEASUREMENT FOR PERFORMANCE CHECK 03
Unloader valve
・Engine speed measurement procedure in steering valve relief mode Measure the engine speed with the following procedure in the torque converter stall mode. 1. Lower the boom to the lowest limit. Roll back the bucket fully until the bucket contacts to the stopper.
WARNING Stop bolt Stop valve
Do not enter the articulation area of the machine if the engine is running. An accident resulting in injury or death may occur. To enter the articulation area, be sure to stop the engine, and remove the starter key. In addition, hang a "DO NOT START" tag on the steering wheel.
Steering valve
Stop bolt 115K03001
2. Slowly steer the machine fully to one side. Stop the engine. Remove the stopper bolt. Note : Record the extention amount of the stopper bolt so that it can be reset to the original length later. 3. Start the engine. Set the parking brake switch to the "OFF" position. 4. Steer the machine until the front and rear chassis contact each other. Increase the engine speed, and measure the maximum speed. Continue to turn the steering wheel while measuring and recording the engine speed. 5. Turn the machine full to the opposite direction and stop the engine.
6. Return the stopper bolt to the original position, and then tighten the locknut. To check that the stopper bolt is properly positioned, press the accelerator all the way to the floor, and then quickly turn the steering wheel. Check that the front and rear chassis has only light contact . If the front and rear chassis violently come in contact with each other, extend the stopper bolt. If the front and rear chassis do not come in contact with each other, shorten the stopper bolt.
・Cause of extremely high or low measurement value and solution Minimum no-load speed(HI) low
speed(LI)
or
maximum
Possible cause
no-load
Solution
Insufficient warm up
Warm up
Malfunctioning accelerator control link
Adjustment
Clogged fuel filter
Clean
Defective fuel pump
Repair
Defective fuel injection nozzle
Repair
Valve clearances incorrenct
Adjustment
Insufficient compression pressure
Repair
03-12
115Z Ⅳ -2
Measuring Engine Speed
The engine speed is too high in torque converter stall mode. Possible cause
Solution
Slipping transmission clutch or defect inside of transmission
Disassembly &repair
Defect inside torque converter
Disassembly & repair
MEASUREMENT FOR PERFORMANCE CHECK 03
The engine speed is too high in torque converter stall plus multiple control valve relief mode.
The engine speed is too low in torque converter stall mode.
Possible cause
Solution
Slipping transmission clutch or defect inside of transmission or T/C
Disassembly & repair
Relief pressure too low
Adjustment
Defective pump / pump seals
Disassembly & repair
Caused by reduction in engine power Possible cause
Solution
Clogged air cleaner element
Cleaning
Improper type of fuel Clogged fuel filter or suction strainer Frozen fuel / wax build up Malfunctioning accelerator control link
The engine speed is too low in torque converter stall plus multiple control valve relief mode. Possible cause
Fuel replacement Clean or replace Use antifreeze mixture Adjustment
Defective fuel pump
Repair
Defective fuel injector nozzle
Repair
Insufficient compression pressure
Repair
The engine speed is too high in multiple control valve relief mode.
Possible cause
Solution
Relief valve pressure too low
Adjustment or disassembly
Defective pump / pump seals
Disassembly & repair
The engine speed is too low in multiple control valve relief mode. Possible cause
Solution
Engine low power
Inspection & repair
Extremely high relief pressure of multiple control valve
Adjustment
03-13
Solution
Engine low power
Inspection & repair
Extremely high relief pressure of multiple control valve or steering valve
Adjustment
115Z Ⅳ -2
Oil Oil Pressure Pressure Gauge Gauge Port Port with with Quick Quick Coupler Coupler
MEASUREMENT FOR PERFORMANCE CHECK 03
Oil Pressure Gauge Port with Quick Coupler
C Detail
Relief valve
2
4
1
4
2
A Detail
1
3
(For USA Spec.)
115V03001
1. T/M clutch oil pressure 2. Hydraulic line oil pressure 3. Steering line oil pressure
4. Pilot line oil pressure
03-14
Measuring Clutch Oil Pressure&Time Lag
115Z Ⅳ -2
MEASUREMENT FOR PERFORMANCE CHECK 03
Measuring Clutch Oil Pressure and Time Lag WARNING Unexpected movement of the machine may cause an accident resulting in injury or death. Therefore, to provide repair service with the engine running, be sure to observe the following items: ・ Park the machine on level ground. ・ Apply the parking brake. ・ Block the tires with chocks to prevent the tires from moving. ・ Determine the signals between the service men. ・ Prohibit any person from walking into dangerous areas. ・ Near articulation area of the machine ・ Under the machine ・ Around the engine ・ In front of or behind the machine
・ Standard measurement value
Low idle Clutch pressure MPa (kgf/cm2) (psi)
Engine speed High idle
・ Measurement instruments:
Clutch time lag (sec)
・ Pressure gauge : 4.9MPa(50kgf/cm2)(711 psi) with 2〜3m(6〜10 ft. ) hose Pressure measurement port : 1st clutch PF1/4 Except 1st clutch PT3/8 ・ Tachometer ・ Stop watch
1st speed Except 1st 1st speed Except 1st
Neutral → 1st forward speed (engine speed : 1500min-1(rpm))
R clutch
L clutch
3rd speed clutch
2nd speed clutch
2.2-2.3 (22-23) (313-327) 2.5-2.6 (25-26) (356-370) 2.5-2.6 (25-26) (356-370) 2.7-2.9 (27-30) (384-427) 0.3 ± 0.1
・ Measure the engine speed and clutch oil pressure after warm-up ・ Clutch oil pressure measurement procedure 1. Lower the boom to the lowest limit, and lower the bucket onto the ground. 2. Set the parking brake to the "ON" position. 3. Set the transmission shift lever to the neutral position. 4. Stop the engine. Attach the pressure gauge to the pressure measurement port. Place the gauge inside the operator's area, start the engine. 5. As the clutch oil pressure rises just after the engine is started, adjust the engine to the specified speed before the pressure measurement. 6. Measure and record the pressure in each speed range. 7. Change the transmission speed range while keeping the shift lever at the neutral position. Check that the pressure instantaneously lowers just after speed change, and then rises to the original pressure again.
１１５ＺＡ３２−１６
3rd speed clutch
Main clutch
2nd speed clutch
1st speed clutch
１１５Ｋ０３００２
Ｔｒａｎｓｍｉ ｓｓ ｉ ｏｎ ｏ ｉ ｌｐ ｒ ｅｓｓｕ ｒ ｅｔ ｅｓ ｔ ｐｏｒ ｔｌ ｏｃａ ｔ ｉ ｏｎ
03-15
115Z Ⅳ -2
Measuring Clutch Oil Pressure&Time Lag
・Time lag measurement procedure: 1. Lower the boom to the lowest limit, and fully roll back the bucket until the bucket contacts to the stopper. 2. Set the parking brake switch to the "OFF" position. Do not apply the service brakes. 3. Set the transmission shift lever to the neutral 1st speed. 4. Keep the engine speed at 1,500min-1 (rpm). 5. Move the shift lever to the forward position. At the same time, start the stop watch to measure the time required before the machine moves. ・Possible causes for low clutch oil pressure and clutch time lag Clutch oil pressure
Possible cause
Solution
Malfunctioning modulator valve (1) operation
Inspection & repair
Malfunctioning modulator valve (2) operation
Inspection & repair
Defective controller
Replacement
Oil leakage from clutch
Disassembly & repair
Clutch time lag
Possible cause
Solution
Defective pressure difference sensor
Replacement
Malfunctioning modulator valve (1) operation
Inspection & repair
Malfunctioning modulator valve (2) operation
Inspection & repair
Defective controller
Replacement
Defective clutch
Disassembly & repair
03-16
MEASUREMENT FOR PERFORMANCE CHECK 03
WARNING Unexpected movement of the machine may cause an accident resulting in injury or death. To crawl under the machine, be sure to stop the engine, and block the tires with chocks to prevent them from moving. Give signals to the person in the cab during the work.
115Z Ⅳ -2
Measuring Cylinder Drift
MEASUREMENT FOR PERFORMANCE CHECK 03
Measuring Cylinder Drift WARNING Standing under the boom or bucket during service work is dangerous. An accident resulting in injury or death may be caused. To prevent such an accident, be sure to lock the boom and bucket control levers in the cab, securely support the boom, and remove the starter key. In addition, hang a "DO NOT OPERATE!" tag on the steering wheel.
・Measurement instrument ・ Scale : 150 to 300mm (1 ft.) ・ Stop watch ・ Black vinyl "electrician's" tape ・Warm-up the cylinder drift
hydraulic
oil
Reference :
before
measuring
Drift rate depends on the viscosity of the hydraulic oil and its temperature. In other words, high temperature of the hydraulic oil reduces the viscosity. Reduction in oil viscosity increases oil leakage through the seals, and increases the drift rate. Cold thick oil reduces the drift rate.
・Standard measurement value(mm/min) (in/min) Boom cylinder
3 (1/8) or less
Bucket cylinder
4 (5/32) or less
・Measurement procedure 1. Unload the bucket. 2. Keep the boom and bucket horizontal. 3. Set the parking brake switch to the "ON" position. 4. Lock the boom and bucket control levers using the safety lock. 5. Stop the engine. 6. Attach vinyl tape to the cylinder rod at a point 100 to 150mm (4 〜 6 in) away from the cylinder head cover. 7. Measure the accurate distance from the cylinder head cover to the vinyl tape. This is distance "A" mm (in). Measure the distance again 5 minutes later. This is distance "B" mm (in). A-B (mm) (in) Cylinder drift (mm/min) = 5 (min) (in/min)
03-17
Vinyl tape
Scale ９０ＺＡ０３０１
IMPORTANT At the completion of measurement, if the vinyl tape used for measurement is not removed from the cylinder rod, the tape may be caught by the rod seal. The tape will cause oil leakage from the rod seal. To prevent oil leakage, be sure to remove the vinyl tape.
115Z Ⅳ -2
Measuring Cylinder Drift
MEASUREMENT FOR PERFORMANCE CHECK 03
・Possible causes of excessive cylinder drift: Bucket cylinder
Possible cause
Solution
Damaged cylinder piston seal / barrel
Disassembly & repair
Defective multiple control overload relief valve
Disassembly & repair
Oil leakage from multiple control valve main spool
Disassembly & repair
Boom cylinder
Possible cause
Solution
Damaged cylinder piston seal / barrel
Disassembly & repair
Oil leakage in pilot relief valve
Disassembly & repair
Oil leakage from multiple control valve main spool
Disassembly & repair
・ Identifying defective part (S/N 11C3-5501〜5700) There is a hose that supplies compressed oil from the bottom of the boom cylinder to the pilot relief valve. Lower the boom and bucket to the ground and relieve all pressure. Remove the hose from the pilot relief valve, and plug the hose. Cap the fitting in the valve. Perform the cylinder drift test again. If the obtained cylinder drift rate is within the specified range, the cause is the internal leakage of the pilot relief valve.
Multiple control valve
If drift continues the leakage is in the boom cylinder or multiple control valve. １１５Ｋ０３００５
03-18
115Z Ⅳ -2
Measuring Boom Cycle Time
MEASUREMENT FOR PERFORMANCE CHECK 03
Measuring Boom Cycle Time WARNING Standing under the boom or bucket during service work is dangerous. An accident resulting in injury or death may occur. Stay out of the area around the raised boom.
・Measuring instrument ・ Stop watch ・ Tachometer ・Warm-up the engine before measuring boom rising time ・Standard measurement value(sec) Idling (LI) Engine speed
-1
23 ± 3.0
1500min (RPM)
10.5 ± 1.0
Maximum (HI)
8.1 ± 0.5
・Measurement procedure 1. Unload the bucket. 2. Lower the boom to the lower limit, and roll back the bucket. 3. Set the parking brake switch to the "ON" position. Stop the engine and install the tachometer. 4. Adjust the engine speed to the specified point. 5.Measure the time required for raising the boom from the lowest limit to the highest limit. Note : Even if the boom kick out system (optional) is installed, the boom control lever should be held in the UP position until the boom rises to the highest limit.
・Possible causes of slow boom cycle time: Boom cylinder
Possible cause Damaged main pump / seals Damaged steering pump / seals Multiple control valve spool sticking
Solution Disassembly & repair Disassembly & repair
To steering line Multiple control Steering valve
Repair
How to determine the cause (damaged main pump or steering pump): Measure the full steering time. If normal the main pump is damaged. If steering time is also slow the steering pump is damaged.
03-19
Steering pump Main pump
Hydraulic oil tank
115Z Ⅳ -2
Measuring Full Steering Cycle Time
MEASUREMENT FOR PERFORMANCE CHECK 03
Measuring Full Steering Cycle Time WARNING Standing in the articulation area during service work is dangerous. An accident resulting in injury or death may occur. During this test, prevent any person from walking around the machine or in the articulation area.
・Measurement instrument ・ Stop watch ・ Tachometer ・Warm-up the engine before measuring full steering time ・Standard measurement value(sec) 5 ± 0.5
Idling (LI) Engine speed
-1
1500min (RPM)
3.9 ± 0.3
Maximum (HI)
3.9 ± 0.3
・Measurement procedure 1. Unload the bucket. 2. Lower the boom to the lower limit, and roll back the bucket. 3. Set the parking brake switch to the "OFF" position and release the brake pedal. 4. Adjust the engine speed to the specified point. 5. Measure and record the time required for full steering. ・ From full left to full right or ・ From full right to full left Turn the steering wheel as fast as possible during the test.
Full steering
・Possible causes for slow steering times: Possible cause
Solution
Damaged steering pump / seals
Disassembly & repair
Malfunctioning steering valve flow control plunger
Disassembly & repair
Flow control plunger
Steering valve 90Z Ⅳ 0301
03-20
Measuring Relief Valve Setting Pressures
115Z Ⅳ -2
MEASUREMENT FOR PERFORMANCE CHECK 03
Measuring Relief Valve Setting Pressures WARNING Unexpected movement of the machine may cause an accident resulting in injury or death. Therefore, to provide repair service with the engine running, be sure to observe the following items: ・ Park the machine on level ground. ・ Apply the parking brake. ・ Block the tires with chocks to prevent the tires from moving. ・ Determine the signals between the service men. ・ Prohibit any person from walking into dangerous areas. ・ Near articulation area of the machine ・ Under the machine ・ Around the engine ・ In front of or behind the machine
CAUTION Do not touch the fan or V-belt of the engine or a high-temperature section if the engine is running. An accident resulting in injury may occur. Be sure to stop the engine before you open the side cover of the engine room. Keep all guards in place. Avoid high temperature components even after the engine is stopped.
Reference:
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 oil tank before removing the plug from the pressure measurement port.
Releasing residual pressure from pipe: Keep the bottom surface of the bucket horizontal, and stop the engine when the bucket is approximately 30cm(1 ft.) above the ground. Tilt down the bucket until it comes in contact with the ground. Place the bucket control lever in the roll back position, and then lower the boom. Open the cap of the hydraulic oil tank.
03-21
115Z Ⅳ -2
Measuring Relief Valve Setting Pressures
・Measurement instruments: 2 ・ Pressure gauge 29.4MPa(300kgf/cm )(5,000psi) (for loading and steering lines) with 1.5〜3m (4〜10 ft. ) hose 2 4.9MPa (50kgf/cm ) (1,000 psi) (for pilot line) with 2 〜 3m (6 〜 10 ft. ) hose Pressure measurement port: JIS PF 1/4 O-ring port Note : For safety, route the gauge to an area where it may be safely read by the person doing the test.
MEASUREMENT FOR PERFORMANCE CHECK 03
Tilt cylinder (RH)
・Warm-up the engine before measuring relief valve setting pressures (LH) 2
・Standard measurement value MPa (kgf/cm ) (psi) Loading line main relief pressure (at maximum speed)
20.6 ± 1(210 ± 10) (2,990 ± 140)
Loading line overload relief pressure (at idling speed)
23.5 ±0.51 (240 ±105 ) 70 (3,410 ±140 )
Steering line main relief pressure (at maximum speed)
20.6 ± 1(210 ± 10) (2,990 ± 140)
Steering line overload relief pressure (at idling speed)
24.5 ±0.51 (250 ±105 ) 70 (3,560 ±140 )
Pilot line
Relief valve (at Idling speed)
4.0 ± 0.3(41 ± 3) (583 ± 40)
Reducing valve ＊ (at engine stopped)
1.5 ± 0.3(15 ± 3.5) (210 ± 50)
(RH) １１５Ｋ０３００６
Pressure gauge port for measurement of multiple control valve main relief pressure and bucket cylinder bottom side overload relief pressures
Bucket cylinder bottom side overload relief valve
Main relief valve
＊ Operational check only. (S/N 11C3-5501〜5700) ・Measuring loading line main relief pressure 1. Unload the bucket. 2. Lower the boom to the lowest limit. 2 3. Attach the pressure gauge 29.4MPa (300kgf/cm ) (5,000 psi) 4. Set the parking brake switch to the "ON" position. 5. Move the bucket control lever to the roll back position. Hold the lever at that position. 6. Increase the engine speed to the maximum, and measure and record the pressure using the pressure gauge.
Bucket cylinder rod side overload relief valve
Relief poppet Adjusting screw
Plunger Tank port
・Measuring loading line overload relief pressure (bucket cylinder bottom side) 1.Adjust the main relief valve pressure to 2 26.5MPa(270kgf/cm )(3,800 psi) where the pressure is above the overload relief pressure.
Pump port
90Z Ⅳ 0302
Multiple control valve, Main relief valve
03-22
Measuring Relief Valve Setting Pressures
115Z Ⅳ -2
Reference:
MEASUREMENT FOR PERFORMANCE CHECK 03
Tilt cylinder
One turn of the main relief valve pressure adjustment screw increases or reduces the 2 pressure approximately 9.8MPa(100kgf/cm ) (1,420 psi).
(RH)
2. Measure and record the overload relief pressure by following the main relief pressure measurement procedure described above. Note that the engine speed should be kept as low as possible during pressure measurement.
・Measuring loading line overload relief pressure (on bucket cylinder rod side) Refer to the measurement procedure for the cylinder bottom side, and observe the following points: ・ Keep the boom horizontal. ・ Move the bucket control lever to the dump position, hold, and then measure and record the pressure.
(LH)
(RH)
115K03006
Pressure gauge port for measurement of bucket cylinder rod side overload relief pressure
IMPORTANT At the completion of check and adjustment of overload relief valve pressure, be sure to reset the main relief valve to the original condition.
・Measuring steering line main relief pressure 1. Set the steering oil pressure to the relief by following the procedure for "Engine speed measurement procedure in steering valve relief mode". 2. Measure and record the relief pressure when the engine speed is at its maximum. ・Measuring steering line overload relief pressure on right side 1. Adjust the main relief valve pressure to 26.5MPa 2 (270kgf/cm ) (3,800 psi) where the pressure is above the overload relief pressure.
Steering valve
Steering cylinder 115K03007
Pressure gauge port for measurement of steering relief pressure and overload relief pressure Main relief valve Overload relief valve
Overload relief valve
Front
115K03008
Steering valve 03-23
Measuring Relief Valve Setting Pressures
115ZIV-2
Reference: One turn of the main relief valve pressure adjustment screw (2) increases or reduces the pressure approximately 17.7MPa(180kgf/cm2)(2,560psi). 2.Measure and record the overload relief pressure by following the steering line main relief pressure measurement procedure described above. Note that the engine speed should be kept as low as possible during pressure measurement. ・Measuring steering line overload relief pressure on left side Attach the pressure gauge to the right cylinder, and then measure and record the pressure by following the pressure measurement procedure described above.
MEASUREMENT FOR PERFORMANCE CHECK 03
2
1 1. Locking jam nut 2. Adjusting screw Steering valve main relief valve Pilot valve
IMPORTANT At the completion of check and adjustment of overload relief valve pressure, be sure to reset the main relief valve to the original condition.
・Measuring pilot line relief pressure 1.Attach the pressure gauge 4.9MPa (50kgf/cm2) (1,000psi) 2.Lower the boom to the lowest limit. 3.Unload and roll back the bucket fully till the bucket contacts to the stopper. Hold this position. 4.Measure and record the relief pressure when the engine speed is at low idle speed. ・Pilot line pressure reducing valve - operational check (S/N 11C3-5501〜5700) 1.Fully roll back the bucket. 2.Lower the boom to about 50cm (20in.) above the ground. 3.Stop the engine. 4.Slowly push the boom lever to the "Boom Down" position. 5.If the boom moves down the pilot pressure reducing valve is operating normally (reducing pressure is approximately 1.5MPa (15kgf/cm2) [213 psi] ). If the boom will not lower start the machine, lower the boom and bucket, relieve tank pressure, and stop the engine. Remove and inspect the pressure reducing valve. Clean or replace as necessary. 03-24
Relief valve
115K03009
Pressure gauge port for measurement of pilot line relief pressure Pilot valve
Relief valve
115K03009
Pressure gauge port for measurement of pilot line reducing pressure
115Z Ⅳ -2
Checking Brake Performance
MEASUREMENT FOR PERFORMANCE CHECK 03
・Cause of extremely high or low measurement value and solution The set pressure is too high.
The set pressure is too low.
Possible cause
Solution
Possible cause
Solution
Pressure setting screw not set properly
Adjustment
Pressure setting screw not set properly
Adjustment
Relief valve spring broken
Disassembly & repair
Debris stuck in valve
Disassembly & cleaning
Damaged pump / seals
Disassembly & repair
If the inside of the pump is damaged, boom rising time and steering time may be also slow. The pilot pump damage may only reduce pilot pump pressure.
Checking Brake Performance WARNING
Parking brake:
Unexpected movement of the machine may cause an accident resulting in injury or death. Before starting brake performance check, be sure to observe the following items: ・ Place the machine on level ground. ・ Check that there is enough clearance for brake performance check around the machine. ・ During performance check, prohibit any person to walking near the machine.
・Measurement instrument None ・Warm-up the performance
engine
before
checking
brake
・Test on hard level ground ・Standard measurement value Service brake: Shift lever position Engine speed Left brake pedal T/M cut-off switch
2nd reverse speed Maximum speed Fully depressed
Shift lever position
2nd forward speed
Engine speed
Maximum speed
Parking brake switch
"OFF" (Parking brake solenoid valve wire disconnected)
Slowly increase the engine speed, and check that the machine does not move at the maximum engine speed.
・Checking performance of service brake 1. Lower the boom to the lowest limit, and roll back the bucket fully until the bucket contacts to the stopper. 2. Set the parking brake switch to the "OFF" position. 3. Set the T/M (transmission) cut-off switch to OFF, and then depress the left brake pedal all the way to the floor. 4. Set the shift lever to 2nd reverse speed. 5. Gradually increase the engine speed. The machine should not move at the maximum engine speed.
Slowly increase the engine speed, and check that the machine does not move at the maximum engine speed.
"OFF"
03-25
115Z Ⅳ -2
Checking Brake Performance
・Checking performance of parking brake 1. Steer the machine to the right side. Lower boom and bucket to the ground. Stop the engine. Remove the connector of the electrical line from the parking brake solenoid valve to apply the parking brake. 2. Start the engine. Lower the boom to the lower limit, and roll back the bucket until it contacts the stopper. 3. Set the shift lever to 2nd forward speed. 4. Gradually increase the engine speed. The machine should not move at the maximum speed.
MEASUREMENT FOR PERFORMANCE CHECK 03
Parking solenoid valve
IMPORTANT If the machine begins to move with the parking brake applied, the brake shoes are burnt or misadjusted. At the completion of parking brake test, be sure to connect the connector of electrical line to the solenoid valve again. 115K03010
・Cause of machine moving performance check and solution
during
brake
Service brake
Possible cause
Parking brake
Solution
Possible cause
Solution
Defective pilot pump
Replacement
Clearance between brake drum and shoe too large
Clearance adjustment
Malfunctioning unloader valve
Check and repair
Improperly adjusted brake cylinder stroke
Check and adjustment
Malfunctioning accumulator
Check and repair
Broken brake cylinder spring
Check and repair
Malfunctioning brake valve
Check and repair
Malfunctioning hydro master
Check and repair
Worn brake disk
Check and repair
03-26
Measuring Brake Line Setting Pressure
115Z Ⅳ -2
MEASUREMENT FOR PERFORMANCE CHECK 03
Measuring Brake Line Setting Pressure WARNING
CAUTION
Unexpected movement of the machine may cause an accident resulting in injury or death. Therefore, to provide repair service with the engine running, be sure to observe the following items: ・ Park the machine on level ground. ・ Apply the parking brake. ・ Block the tires with chocks to prevent the tires from moving. ・ Determine the signals between the service men. ・ Prohibit any person from walking into dangerous areas. ・ Near articulation area of the machine ・ Under the machine ・ Around the engine ・ In front of or behind the machine
Do not touch the fan or V-belt of the engine or a high-temperature section if the engine is running. An accident resulting in injury may occur. Be sure to stop the engine before you open the side cover of the engine room. Keep all guards in place. Avoid high temperature components even when the engine is off.
・Measurement instrument ・ Hydraulic pressure gauge : 2 19.6MPa (200kgf/cm ) (3,000psi) with 2.5〜3m (8〜10ft. ) hose Pressure measurement port :PF1/2 Note : For safety, route the gauge to an area where it may be safely read by the person doing the test. ・Standard measurement value MPa (kgf/cm2 ) (psi) Unloader valve setting pressure Low-pressure alarm switch setting pressure
off on
11.8 ± 0.5 (120 ± 5)(1,700 ± 70) 6.9 ± 1 (70 ± 10)(995 ± 140) 3.9 ± 0.3 (40 ± 3)(570 ± 40)
(S/N 5309〜5700)
・Measuring pressure Measuring unloader valve set pressure 1. Lower the boom to the lowest limit, and tilt down the bucket onto the ground. 2. Set the parking brake switch to the "ON" position and stop the engine. 3. Repeatedly depress and release the brake pedal to discharge accumulator pressure. 4. Attach the pressure gauge to the unloader valve at one of two gauge ports (see the arrows). 5. Start the engine, and keep the speed at low idle. 6. Measure and record the pressure when the pointer of the pressure gauge stops rising (unloader valve off). 7. Keep the engine at low idle, and repeatedly depress and release the brake pedal to reduce the accumulator pressure. Measure and record the pressure when the pointer of the pressure gauge stops and then starts rising again (unloader valve on). 03-27
Pressure gauge port for measurement of unloader valve pressure
Gauge port
UNLOADER VALVE (S/N 5701〜)
Pressure gauge port for measurement of unloader valve pressure
115Z Ⅳ -2
Measuring Brake Line Setting Pressure
MEASUREMENT FOR PERFORMANCE CHECK 03
・Measuring low pressure alarm switch setting pressure 1. Attach the pressure gauge to the unloader valve. 2. Start the engine, and keep the speed at low idle. 3. Stop the engine when the pointer of the pressure gauge stops rising (unloder valve off). 4. Set the starter key to ON. 5. Repeatedly depress and release the brake pedal. 6. Measure and record the pressure when the low-pressure alarm buzzer sounds.
・Possible causes of extremely high or low pressure The unloader valve set pressure is high or low
Possible cause
Solution
Unloader valve setting screw not set properly
Readjustment
Damaged pilot pump
Disassembly & repair
Low pressure alarm switch setting
①
pressure high or low
Possible cause
Solution
Defective low pressure alarm switch
Replacement
③ ②
・Adjustment ・ Remove the cap nut (1) and loosen the lock nut (2). ・ Adjust the pressure by adjusting the screw (3).
03-28
Measuring Brake Pressure Difference
115Z Ⅳ -2
MEASUREMENT FOR PERFORMANCE CHECK 03
Measuring Brake Pressure Difference Switch Setting Pressure (S/N 11C3-5501〜5600) CAUTION
WARNING Unexpected movement of the machine may cause an accident resulting in injury or death. Therefore, to provide repair service with the engine running, be sure to observe the following items: ・ Park the machine on level ground. ・ Apply the parking brake. ・ Block the tires with chocks to prevent the tires from moving. ・ Determine the signals between the service men. ・ Prohibit any person from walking into dangerous areas. ・ Near articulation area of the machine ・ Under the machine ・ Around the engine ・ In front of or behind the machine
Do not touch the fan or V-belt of the engine or a high-temperature section if the engine is running. An accident resulting in injury may occur. Be sure to stop the engine before you open the side cover of the engine room. Keep all guards in place. Avoid high temperature components even when the engine is off.
・Cause of extremely high or low measurement value and solution Pressure difference switch setting pressure low or high
・Measurement instrument ・ Hydraulic pressure gauge (2 pcs) : 2 4.9MPa (50kgf/cm ) (1,000 psi) with 2.5〜3m (8〜10ft. ) hose Pressure measurement port :M10×1 Note : For safety, route the gauge to an area where it may be safely read by the person doing the test. ・Standard measurement value MPa (kgf/cm2 ) (psi) Switch pressure difference
Possible cause Defective switch
Replacement
Remove this bleeder and install the pressure gauge (Front and rear axles)
From brake valve
1.5 ± 0.3 (15 ± 3) (210 ± 40)
・Measuring pressure 1. Lower the boom to the lowest limit, and tilt down the bucket onto the ground. 2. Set the parking brake switch to the "ON" position and stop the engine. 3. Remove the air bleeder on the hydro master both for the front and rear axles. 4. Install the pressure gauges. 5. Start the engine, and depress the brake pedal. Keeping the brake pedal depressed. 6. Release one of the air bleeders on the auto adjuster valve and drain oil. 7. Pressure difference occurs between two brake circuits. Measure and record the pressure for the front and rear axles when the buzzer starts to sound. Calculate the pressure difference.
Solution
To auto adjuster valve
Hydro master ９７ＺＡ０３０２
Release one of the air bleeders and drain oil
To brake piston
03-29
To brake piston
From hydro master
Auto adjuster valve
９７ＺＡ０３０３
115Z Ⅳ -2
Measuring Accumulator Charging Time
MEASUREMENT FOR PERFORMANCE CHECK 03
Measuring Accumulator Charging Time CAUTION
WARNING
Do not touch the fan or V-belt of the engine or a high-temperature section if the engine is running. An accident resulting in injury may occur. Avoid high temperature components even when the engine is stopped.
Unexpected movement of the machine may cause an accident resulting in injury or death. Therefore, to provide repair service with the engine running, be sure to observe the following items: ・ Park the machine on level ground. ・ Apply the parking brake. ・ Block the tires with chocks to prevent the tires from moving. ・ Determine the signals between the service men. ・ Prohibit any person from walking into dangerous areas. ・ Near articulation area of the machine ・ Under the machine ・ Around the engine ・ In front of or behind the machine
・Measurement instrument ・ Hydraulic pressure gauge : 2 19.6MPa (200kgf/cm ) (3,000 psi) with 2.5〜3m (8〜10 ft. ) hose Pressure measurement port :PF1/2 ・ Stop watch Note : For safety, route the gauge to an area where it may be safely read by the person doing the test. ・Standard measurement value (sec) Engine speed: Low idle
(S/N 5334〜5800)
Pressure gauge port for measurement of unloader valve pressure
Unloader valve pressure 3.9MPa → 11.8MPa (40kgf/cm2) (120kgf/cm2) (570 psi)(1,700 psi)
22 ± 5 Gauge port
・Measurement procedure 1. Lower the boom to the lowest limit, and tilt down the bucket to the ground. 2. Set the parking brake switch to the "ON" position. 3. Stop the engine. Repeatedly depress and release the brake pedal to discharge accumulator pressure. 4. Attach the pressure gauge to the unloader valve. 5. Start the engine, and keep the engine speed at low idle speed. 6. Measure and record the time from the low pressure alarm is turned off (3.9 ± 0.3MPa (40 ± 3kgf/cm2) (570 ± 40 psi)) till the pointer of the pressure gauge 2 stops rising (11.8 ± 0.5MPa (120 ± 5kgf/cm ) (1,700 ± 70 psi)).
03-30
UNLOADER VALVE (S/N 5801〜)
Pressure gauge port for measurement of unloader valve pressure
115Z Ⅳ -2
Measuring Accumulator Charging Time
・Possible causes of extremely high measurement value and solution The accumulator charging time is too long
Possible cause Defective unloader valve
Solution Disassembly & repair
Oil leakage from pipe
Check and repair
Defective pilot pump
Disassembly & repair
03-31
MEASUREMENT FOR PERFORMANCE CHECK 03
115Z Ⅳ -2
Number of Brake Pedal Applications
MEASUREMENT FOR PERFORMANCE CHECK 03
Measuring Number of Brake Pedal Applications WARNING
CAUTION
Unexpected movement of the machine may cause an accident resulting in injury or death. Therefore, to provide repair service with the engine running, be sure to observe the following items: ・ Park the machine on level ground. ・ Apply the parking brake. ・ Block the tires with chocks to prevent the tires from moving. ・ Determine the signals between the service men. ・ Prohibit any person from walking into dangerous areas. ・ Near articulation area of the machine ・ Under the machine ・ Around the engine ・ In front of or behind the machine
Do not touch the fan or V-belt of the engine or a high-temperature section if the engine is running. An accident resulting in injury may occur. Avoid high temperature components even when the engine is stopped.
・Standard measurement value Run engine 1 minute high idle, then stop the engine. Step on the brake pedal and release, and check the number of times until the low pressure alarm is turned on (3.9 ± 0.3MPa (40 ± 3kgf/cm2) (570 ± 40 psi)).
・Possible causes of extremely low measurement value and solution 10 times or more
・Measurement procedure 1. Lower the boom to the lowest limit, and tilt down the bucket to the ground. 2. Set the parking brake switch to the "ON" position. 3. Run engine 1 minute high idle, then stop the engine. 4. Turn the starter switch to "ON". 5. Depress the right brake pedal all the way to the floor, and hold down the pedal for 5 seconds. Release the pedal, and wait for 5 seconds to depress the pedal again. Repeat. 6. Count and record the number of pedal applications until the low pressure alarm buzzer starts to sound.
03-32
Possible cause
Solution
Insufficient accumulator pressure due to defective unloader valve
Check and repair
Insufficient accumulator pressure
Charging
Insufficient accumulator pressure due to defective pilot pump
Check and repair
Defective brake valve
Check and repair
Oil leakage from pipe
Check and repair
115Z Ⅳ -2
Measuring Declutch Engagement
MEASUREMENT FOR PERFORMANCE CHECK 03
Measuring Declutch Engagement WARNING Checking the machine on a slope is dangerous work. An accident resulting in injury or death may occur. Before starting declutch engagement test observe the following: ・ Check that the slope is smooth. ・ Check that the brake works well. ・ Prohibit any person from walking into the dangerous area. ・ Determine the signs between the service men. ・ Do not enter the area near the moving machine.
・Measurement instrument ・ Chalk ・ Scale (approx. 1 m) (3 ft.) or tapemeasure ・ Thin rod (approx. 1 m) (3 ft.) used as measurement rod ・ Vinyl tape ・ Assistant / operator ・ Nylon tie straps (2 or 3)
９７Ｋ０３０１３
Measurement rod attached to step
・Cause of extremely high measurement value and solution
・Warm-up the engine before measuring declutch engagement ・Standard measurement value 1/5 slope (approx. 11 ° ), unloaded bucket, engine maximum speed at 1st speed position, quickly released inching pedal
15cm (6 in) or less
・Measurement procedure 1. Attach the measurement rod to the step. 2. Position the boom approximately 50 cm (1 1/2 ft.) above the ground. Roll the bucket fully back until the bucket contacts to the stopper. 3. Stop the machine on a 1/5 slope (approx. 11 ° ) so that the machine is in the climbing direction (bucket up hill) . 4. Set the inching cut-off switch to ON. 5. Set the parking brake switch to the "OFF" position. 6. Press the inching brake pedal (left pedal) all the way to floor. 7. Mark the ground at the pointer position with chalk or tape. Increase the engine speed to its maximum, and set the transmission shift lever to the 1st forward speed. 8. Quickly release the inching brake pedal, and mark the point at which the machine stops rolling back (using the pointer) and starts moving up the slope. 9. Measure and record the distance on the slope from step 7 to step 8. 03-33
Possible cause
Solution
Too much delay in resetting declutch switch
Check and replace declutch switch
Too much time lag in engaging clutch
Refer to "Time lag measurement procedure" .
Measuring Radiator Cooling Capability
115Z Ⅳ -2
MEASUREMENT FOR PERFORMANCE CHECK 03
Measuring Radiator Cooling Capability CAUTION
WARNING Unexpected movement of the machine may cause an accident resulting in injury or death. Therefore, to provide repair service with the engine running, be sure to observe the following items: ・ Park the machine on level ground. ・ Apply the parking brake. ・ Block the tires with chocks to prevent the tires from moving. ・ Determine the signals between the service men. ・ Prohibit any person from walking into dangerous areas. ・ Near articulation area of the machine ・ Under the machine ・ Around the engine ・ In front of or behind the machine
Do not touch the fan or V-belt of the engine or a high-temperature section if the engine is running. An accident resulting in injury may occur.
・Measurement instrument ・ Contact thermometer ・Standard measurement value( ° C) Coolant temperature at engine outlet ＊
40〜45 ° C above air temperature (72〜81 ° F above air temperature)
Difference in torque converter oil temperature between cooler inlet and outlet
10〜15 ° C (18〜27 ° F)
Difference in hydraulic oil temperature between cooler inlet and outlet
3 〜5 ° C (5〜9 ° F)
・Measurement procedure 1. Lower the boom to the lowest limit, and tilt down the bucket to the ground. 2. Set the parking brake switch to the "ON" position. 3. Apply no load to the engine, and increase the speed to its maximum. 4. Measure the temperature of coolant, torque converter oil, and hydraulic oil at each point when the temperature stops rising (stable temperature status). Note : To judge whether the temperature is stable, check the water temperature gauge and torque converter oil temperature gauge (in the operator's room) and outer surface of the hydraulic oil tank. C the coolant ＊ For example, if air temperature is 26 ° temperature should stabilize at about 66 ° 〜71 ° C. (80 ° F should stabilize at about 152 ° 〜161 ° F).
03-34
Cooler IN
Cooler OUT
Ｔｏ ｒ ｑｕｅ ｃｏｎｖｅ ｒ ｔ ｅ ｒｏ ｉ ｌ ｃｏｏ ｌ ｅｒ ｏｎ ｅｎｇ ｉ ｎｅ
115Z Ⅳ -2
Measuring Radiator Cooling Capability
MEASUREMENT FOR PERFORMANCE CHECK 03
The torque converter oil is overheated
Possible cause
Hydraulic oil IN
Coolant IN
Hydraulic oil OUT
Fuel oil OUT
Fuel oil IN Torque converter oil OUT Coolant OUT Torque converter oil IN
１１５Ｖ２２００３
Solution
Damage inside torque converter
Disassembly & repair
Damaged transmission clutch
Disassembly & repair
Torque converter pump discharge amount too small
Disassembly & repair
Torque converter inlet or outlet relief pressure too low
Disassembly & repair
Water pump output too low
Disassembly & repair
Scale deposited in coolant side for torque converter cooler
Disassembly & clean
Overheated engine coolant
Refer to "The engine coolant is overheated" described
Debris inside cooler from T/M or T/C failure
Replace
Brakes dragging
Check & repair
Temperature measurement points at radiator inlet and outlet
・Possible causes of extremely measurement value and solution
high
or
low
The engine coolant is overheated
Possible cause
The hydraulic oil is overheated
Solution
Possible cause
Solution
Cooler bypass valve remains open
Disassembly & repair
Distorted or damaged fan
Replace
Pump discharge amount too small
Disassembly & repair
Improper lap clearance of fan and fan shroud
Repair
Clogged radiator fin ＊
Clean
Water pump output too low
Repair
Scale deposited inside radiator water tubes
Cleaning
Malfunction of thermostat
Replace
Insufficient air flow
Reduction in fan speed due to belt Tension check and slippage adjustment
Clogged return filter
Check and cleaning
Insufficient air flow
Refer to "The engine coolant is overheated" described above.
Clogged hydraulic oil cooler ＊
Overload due to damage inside torque converter
Disassembly & repair
Overload due to damage transmission clutch
Disassembly & repair
Overheated torque converter oil
Refer to "The torque converter oil is overheated" described above.
Brakes dragging
Check & repair
Clean
＊ Be sure to check for clogging between the hydraulic oil
03-35
cooler and the radiator. This is not visible from the fan side. The oil cooler must be removed to check and clean completely.
Measuring Radiator Cooling Capability
115Z Ⅳ -2
MEASUREMENT FOR PERFORMANCE CHECK 03
Ｔ／Ｃ ＆ Ｔ／Ｍ ＨＹＤＲＡＵＬ Ｉ ＣＬ ＩＮＥ
１１５Ｖ０３００２
ＨＹＤＲＡＵＬ Ｉ ＣＬ ＩＮＥ − ＯＩＬ ＣＯＯＬＥＲ
１１５Ｖ０３００３
03-36
115Z Ⅳ -2 Troubleshooting,Measurement for Performance Check AAA-S11C3V01-979 AAA-S11C3V01-012
① 1997.9
K
② 2001.2
KAWASAKI HEAVY INDUSTRIES, LTD. Rolling Stock, Construction Machinery & Crushing Plant Company Construction Machinery Division Tokyo Head Office
W.T.C. Bldg., 2-4-1 Hamamatsu-cho Minato-ku, Tokyo 105-6116
Kobe Head Office
Kobe Crystal Tower, 1-1-3 Higashi Kawasaki-cho Chuo-ku, Kobe, Hyogo 650-0044
Banshu Works
2680 Oka Inami-cho Kako-gun, Hyogo 675-1113
All rights reserved. No copy allowed without written consent.