DOWNLOAD PDF :Kawasaki 115ZIV-3 WHEEL LOADER SHOP MANUAL AAA-S11M1E01-00Z

AAA-S11M1E01-00Z

WHEEL LOADER SHOP MANUAL

115Z -3 Powered by MITSUBISHI S6A3 Engine.

SERIAL NUMBERS 11M1-9001 and up.

Troubleshooting Measurement for Performance Check

FOREWORD

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.

Troubleshootiing Measurement for Performance Check Note: ① For General Information and Functions and Structure, refer to the 115ZIV-3 Shop Manual AAA-S11M1E00-00Z (93216-00102). ② For Disassembly and reassembly and Service standard, refer to the 115ZIV-3 Shop Manual AAAS11M1E14-00Z (93216-00122). 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 (196N (20kg) 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

Weight

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 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.

l

Coating

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

Oil or water supply

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

Drainage

Shows the oil or water drain port and the drain amount.

（4）

TROUBLESHOOTING ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 01-1 MEASUREMENT FOR PERFORMANCE CHECK ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 03-1

TROUBLESHOOTING 01 Cautions Regarding Troubleshooting ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 01-3 ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 01-4 How to Use Quick Troubleshooting Table ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 01-5 Safety Precautions ・

Quick Troubleshooting Table Torque Converter and Transmission Group 1.

・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 01-6 Machine does not move in any shift lever position ・

2.

・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 01-7 Machine does not move at a certain shift lever position ・

(or: Machine moves only in a certain shift lever position) 3.

・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 01-8 Machine moves at the neutral position ・

(Example: Machine moves forward at the neutral position) 4.

・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 01-9 Large shock at starting or changing speeds / direction ・

5.

・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 01-10 Large time lag at starting or changing speed / direction ・

6.

・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 01-11 Low power ・

(Defective torque converter or transmission) 7.

・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 01-12 Torque converter oil is overheating ・

8.

Machine moves reverse when starting to ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 01-13 climb up on a slope using inching brake ・

9.

・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 01-14 Automatic speed change is not possible ・

10.

・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 01-15 QUAD (PUS) switch does not work ・

Hydraulic Group 1.

・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 01-16 Boom and/or bucket do not move ・

2.

・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 01-17 Boom and/or bucket have low power, or move too slowly ・

3.

・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 01-19 Excessive cylinder drift ・

4.

・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 01-21 Boom and/or bucket are spongy ・

(Holding bucket against the ground is not possible) 5.

・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 01-22 Bucket positioner (kick-out) does not work ・

01-1

6.

Steering is not possible or hard to steer ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 01-23

7.

・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 01-24 Machine sways, or has a shock during steering ・

8.

・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 01-25 Abnormal noise in hydraulic system ・

9.

・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 01-26 Others ・

Brake Group 1.

Brake does not work well ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 01-27 (In the worst case, the brake does not work at all) ・

2.

・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 01-28 Brake is dragging when released ・

3.

・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 01-29 Stepping on the brake pedal sounds the buzzer ・

4.

・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 01-30 Accumulator pressure does not rise, or too slow in rising ・

5.

・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 01-31 Parking brake does not work ・

(or: Releasing the brake is not possible) 6.

・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 01-32 Auto brake does not work ・

Electrical Group 1.

・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 01-33 Engine hard to start or will not start ・

2.

Engine will not stop even if the starter switch is turned ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 01-34 to "OFF" (or: Starting the engine is not possible) ・

3.

・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 01-35 Instrument panel does not indicate properly ・

4.

・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 01-36 Circuit protector of the transmission controller is turned off ・

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 of this problem?

and system, you can easily determine the cause of

4. When the problem occurred, what kind of work

the problem.

was the operator doing?

There may be various causes for each problem,

5. Has the machine had the same kind of problem

therefore experience will be needed to determine

before?

which is the actual cause of the problem.

6. Has the machine been repaired or inspected

It is necessary to know the normal operation of

recently?

each component. In addition, it is also important to

7. Does the machine have any other problem?

know the abnormal condition when a problem occurs. This chapter shows various examples of

・ Troubleshooting

past problems, and describes possible causes and

・ Check before determination of cause

remedies for each problem.

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

possible, check the machine by repeating the

unnecessary tests.

symptom.

・ Inspection procedure

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

incorrect diagnosis.

the

"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

Torque Transmission Group MachineConverter does notand move in any shift lever position

115ZIV-3

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

Torque Group MachineConverter does not and moveTransmission at a certain shift lever positon

115ZIV-3

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

Circuit protector of the controller will be turned off at a certain shift lever position

Controller input LED will not light 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**

○ &repair

Disassembly &repair

Clutch oil leaks internally

○

○

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

Disassembly

○ ○

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

24V power is not supplied to the solenoid valve (output LED OK)

Resistance of the solenoid valve coil is too high (more than 14 Ω )

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

Ｐｏｓｓ ｉ ｂ ｌ ｅ ｃａｕｓｅ

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

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.

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

WARNING

Ｓｙｍｐ ｔ ｏｍｓ／ｃｈｅｃｋ ｐｏ ｉ ｎ ｔ

2. Machine does not move at a certain shift lever position (OR : Machine moves only in a certain shift lever position)

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

Torque Converter and Transmission Group

Controller replacement

Torque Converter and Transmission Group Machine moves at the neutral position

115ZIV-3

QUICK TROUBLESHOOTING TABLE 01

Seized clutch on forward side *

○

○

Malfunctioning forward solenoid valve (sticking at ON position)*

○

○

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.

Oil is black and smells scorched

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

Controller output LED "F" indicator is on and will not go out

Check before starting work

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 neutral position)

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

Torque Converter and Transmission Group

Ｓ ｏ ｌ ｕ ｔｉｏ ｎ T/M disassembly and repair

○

Solenoid valve replacement

○ ○ ○

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

Torqueshock Converter and Transmission Large at starting or changing Group speeds / direction

115ZIV-3

QUICK TROUBLESHOOTING TABLE 01

Torque Converter and Transmission Group

Resistance of the modulator valve (2) coil is infinite Ω

Foreign material is on the line filter

Temperature of the torque converter oil is too high

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

Torquetime Converter and Transmission Large lag at starting or changingGroup speed / direction

115ZIV-3

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

Low power

115ZIV-3

QUICK TROUBLESHOOTING TABLE 01

Torque Converter and Transmission Group

Air drawn into suction line of torque converter

○

Broken torque converter turbine and pump

○

Torque converter internal pressure too low

○

○

○

○ ○

Iron and/or fiber material in line filter and strainer

Pump produces an abnormal(shrieking)noise

Pump is extremely heated

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

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

Torque converter oil is milky and cloudy in color

Ｐｏｓｓ ｉ ｂ ｌ ｅ ｃａｕｓｅ

Torque converter oil is discolored or emits nasty smell

hydraulic line(like excessive pilot pressure).

Temperature of the torque converter oil is too high

(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*

6. Low power (Defective torque converter or 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

Torque converter oil is overheating

115ZIV-3

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

Parking brake is excessively hot / discolored

One or more planetaries are hotter than others

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.

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

(1) Check the torque converter oil level.

Torque converter oil is discolored or emits nasty smell

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

115ZIV-3

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 (Page 03-10)

○

01-13

Switch replacement

Automatic speed change is not possible

115ZIV-3

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

Controller LED for machine speed does not change even if machine speed is changed

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

certain shift lever position."

Controller input LED "A" indicator does not light

refer to the section "Machine does not move at a

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

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

Torque Converter and Transmission Group

○ ○ ○

01-14

Inspection&repair

○

Repair brake circuit

QUAD switch does not work

115ZIV-3

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

Boom and/or bucket do not move

115ZIV-3

QUICK TROUBLESHOOTING TABLE 01

Hydraulic Group

Broken pump drive shaft

○

Internally damaged steering pump

○

Internally damaged main pump

○

○

Internally damaged pilot pump

○ ○

Oil leakage from overload relief valve (Bucket)

○

○

○

○

●

○

●

Disassembly &readjustment Disassembly &readjustment

○ ○

Plunger replacement Disassembly &readjustment

● ● ○

Pump is extremely heated

Disassembly

○ &repair

○ ○ ○

Main relief valve produces a noise

○ &repair

○

Defective pilot relief valve

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

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

After warm-up, it is possible to operate the bucket and boom

Pilot relief pressure is too low

No pilot relief pressure built

Disassembly

○ ● ●

○

Internally damaged cylinder

Disassembly

○ &repair

○ ○

Oil leakage from main relief valve

Ｓｏｌｕｔ ｉｏｎ Pump replacement

○

● ○

Multiple control valve plunger sticking

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

○ ○

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

No main relief pressure built

(1) Check the oil level.

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

Check before starting work

Boom and bucket do not move normally while the engine runs at low idle but appears to move normally while it runs at full speed

1. Boom and/or bucket do not move

○

Disassembly &repair

* Remarks

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

01-16

Hydraulic Group Boom and/or bucket have low power or slow

115ZIV-3

QUICK TROUBLESHOOTING TABLE 01

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)

power and speed.)

(5) Check that the pilot valve filter is not clogged.

Oil is foamy or milky looking after operation, but normal after stopping engine and letting the oil sit for 1 hour

moving.(Static testing will show normal hydraulic

Only boom lifting operation is abnormal

If the brakes, service or parking, drag it reduces the power available to hydraulics when the machine is

Only bucket operation is abnormal

to hydraulics.

(4) Check that the machine rolls freely in neutral.

Either the boom and bucket does not operate properly

Dragging/seized clutches reduce power available

Both the boom and bucket do not operate properly

lever of the transmission is at the neutral position.

Steering system operates properly

(3) Check that the machine does not move if the shift

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 (S/N 11M1-9001〜9100)

Stop the engine when the boom is on its way up(or down). Holding the boom at that position is not possible

Hydraulic Group

○

Check & repair

○ suction line

Check & repair

○ suction line

Hydraulic Group Boom and/or bucket have low power or slow

115ZIV-3

QUICK TROUBLESHOOTING TABLE 01

Check before starting work (1) Check the oil level.

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

○

Internallly 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

power and speed.)

(5) Check that the pilot valve filter is not clogged.

Pump is extremely heated

moving.(Static testing will show normal hydraulic

Main relief valve produces a noise

If the brakes, service or parking, drag it reduces the power available to hydraulics when the machine is

Only bucket operation is abnormal

to hydraulics.

(4) Check that the machine rolls freely in neutral.

Either the boom and bucket does not operate properly

Dragging/seized clutches reduce power available

Both the boom and bucket do not operate properly

lever of the transmission is at the neutral position.

Steering system operates properly

(3) Check that the machine does not move if the shift

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 (S/N 11M1-9101〜)

Oil is foamy or milky looking after operation, but normal after stopping engine and letting the oil sit for 1 hour

Hydraulic Group

○

○

Check & repair suction line

○

Check & repair suction line

Excessive cylinder drift

115ZIV-3

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 "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 (S/N 11M1-9001〜9100)

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

Hydraulic Group

○ ○ ○ ○

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

Excessive cylinder drift

115ZIV-3

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 "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 (S/N 11M1-9101〜)

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

Hydraulic Group

○ ○

01-20

Seal replacement Seal replacement

○ ○ ○

Ｓｏｌｕｔｉｏｎ

○ ○

Disassembly&repair Disassembly&repair

The boom or bucket is spongy

115ZIV-3

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

○

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.

○

Ｐｏｓｓ ｉ ｂ ｌ ｅ ｃａｕｓｅ

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 possible-front wheels off the ground)

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

115ZIV-3

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 pilot valve detent magnet coil 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

Hydraulic Group Steering is not possible or hard to steer

115ZIV-3

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

Pump is extremely heated

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

○

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 relief valve produces a noise

(1) Check the oil level in the hydraulic tank.

Steering is possible in either the right or left direction

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

Hydraulic Group Machine sways,or has a shock during steering

115ZIV-3

QUICK TROUBLESHOOTING TABLE 01

Tire having different diameter

○

Large difference in air pressure of tires

○

Steering cylinders or circuit recently repaired

Complaint is only while roading the machine

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

Shock is noticed only when steering fully to right or left

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

Abnormal noise in hydraulic system

115ZIV-3

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

Others

115ZIV-3

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 11M1 - 9101〜)

01-26

Brake does not work well

115ZIV-3

QUICK TROUBLESHOOTING TABLE 01

Machine turns when the brake is applied suddenly (the steering wheel slips from your hands)

○

○

Damaged brake piston seals one wheel

○

○

accumulator.

(2) Check the brake oil level.

(3) Check the brake piping for leakage

Ｐｏｓｓ ｉ ｂ ｌ ｅ ｃａｕｓｅ

Worn brake disk

Ｓｙｍｐ ｔ ｏｍｓ／ｃｈｅｃｋ ｐｏ ｉ ｎ ｔ

(1) Check the Nitrogen gas pressure in the

Both the right and left pedals have low braking resistance when pressed

○

Check before starting work

The brake oil pressure from the auto adjuster valve for right wheel greatly differs from the auto adjuster valve for left wheel.

Damaged brake oil pipe

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

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

When the brake pedal is pressed, the brake oil pressure of the front axle greatly differs from that of the rear axle.

Brake Group

○

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

Brake is dragging when released

115ZIV-3

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

the tire is not possible.

Ｐｏｓｓ ｉ ｂ ｌ ｅ ｃａｕｓｅ Stepping on brake pedal during traveling (Riding the brakes)

Insufficient return of brake pedal

Manual rotation of the tire is not possible

(2) Jack up the tires, and check that manual rotation of

Either the left or right wheel causes dragging

hot(more than 100 ° C ).

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.

○

Ｓ ｏ ｌ ｕ ｔｉｏ ｎ Instruction for operator

○

Incomplete air bleeding from the brake circuit (axle shaft end)

Disassembly&repair Disassembly, repair, and air bleeding

○

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

Stepping on brake pedal sounds buzzer

115ZIV-3

QUICK TROUBLESHOOTING TABLE 01

Brake Group

Auto brake does not work well

Parking brake is not released

Ｐｏｓｓ ｉ ｂ ｌ ｅ ｃａｕｓｅ

External pipe is oily, leaking

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

Too much time is required for accumulator gas charging

(1) Check the accumulator Nitrogen gas pressure

Unloader valve on-load pressure is too low

Check before starting work:

Buzzer sounds when the pedal is repeatedly depressed

2

(1.47MPa (15kgf/cm ) or more).

Buzzer sounds each time the brake pedal is stepped on

(2) Oil pressure difference

Ｓｙｍｐ ｔ ｏｍｓ／ｃｈｅｃｋ ｐｏ ｉ ｎ ｔ

(1) Low accumulator pressure 2 (3.92MPa(40kgf/cm ) or less).

Pedal resistance is too low when depressed

Conditions for buzzer sounding:

Pressure difference switch of either the front or rear axle is actuated

3. Stepping on the brake pedal sounds the buzzer

○ ○

Ｓ ｏ ｌ ｕ ｔｉｏ ｎ

Insufficient Nitrogen gas pressure in main accumulator

○ ○

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

Adjust gas pressure

Disassembly&repair

○

Brake oil piping damaged or loose

Repair / tighten

Brake plates warped in one or more wheels

○

Disassembly & repair

Diffective low oil pressure warning switch

○

Replace switch

Defective pressure difference switch

○ ○

Replace switch

○

Defective pilot pump

01-29

Replace pump

Brake Group Accumulator pressure does not rise,or too

115ZIV-3

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

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

○

01-30

Disassembly &repair Replace pump

Parking brake does not work

115ZIV-3

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 activates the link under the cylinder

WARNING

Ｓｙｍｐ ｔ ｏｍｓ／ｃｈｅｃｋ ｐｏ ｉ ｎ ｔ

(2) Check the main accumulator pressure.

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

(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

5. 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

○ ○

01-31

○

Inspection&repair

○ ○

Inspection&repair

○ ○

Readjustment

○

○

Inspection&repair

Auto brake does not work

115ZIV-3

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

01-32

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

6. 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

Engine hard to start or will not start

115ZIV-3

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 ｌｓｙｓｔｅｍ

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

○

01-33

○

Battery charge

Change oil&viscosity

Engine will not stop

115ZIV-3

QUICK TROUBLESHOOTING TABLE 01

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". (or: Starting the engine is not possible.)

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

01-34

Diode replacement

Electrical Group Instrument panel does not indicate properly

115ZIV-3

QUICK TROUBLESHOOTING TABLE 01

Bulb of monitor lamp burnt out

T/M(transmission) solenoid valve does not operate based on the speed set by the shift lever

Speed indicated on the instrument panel does not correspond with 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.

One of the gauge pointers does not move

lamps-not green or amber lamps which are

Pointer of the tachometer 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 circuit protector 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.

01-35

Electrical Group of the transmission controller Circuit protector is turned off

115ZIV-3

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

Circuit protector 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

Circuit protector is turned off if the machine sways during travelling

Ｐｏｓｓ ｉ ｂ ｌ ｅ ｃａｕｓｅ

Circuit protector is turned off immediately after turning on

Ｓｙｍｐ ｔ ｏｍｓ／ｃｈｅｃｋ ｐｏ ｉ ｎ ｔ

4. Circuit protector 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

○ ○

01-36

Inspection&repair Inspection&repair

MEASUREMENT FOR PERFORMANCE CHECK 03 Standard Measurement Values for Performance Check ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 03-2 ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 03-4 Preparation for Performance Check ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 03-6 Measuring Engine Speed ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 03-10 Measuring Clutch Oil Pressure and Time Lag ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 03-12 Measuring Cylinder Drift ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 03-14 Measuring Boom Cycle Time ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 03-15 Measuring Full Steering CycleTime ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 03-16 Adjusting Steering Stopper ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 03-17 Measuring Steering Wheel/Lever Operating Force ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 03-18 Measuring Relief Valve Setting Pressures ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 03-22 Checking Brake Performance ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 03-24 Measuring Brake Line Setting Pressure ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 03-29 Measuring Accumulator Charging Time ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 03-31 Measuring Number of Brake Pedal Applications ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 03-32 Measuring Declutch Engagement ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ 03-33 Measuring Radiator Cooling Capability ・

03-1

Standard Measurement Values

115ZIV-3 MEASUREMENT FOR PERFORMANCE CHECK 03

Standard Measurement Values for Performance Check Measurement conditions : C Temperature of torque converter oil : 50 to 80 ° C Temperature of hydraulic oil : 50 to 80 ° Temperature of engine coolant : 50 to 80 ° C 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)

2,080 ± 50

Maximum speed in torque converter stall mode

2,050 ± 100

Maximum speed in multiple control valve relief mode

2,050 ± 100

Engine

System

Engine speed (min-1)

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

+150 1,630 -100

Maximum speed in torque converter stall plus steering valve relief mode

+150 1,830 -100

Remarks

1st speed

2.2〜2.3 (22〜23)

Except 1st speed

2.5〜2.6 (25〜26)

1st speed

2.5〜2.6 (25〜26)

Except 1st speed

2.7〜2.9 (27〜30)

Transmission

Low idle Clutch pressure 2 MPa(kgf/cm )

Engine speed High idle

Clutch time lag (sec)

-1

Neutral → Forward 1st speed (engine speed: 1500 min )

Hydraulic pressure

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

Full steering time (sec)

Engine speed

4 or less 23 ± 3.0

-1

1500min

10.5 ± 1.0

Maximum (HI)

8.1 ± 0.5

Idling (LI)

5 ± 0.5

-1

1500min

3.9 ± 0.3

Maximum (HI)

3.9 ± 0.3 20.6 ± 1.0(210 ± 10)

Loading line main relief pressure (HI) Relief valve setting pressure 2 MPa(kgf/cm )

Before wheels move

3 or less

Idling (LI) Engine speed

0.3 ± 0.1

+ 0.5

+5

Loading line overload relief pressure (LI)

23.5 -1.0 (240 -10 )

Steering line main relief pressure (HI)

20.6 ± 1.0 (210 ± 10) +0.5

+5

Steering line overload relief pressure (LI)

24.5 -1.0 (250 -10 )

Pilot line

4.0 ± 0.3 (41 ± 3)

Relief valve (LI)

03-2

Run engine at lowest possible speed while setting

Run engine at lowest possible speed while setting

Standard Measurement Values

115ZIV-3 MEASUREMENT FOR PERFORMANCE CHECK 03

Item System

Measurement item Performance of service brake

Brake

Performance of parking brake

Brake line setting pressure 2 MPa(kgf/cm )

Shift lever position

2nd speed reverse

Engine speed

Maximum (HI)

Shift lever position

2nd speed forward

Engine speed

Maximum (HI)

Unloader valve setting pressure

Number of brake pedal applications

Declutch engagement (cm)

Engine speed (LI)

Off

11.8 ± 0.5(120 ± 5)

On

6.9 ± 1.0(65 ± 10)

Hydraulic oil

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

3.9 ± 0.3(40 ± 3 ) 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 or less

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

Engine cooling water

Torque converter oil

The time from the low-pressure alarm is turned off till the unloading valve cuts off pressure

Remarks

Slowly increase the engine speed, and check that the machine does not move at the

↑

Low-pressure alarm switch setting pressure Accumulator charge time (sec)

Radiator

Standard measurement values for performance check

Balanced temperature when engine is at HI speed

Engine outlet temperature ( ℃ )

40〜45 ° C above air temperature

Temperature difference between radiator inlet and outlet ( ℃ )

10〜15

Temperature difference between radiator inlet and outlet ( ℃ )

3〜5

03-3

Preparation for Performance Check

115ZIV-3 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

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

・ 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.

03-4

Preparation for Performance Check

115ZIV-3 MEASUREMENT FOR PERFORMANCE CHECK 03

・ Procedure for warm-up 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.

03-5

60℃

80℃ 100℃ 110℃

C

H T/C OIL TEMP

Torque converter oil temperature gauge

60℃

80℃

90℃

110℃

H

C WATER TEMP

Engine coolant temperature gauge

Measuring Engine Speed

115ZIV-3 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

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

・Measurement instrument ・ Tachometer drive port ・Warm-up the engine before measuring the engine speed

・Standard measurement value(min-1) Minimum no-load speed (LI)

800 ± 50

Maximum no-load speed (HI)

2,080 ± 50

Maximum speed in torque converter stall mode

2,050 ± 100

Maximum speed in multiple control valve relief mode

2,050 ± 100

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

+150 1,630 -100

Maximum speed in torque converter stall plus steering valve relief mode

+150 1,830 -100

03-6

Measuring Engine Speed

115ZIV-3 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 revolution/min 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.

03-7

Measuring Engine Speed

115ZIV-3 MEASUREMENT FOR PERFORMANCE CHECK 03

Unloader valve

・Engine speed measurement procedure in steering valve relief mode 1. Lower the boom to the lowest limit. Roll back the bucket fully until the bucket contacts to the stopper.

WARNING WARNING 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.

Stop bolt Stop valve

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

Possible cause

maximum

no-load

Solution

Insufficient warm up

Warm up

Clogged fuel filterMalfunctioning

Clean

Defective fuel pump

Repair

Defective fuel injection nozzle

Repair

Valve clearances incorrenct

Adjustment

Insufficient compression pressure

Repair

03-8

Measuring Engine Speed

115ZIV-3 MEASUREMENT FOR PERFORMANCE CHECK 03

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

Possible cause

Solution

Slipping transmission clutch or defect inside of transmission

Disassembly &repair

Defect inside torque converter

Disassembly & repair

The engine speed is too 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

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

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

03-9

Solution

Engine low power

Inspection & repair

Extremely high relief pressure of multiple control valve or steering valve

Adjustment

Measuring Clutch Oil Pressure&Time Lag

115ZIV-3 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

・ Standard measurement value

・ Measurement instruments: 2 ・ Pressure gauge : 4.9MPa(50kgf/cm ) with 2〜3m hose Pressure measurement port : 1st clutch PF1/4 Except 1st clutch PT3/8 ・ Tachometer ・ Stop watch

・ Measure the engine speed and clutch oil pressure after warm-up

Low idle Clutch pressure 2 MPa(kgf/cm )

Engine speed High idle

1st speed

2.2〜2.3 (22〜23)

Except 1st

2.5〜2.6 (25〜26)

1st speed

2.5〜2.6 (25〜26)

Except 1st

2.7〜2.9 (27〜30)

Clutch time lag (sec)

Neutral → 1st forward speed (engine speed : 1500min-1)

R clutch

L clutch

3rd speed clutch

2nd speed clutch

0.3 ± 0.1

１１５ＺＡ３２−１６

・ 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.

03-10

3rd speed clutch

Main clutch

2nd speed clutch

1st speed clutch

１１５Ｋ０３００２

Ｔ ｒ ａｎｓｍｉ ｓｓ ｉ ｏｎ ｏ ｉ ｌ ｐｒｅｓｓｕｒｅｔｅｓｔ ｐｏ ｒ ｔｌ ｏｃａｔ ｉ ｏｎ

Measuring Clutch Oil Pressure&Time Lag

115ZIV-3 MEASUREMENT FOR PERFORMANCE CHECK 03

・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.

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.

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.

・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

03-11

Measuring Cylinder Drift

115ZIV-3 MEASUREMENT FOR PERFORMANCE CHECK 03

Measuring Cylinder Drift WARNING 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

・Measurement instrument ・ Scale : 150 to 300mm ・ Stop watch ・ Black vinyl "electrician's" tape ・Warm-up the cylinder drift

hydraulic

oil

before

measuring

Reference: 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) Boom cylinder

3 or less

Bucket cylinder

4 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 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. Measure the distance again 5 minutes later.

This is distance "B" mm .

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

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.

03-12

Measuring Cylinder Drift

115ZIV-3 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

03-13

Measuring Boom Cycle Time

115ZIV-3 MEASUREMENT FOR PERFORMANCE CHECK 03

Measuring Boom Cycle Time WARNING 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

1500min

-1

Maximum (HI)

23 ± 3.0 10.5 ± 1.0 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.

03-14

Steering pump Main pump

Hydraulic oil tank

Measuring Full Steering Cycle Time

115ZIV-3 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

1500min

-1

Maximum (HI)

3.9 ± 0.3 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

03-15

Adjusting Steering Stopper

115ZIV-3 MEASUREMENT FOR PERFORMANCE CHECK 03

Adjusting Steering Stopper WARNING Unexpected movement of the machine may cause a serious injury or death. There is a possibility that a service man may be crushed in the articulation area if the machine unexpectedly turns during steering stopper adjustment.

To prevent such an accident, be sure to observe the following items: ・ Stop engine before adjusting steering stopper ・ After adjusting steering stopper, prohibit any person near articulation area of the machine when checking operation.

28〜32mm

Stop valve Installed on rear chassis

Stopper Installed on front chassis

3mm

Operating position of stop valve 90Z Ⅳ 4304

・ Adjust the steering stopper so that the stopper works when the stop valve is depressed 3 mm . ・ Adjust the dimension of the stopper bolt shown above so that the stopper works when the clearance of the stopper on the chassis becomes 25 〜 39 mm (an articulation angle of 37〜35°) is reached. ・ After adjusting, turn the steering wheel one turn (slowly) over a period of 5 seconds to check the stopper for operation.

25〜

Adjusting dimension (for reference) Articulation angle

40 °

39 °

38 °

37 °

36 °

35 °

34 °

Clearance of body stopper (mm)

0

9

18

25

32

39

50

Length of setting bolt (mm)

21

23

26

28

30

32

35

03-16

Measuring Steering Wheel/Lever

115ZIV-3 MEASUREMENT FOR PERFORMANCE CHECK 03

Measuring Steering Wheel/Lever Operating Force WARNING Unexpected movement of the machine may cause an accident resulting in injury or death. To prevent such an accident, observe the following items before starting test: Park the machine on solid and level ground.

Apply the parking brake.

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

Determine the signals between the service persons.

Prohibit any person from entering dangerous areas.

Under raised components or in articulation area Under the machine Front or rear of the machine

Measuring steering wheel operating force 1. Measurement instrument Pull scale or spring balance 2. Measurement procedure Stop the engine, and attach the push-pull scale to the steering wheel. Gradually turn the steering wheel.

3. Standard measurement value Operating force at start of turning (for both clockwise and counter clockwise):15±4.9N (1.5±0.5kgf) Measuring pilot valve lever operating force 1. Measuring instrument Push-pull scale or spring balance 2. Measurement procedure Operate the engine at the idling speed, and pull the center of the lever knob using the pull scale.

3. Standard measurement value

Boom lever operating force

Bucket lever operating force

Raising boom

Lowering boom

29 ± 15N (3.0 ± 1.5kg-f)

29 ± 15N (3.0 ± 1.5kg-f)

Dumping load from bucket

Tilting up bucket

34.3 ± 15N (3.5 ± 1.5kg-f)

34.3 ± 15N (3.5 ± 1.5kg-f)

Measurement conditions Hydraulic oil temperature … 50 ℃ to 80 ℃ (122〜176 ° F) Lever angle … Just before full stroke

03-17

Measuring Relief Valve Setting Pressures

115ZIV-3 MEASUREMENT FOR PERFORMANCE CHECK 03

Measuring Relief Valve Setting Pressures 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

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.

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

Reference: Releasing residual pressure from pipe: Keep the bottom surface of the bucket horizontal, and stop the engine when the bucket is approximately 30cm 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.

03-18

Measuring Relief Valve Setting Pressures

115ZIV-3 MEASUREMENT FOR PERFORMANCE CHECK 03

・Measurement instruments: 2 ・ Pressure gauge 29.4MPa(300kgf/cm )(for loading and steering lines) with 1.5 〜3m hose 2 4.9MPa(50kgf/cm ) (for pilot line) with 2〜3m 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.

Tilt cylinder (RH)

(LH)

・Warm-up the engine before measuring relief valve setting pressures ・Standard measurement value(MPa)(kgf/cm2 ) Loading line main relief pressure (at maximum speed)

20.6 ± 1.0 (210 ± 10)

Loading line overload relief pressure (at idling speed)

23.5-1.0 +5 (240 -10 )

Steering line main relief pressure (at maximum speed)

20.6 ± 1.0 (210 ± 10)

Steering line overload relief pressure (at idling speed)

+ 0.5 24.5-1.0 +5 ) (250 -10

Pilot line

Relief valve (at idling speed)

(RH) １１５Ｍ０３００１

Ｐｒｅｓｓｕｒｅ ｇａｕｇｅ ｐｏｒ ｔｆ ｏ ｒ ｍｅａｓｕｒｅｍｅｎｔｏｆ ｍｕ ｌ ｔ ｉ ｐ ｌ ｅ ｃｏｎｔ ｒ ｏ ｌ ｖａ ｌ ｖｅ ｍａ ｉ ｎ ｒ ｅ ｌ ｉ ｅ ｆ ｐｒｅｓｓｕｒｅ ａｎｄ ｂｕｃｋｅ ｔ ｃ ｙ ｌ ｉ ｎｄｅ ｒ ｂｏｔ ｔ ｏｍ ｓ ｉ ｄｅ ｏｖｅｒ ｌ ｏａｄ ｒ ｅ ｌ ｉ ｅ ｆ ｐｒｅｓｓｕｒｅｓ

+ 0.5

Bucket cylinder bottom side overload relief valve

Main relief valve

4.0 ± 0.3 (41 ± 3)

・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 ) to the right hand tilt cylinder.

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 26.5MPa (270kgf/cm2) where the pressure is above the overload relief pressure.

Pump port

90Z Ⅳ 0302

Multiple control valve, Main relief valve

03-19

Measuring Relief Valve Setting Pressures

115ZIV-3 MEASUREMENT FOR PERFORMANCE CHECK 03

Reference: One turn of the main relief valve pressure adjustment screw increases or reduces the pressure approximately 9.8MPa (100kgf/cm2).

Tilt cylinder (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) １１５Ｍ０３００２

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 on "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 2 26.5MPa( 270kgf/cm ) 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

Ｓｔｅｅｒ ｉ ｎｇ ｖａ ｌ ｖｅ

03-20

Measuring Relief Valve Setting Pressures

115ZIV-3 MEASUREMENT FOR PERFORMANCE CHECK 03

Reference: One turn of the main relief valve pressure adjustment screw (2) increases or reduces the pressure approximately 17.6MPa(180kgf/cm2).

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 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.

2

1 Steering valve main relief valve 1. Locking jam nut 2. Adjusting screw

(S/N 11M1-9001〜9100)

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) 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 11M1-9001〜9100) 1. Fully roll back the bucket.

2. Lower the boom to about 50cm 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] ).

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.

03-21

１１５Ｍ０３００３

(S/N 11M1-9101〜)

１１５Ｍ０３００４

Pressure gauge port for measurement of pilot line relief pressure

(S/N 11M1-9001〜9100)

１１５Ｍ０３００５

Pressure gauge port for measurement of pilot line reducing pressure

Checking Brake Performance

115ZIV-3 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

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.

Solution

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 a 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

2nd reverse speed Maximum speed Fully depressed

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.

・Standard measurement value Service brake: Shift lever position Engine speed Left brake pedal T/M cut-off switch

Shift lever position

Slowly increase the engine speed, and check that the machine does not move at the maximum engine speed.

"OFF"

03-22

Checking Brake Performance

115ZIV-3 MEASUREMENT FOR PERFORMANCE CHECK 03

・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.

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. ・Cause of machine moving performance check and solution

during

(S/N 11M1-9001〜9100)

brake

Service brake

Possible cause

Parking solenoid valve

Solution

Defective pilot pump

Replacement

Malfunctioning unloader valve

Check and repair

Malfunctioning accumulator

Check and repair

Malfunctioning brake valve

Check and repair

Worn brake disk

Check and repair

(S/N 11M1-9101〜)

Parking brake

Possible cause

１１５Ｍ０３００６

Solution

Clearance between brake drum and shoe too large

Clearance adjustment

Improperly adjusted brake cylinder stroke

Check and adjustment

Broken brake cylinder spring

Check and repair

03-23

１１５Ｍ０３００７

Measring Brake Line Setting Pressure

115ZIV-3 MEASUREMENT FOR PERFORMANCE CHECK 03

Measuring Brake Line Setting Pressure (S/N 11M1-9001〜9100) WARNING Unexpected movement of the machine may cause an accident resulting in injury or death. Therefore, to provide repair service with the engine running, be sure to observe the following items: Park the machine on level ground.

Apply the parking brake.

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

Determine the signals between the service men.

Prohibit any person from walking into dangerous areas. ・ Near articulation area of the machine ・ Under the machine ・ Around the engine ・ In front of or behind the machine

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

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

Avoid high temperature components even when the engine is off.

・Measurement instrument ・ Hydraulic pressure gauge : 19.6MPa (200kgf/cm2) with 2.5〜3m 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 Unloader valve setting pressure Low-pressure alarm switch setting pressure

off on

11.8±0.5MPa (120 ± 5kgf/cm2) 6.9±1.0MPa (70 ± 10kgf/cm2) 3.9±0.3MPa (40 ± 3kgf/cm2)

・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.

(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).

03-24

１１５Ｍ０３００８

Low pressure alarm switch Unloader valve setting pressure screw

Unloader valve

１１５Ｍ０３００９

Measring Brake Line Setting Pressure

115ZIV-3 MEASUREMENT FOR PERFORMANCE CHECK 03

・Adjustment ・ Remove the cap nut (1) and loosen the lock nut (2). ・ Adjust the pressure by adjusting the screw (3).

① ③ ②

１１５Ｍ０３０１０

03-25

Measring Brake Line Setting Pressure

115ZIV-3 MEASUREMENT FOR PERFORMANCE CHECK 03

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 pressure high or low

Possible cause

Solution

Defective low pressure alarm switch

Replacement

03-26

Measring Brake Line Setting Pressure

115ZIV-3 MEASUREMENT FOR PERFORMANCE CHECK 03

Measuring Brake Line Setting Pressure (S/N 11M1-9101〜) 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(200kg/cm ) with 2.5〜3m hose Pressure measurement port :PF1/8 Note: For safety, route the gauge to an area where it may be safely read by the person doing the test.

Gauge port

・Standard measurement value MPa(kgf/cm2 ) Unloader valve setting pressure

off

11.8 ± 0.5(120 ± 5)

on

6.9 ± 1.0(70 ± 10)

Low-pressure alarm switch setting pressure

UNLOADER VALVE

3.9 ± 0.3(40 ± 3)

・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.

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).

・Possible causes of extremely high or low pressure

03-27

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

Measring Brake Line Setting Pressure

115ZIV-3 MEASUREMENT FOR PERFORMANCE CHECK 03

・Adjusting Unloader Valve Setting Pressure 1. Remove the cap nut (1) and loosen the lock nut (2).

2. Adjust the pressure by adjusting the screw (3).

① ③ ②

１１５Ｍ０３０１０

Note: In a case, if one of the "ON" pressure and the "OFF" pressure does not match to the standard setting pressure, set the "ON" pressure to the standard setting pressure.

03-28

Measring Accumulator Charging Time

115ZIV-3 MEASUREMENT FOR PERFORMANCE CHECK 03

Measuring Accumulator Charging Time (S/N 11M1-9001〜9100) 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 ・Measurement instrument ・ Hydraulic pressure gauge : 2 19.6MPa(200kgf/cm ) with 2.5 〜 3m hose Pressure measurement port :PF1/2

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.

・ 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 Pressure gauge port for measurement of unloader valve pressure

Unloader valve pressure 3.9MPa → 11.8MPa (40kgf/cm2) (120kgf/cm2)

22 ± 5

・Possible causes of extremely high measurement value and solution

・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 2 alarm is turned off 3.9 ± 0.3MPa(40 ± 3kgf/cm ) till the pointer of the pressure gauge stops rising 11.8 ± 0.5MPa(120 ± 5kgf/cm2)).

03-29

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

Measring Accumulator Charging Time

115ZIV-3 MEASUREMENT FOR PERFORMANCE CHECK 03

Measuring Accumulator Charging Time (S/N 11M1-9101〜) 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 (200kg/cm ) with 2.5〜3m hose Pressure measurement port :PF1/8

Gauge port

・ Stop watch Note: For safety, route the gauge to an area where it may be safely read by the person doing the test.

UNLOADER VALVE

・Standard measurement value (sec) Engine speed: Low idle Pressure gauge port for measurement of unloader valve pressure

Unloader valve pressure 3.9MPa 11.8MPa (40kg/cm2) → (120kg/cm2)

24 ± 5

・Possible causes of extremely high measurement value and solution

・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 2 alarm is turned off (3.9 ± 0.3 (40 ± 3kg/cm )) till the pointer of the pressure gauge stops rising (11.8 ± 0.5 (120 ± 5kg/cm2)).

03-30

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

Number of Brake Pedal Applications

115ZIV-3 MEASUREMENT FOR PERFORMANCE CHECK 03

Measuring Number of Brake Pedal Applications 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 ・Standard measurement value

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.

Avoid high temperature components even when the engine is stopped.

・Possible causes of extremely low measurement value and solution

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

Step on the brake pedal and release, and 10 times check the number of times until the low or more pressure alarm is turned on (3.9 ± 0.3MPa(40 2 ± 3kgf/cm )).

・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.

03-31

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

Measuring Declutch Engagement

115ZIV-3 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) or tapemeasure ・ Thin rod (approx. 1 m) 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 or less

・Measurement procedure 1. Attach the measurement rod to the step.

2. Position the boom approximately 50 cm 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.

03-32

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

115ZIV-3 MEASUREMENT FOR PERFORMANCE CHECK 03

Measuring Radiator Cooling Capability 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

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

Difference in torque converter oil temperature between cooler inlet and outlet

10〜15 ° C

Difference in hydraulic oil temperature between cooler inlet and outlet

3〜5 ° C

・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 ° 〜71 ° C. temperature should stabilize at about 66 °

03-33

Measuring Radiator Cooling Capability

115ZIV-3 MEASUREMENT FOR PERFORMANCE CHECK 03

The torque converter oil is overheated

Possible cause

Coolant IN

Hydraulic oil IN

Hydraulic oil OUT

Torque converter oil OUT

Coolant OUT Torque converter oil IN

１１５ＺＡ０３０１

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

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

Clogged return filter

Check and cleaning

Insufficient air flow

Refer to "The engine coolant is overheated" described above.

Clogged hydraulic oil cooler ＊

Clean

＊ Be sure to check for clogging between the hydraulic oil

cooler and the radiator. This is not visible from the fan side. The oil cooler must be removed to check and clean completely.

03-34

Measuring Radiator Cooling Capability

115ZIV-3 MEASUREMENT FOR PERFORMANCE CHECK 03

T/C & T/M HYDRAULIC LINE

１１５Ｍ０３０１１

HYDRAULIC LINE-OIL COOLER

１１５Ｍ０３０１２

03-35

115Z Ⅳ -3 Troubleshooting, Measurement for Performance Check AAA-S11M1E01-004 AAA-S11M1E00-00Z

① 2000.1.31

K

② 2000.12.15

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

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