95ZV-2
93215-00500 June 2009
SHOP MANUAL
SHOP MANUAL
Troubleshooting
WHEEL LOADER
95ZV-2 Troubleshooting Measurement for Performance Check Check & Adjustment
Printed in Japan (K) ( ヨーロッパ用 )
93215-00500
©2009 KCM Corporation. All rights reserved.
Powered by CUMMINS QSX-15 Engine Serial No. 97C5-9001 and up
93215-00500 June 2009
Foreword To ensure good machine performance, reduce failures or problems, and prolong the service life of each component, it is necessary to operate the machine as is directed in the Operation and Maintenance Manual. To effectively diagnose and repair the machine, it is important to follow the guidelines laid out in this Shop Manual. Troubleshooting Measurement for Performance check For the engine, refer to the engine Shop Manual provided by the engine manufacturer. The purpose of this manual is to provide information on the product and the correct maintenance and repair methods. Please read this manual to ensure correct troubleshooting and good repair service. This manual will be periodically reviewed and revised for more satisfactory content. If you have any opinion or requests, please inform us.
Safety Precautions The most important point in providing repair service is safety. To ensure safety, observe the general cautions described below. - This manual is intended for properly trained and equipped service technicians. - Any work on the machine must be performed by the trained personnel only. - Carefully read this manual to thoroughly understand the operation method before you operate or repair the machine. - Be sure to wear appropriate clothes and protectors, such as safety boots, hard hat and goggles. - Place the machine on level and solid ground, and place chocks against the wheels to prevent movement. - Remove the cable from the battery before starting the service work, and attach a "DO NOT OPERATE!" tag to the steering wheel. - Be sure to release the internal pressure before you remove a pipe, such as the hydraulic oil, air, or engine coolant pipe. - Be sure to apply the articulation stopper before starting work. - While supporting the bottom of the chassis using a jack, be sure to support the chassis using the blocks. - When the boom or bucket is raised or when a unit is lifted by a crane, be sure to place a stand or adequate cribbing under the unit to prevent unexpected dropping. - Do not start to work in an enclosed area if adequate ventilation is not provided. - To remove a heavy unit (20 kg (40 lbs) or more), be sure to use a crane or other lifting device. - Just after stopping operation, be careful not to directly touch a hot component. You may get burned. - Contact tire manufacturer's local dealer for tire servicing and changing. - Always store the tools in good condition, and use them properly. - Keep the work area clean. Clean up spills immediately. - Avoid the use of flammable solvents and cleaners. - When working outdoors keep work areas, ladders, steps, decks and work platforms clear of snow, ice, and mud. - Use safe work platforms to reach higher areas of the machine.
Safety Symbols An accident may occur if you disregard safety rules. In this manual, several expressions are used according to levels of danger for inspection and repair work as shown below. Read the work procedures and cautions described in this manual, and take preventive measures against possible problems before starting service work.
DANGER This danger symbol identifies special warnings or procedures which, if not strictly observed, will result in death or serious injury.
WARNING This warning symbol identifies special warnings or procedures which, if not strictly observed, could result in death or serious injury.
CAUTION This caution symbol identifies special instructions or procedures which, if not strictly observed, may result in minor or moderate injury.
IMPORTANT This important symbol identifies special instructions or procedures which, if not correctly followed, may result in serious machine damage.
We cannot predict all possible accidents or incidents that may occur during service work. Therefore, an accident that is not specifically mentioned in this manual may occur. To protect yourself from all accidents, be careful when doing service work.
Symbols For safe and effective service work, the following symbols are used for notes and useful information in this manual. Symbol
Item
Description
Reference
Shows the condition or procedure that will be useful or efficient in doing service work.
Weight
Shows the weight of a part or unit. The weight should be considered in selecting wire rope or cable for slinging work or determining the working posture.
Tightening Shows the tightening torque of a section that should torque be carefully tightened during assembly work.
Coating
Shows the type of coating or adhesive and the coating section.
Oil or water supply
Shows the oil or water supply port and the refill amount.
Drainage
Shows the oil or water drain port and the drain amount.
IMPORTANT If the specified conditions are not satisfied or the specified procedure is not observed, there is a strong possibility that the product will be damaged or the performance of the product will be reduced. The message shows the preventive measures.
Abbreviation To save space, abbreviations are used in sentences. To understand the contents of this manual, refer to the following abbreviation list. E/G ........... Engine T/C ........... Torque converter T/M ........... Transmission SOL ........... Solenoid valve SW ........... Switch F ........... Front or Forward A/M ........... Auto/Manual B ........... Battery R ........... Rear or Reverse
RH ........... Right hand side LH ........... Left hand side H ........... High L ........... Low GND ........... Ground OPT ........... Option Assy ........... Assembly 1st ........... 1st speed 2nd ........... 2nd speed
3rd ............3rd speed 4th ............4th speed M/C ............Machine min-1 ............RPM ELS ............Efficient loading system MODM ........Machine operation diagnostic module MCU............Machine control unit
CONTENTS TROUBLESHOOTING ......................................................01-1
MEASUREMENT FOR PERFORMANCE CHECK ...........03-1
MEMO
01-1
Troubleshooting 01 Cautions Regarding Troubleshooting ................................................................................................................ 01-3 How to Use Quick Troubleshooting Table ......................................................................................................... 01-4 Safety Precautions ............................................................................................................................................ 01-5
Torque Converter and Transmission Group ...................................................................................................... 01-6 1. Machine dose not move in any shift lever position. ................................................................................ 01-6 2. Machine dose not move at a certain shift lever position. (OR:Machine moves only in a certain shift lever position.) ..................................................................... 01-7 3. Machine moves at the neutral position. (Example: Machine moves forward at the neutral position.) .... 01-8 4. Large shock at starting or changing speed / direction ............................................................................ 01-9 5. Large time lag at starting or changing speed / direction ....................................................................... 01-10 6. Low power (Defective torque converter or transmission) ..................................................................... 01-11 7. Torque converter oil is overheating. ..................................................................................................... 01-12 8. Machine moves reverse when starting to climb up on a slope using inching brake. ............................ 01-13 9. Automatic speed change is not possible. ............................................................................................. 01-14 10. Downshift button does not work. ........................................................................................................... 01-15
Hydraulic Group .............................................................................................................................................. 01-16 1. Boom and/or bucket do not move. ........................................................................................................ 01-16 2. Boom and/or bucket have low power, or move too slowly. ................................................................... 01-17 3. Excessive cylinder drift ......................................................................................................................... 01-18 4. Boom and/or bucket are spongy. (Holding bucket against the ground is not possible-front wheels off the ground.) ................................ 01-19 5. Bucket leveler does not work. Boom lift kickout and lower kickout does not work. .............................. 01-20 6. Steering is not possible or hard to steer. .............................................................................................. 01-21 7. Machine sways, or has a shock during steering ................................................................................... 01-22 8. ELS (Efficient Loading System) does not work. (Excavating and scooping tractive power does not become up during ELS working condition) ........... 01-23
01-2
9. Ride control does not work. .................................................................................................................. 01-24 10. Fan motor rotates abnormally or does not rotate. ................................................................................. 01-25 11. Abnormal noise in hydraulic system. .................................................................................................... 01-26 12. Others ................................................................................................................................................... 01-27
Brake Group .................................................................................................................................................... 01-28 1. Brake does not work well. (In the worst case, the brake does not work at all.) .................................... 01-28 2. Brake is dragging when released. ......................................................................................................... 01-29 3. Stepping on the brake pedal sounds the buzzer. .................................................................................. 01-30 4. Accumulator pressure does not rise, or too slow in rising. .................................................................... 01-31 5. Parking brake does not work. (or: Releasing the parking brake is not possible.) ................................. 01-32
Electrical Group ............................................................................................................................................... 01-33 1. Instrument panel does not indicate properly. ........................................................................................ 01-33 2. Fuse for controller is blown. .................................................................................................................. 01-34 Error code (for chassis) ............................................................................................................................. 01-35 Error code (for engine) .............................................................................................................................. 01-38
Operator Station Group ................................................................................................................................... 01-44 Air conditioner ........................................................................................................................................... 01-44
01-3 95ZV-2 Troubleshooting Cautions Regarding Troubleshooting
Cautions Regarding Troubleshooting Important points The important points for troubleshooting is to carefully read the operation manual and shop manual to get enough information on the operation, circuits, structure, and function of each component. If you have enough knowledge of each component and system, you can easily determine the cause of the problem. There may be various causes for each problem, therefore experience will be needed to determine which is the actual cause of the problem. It is necessary to know the normal operation of each component. In addition, it is also important to know the abnormal condition when a problem occurs. This chapter shows various examples of past problems, and describes possible causes and remedies for each problem.
Before starting troubleshooting To prevent incorrect diagnosis, talk with the persons concerned, particularly with the operator, to get enough information on the problem. If possible, check the machine by repeating the symptom. If the problem cannot be repeated, do not provide any repair service. For instance, assume that the operator complains that the boom power is low, and the rim-pull is also low. In this case, there are two possible causes; low hydraulic power and low rim-pull. The remedies against both causes are much different from each other. If you hastily determine the wrong cause without checking the actual condition of the problem, it will take too much time and expense to solve the problem. As a result, you will not be trusted by the user.
The following questions will be helpful in determining of the cause. Answer the questions to prevent an incorrect diagnosis. 1. Did the problem occur suddenly? 2. When did the operator notice the problem? 3. Is there any past problem that may be the cause of this problem? 4. When the problem occurred, what kind of work was the operator doing? 5. Has the machine had the same kind of problem before? 6. Has the machine been repaired or inspected recently? 7. Does the machine have any other problem?
Troubleshooting - Check before determination of cause A problem may be caused by poor daily maintenance, such as lack of grease, low or improper oil or a clogged filter. Be sure to check the machine for oil level, appearance, unpleasant odor, etc. to prevent time loss due to other unnecessary tests. - Inspection procedure As a rule, check the easy-to-be-repaired system first (excluding the cases where the cause can be easily determined based on the past experiences). This machine is controlled by electrical, hydraulic, and mechanical systems. The most easy-to-berepaired system is the electrical system. Check the electrical system first. If no problem is detected in the electrical system, check the hydraulic system, and then the mechanical system. Note Check the error code on the MODM at first !
01-4 95ZV-2 Troubleshooting How to Use Quick Troubleshooting Table
How to Use Quick Troubleshooting Table To immediately determine the cause of the problem without disassembling parts, use the quick troubleshooting table. From the problem explained by the user and the check points written in the table, you can immediately determine the cause of the problem.
How to use quick troubleshooting table 1. According to the problem explained by the user, open the quick troubleshooting table to the page where the corresponding problem is described. 2. Check the machine according to the "Symptoms/ check point" field in the table. Start from the most easily checked point. 3. Operate the machine, and write the check marks " " in the corresponding circles " " if the problem occurs. 4. Generally, the possible cause that has many check marks will be actual cause. If two or more possible causes have several check marks, check each possible cause to prevent an incorrect diagnosis. In this case, start from the most easily checked item.
01-5 95ZV-2 Troubleshooting Safety Precautions
Safety Precautions DANGER
WARNING
Entering the articulation area of the machine body while the engine is running may cause severe accidents.
Service work under the machine may cause an accident resulting in injury or death. To prevent such an accident, be sure to observe the following items.
Make sure to stop the engine, pull out the starter key, and attach a "DO NOT OPERATE!" tag to the cab before entering the articulation area.
- Park the machine on level ground. - Apply the parking brake. - Block the tires with chocks to prevent the tires from moving. - Stop the engine. - Give signals to the person in the cab during the work.
WARNING Unexpected movement of the machine may cause an accident resulting in injury or death. Therefore, to provide repair service with the engine running, be sure to observe the following items. - Park the machine on level ground. - Apply the parking brake. - Block the tires with chocks to prevent the tires from moving. - Determine the signals between the service man. - Prohibit any person from walking into dangerous areas. - Near articulation areas of the machine - Under the machine - Around the engine - In front of or behind the machine
WARNING Standing under the boom or bucket during service work is dangerous. An accident resulting in injury or death may be caused. To prevent such an accident, be sure to observe the following items. - Park the machine on level ground. - Apply the parking brake. - Block the tires with chocks to prevent the tires from moving. - Place a stand under the boom to support it. - Apply the safety look of the boom and bucket control lever provided in the cab. - Remove the starter key, and attach a "DO NOT OPERATE!" tag to the cab.
CAUTION Do not touch the fan or V-belt of the engine or a hightemperature section if the engine is running. An accident resulting in injury may occur. Be sure to stop the engine before you open the side cover of the engine room. Avoid high temperature components even when the engine is stopped.
CAUTION Be careful not to be burnt by bursting high pressure oil. Release the pressure remaining inside the circuit and open the cap of the hydraulic oil tank before removing the plug from the pressure measurement port so that the internal pressure of the hydraulic oil tank is released and burst of the high pressure oil can be prevented.
01-6 95ZV-2 Troubleshooting Torque Converter and Transmission Group
Torque Converter and Transmission Group
Pump produces an abnormal (shrieking) noise.
Pump is extremely heated.
F5 fuse blows.
Setting the declutch ON/OFF switch to OFF allows normal operation.
Filter of the torque converter is clogged.
Temperature of the torque converter oil is too high.
Torque converter oil becomes milky and cloudy in color.
Possible cause
Low clutch oil pressure at all the shift lever positions.
Check before starting work. 1. Check that the parking brake is released. 2. Check the error code No. shown on the MODM. 3. Check the transmission oil level. 4. Check the fuses of the controller system. 5. Check that the auto brake solenoid valve is released. 6. Check the 70 A fusible link. (If the 70 A fusible link is off, no electrical circuits will operate except horn circuit and hazard flasher [opt.].)
Symptoms / check point
1. Machine dose not move in any shift lever position.
Solution
Air drawn into suction line of the torque converter pump
Tightening hose band
Defective torque converter pump
Pump replacement
Damaged torque converter
Disassembly & repair
Sticking modulator valve (1)
Disassembly & repair
Malfunctioning inching pressure switch
Switch replacement
Defective controller
Controller replacement
Neutral relay, controller fault relay, lift kickout and lower kickout relay, parking switch wirings short circuited
Repairing wiring
Restricted suction line - pinched, plugged, or internally defective.
Replace hose
Malfunctioning clutch pressure regulator valve in modulator valve unit.
Valve replacement
Malfunctioning modulator valve (1)
Valve replacement
Machine may move even when shift lever is in "NEUTRAL".
F5 fuse blows.
Clutch can be engaged at a certain shift lever position, though the clutch will not be engaged at any other position.
Clutch oil pressure is always high despite shift lever position.
Even when pressing solenoid valve, machine does not move.
24V power is not supplied to the solenoid valve.
Resistance of the solenoid valve coil is infinite Ω.
Clutch oil pressure is low at a certain position only. At all the other positions, the pressure is normal.
Torque converter oil looks and smells as if it was scorched (black).
Possible cause
Machine moves at a certain shift lever position, but hesitates to move at any other positions.
Check before starting work. 1. Check the error code No. shown on the MODM.
Symptoms / check point
2. Machine dose not move at a certain shift lever position. (OR:Machine moves only in a certain shift lever position.)
Machine does not move at a certain shift lever position, but moves at all the other positions.
01-7 95ZV-2 Troubleshooting Torque Converter and Transmission Group
Solution
Clutch slipping
Disassembly & repair
Seized clutch
Disassembly & repair
Clutch oil leaks internally.
Disassembly & repair
Coil of clutch solenoid valve is defective.
Solenoid valve replacement
Harness of clutch solenoid valve disconnected
Repair cable
Clutch solenoid valve or clutch valve sticking in OFF position
Replacement or repair
Clutch solenoid valve or clutch valve sticking in ON position
Replacement or repair
Shift lever switch sticking in ON (regardless of position)
Shift lever replacement
Shift lever switch sticking in OFF (regardless of position)
Shift lever replacement
Damaged clutch solenoid valve diode
Solenoid valve replacement
Defective controller
Controller replacement
Short circuited clutch solenoid or wiring
Repair cable
Oil is black and smells scorched.
Possible cause
When the lever is shifted to the reverse position, the machine does not move reverse (as if the brake is applied).
Check before starting work. 1. Check that the ground is level. 2. Check the error code No. shown on the MODM.
Symptoms / check point
3. Machine moves at the neutral position. (Example: Machine moves forward at the neutral position.)
When the lever is shifted to the forward position, the machine moves forward.
01-8 95ZV-2 Troubleshooting Torque Converter and Transmission Group
Seized clutch on forward side ∗
T/M disassembly & repair
Malfunctioning forward solenoid valve (sticking at ON position) ∗
Solenoid valve replacement
Defective controller (malfunctioned after outputting "F") ∗
Controller replacement
Defective shift lever (switch stuck in "F" position) ∗
Shift lever replacement
∗ The same possible cause but involving the reverse clutch or circuit could occur with the opposite symptoms.
Remarks
Solution
01-9 95ZV-2 Troubleshooting Torque Converter and Transmission Group
4. Large shock at starting or changing speed / direction
Line filter is clogged.
Temperature of the torque converter oil is too high.
Main oil pressure rises too quickly at all the shift lever positions.
Large shock at a certain shift lever position only.
Possible cause
Large shock at all the shift lever positions.
Symptoms / check point
Check before starting work. 1. Check the error code No. shown on the MODM.
Solution
Malfunctioning modulator valve (1) (stuck in high pressure position)
Disassembly & repair
Malfunctioning modulator valve (2) (stuck in OFF position)
Disassembly & repair
Disconnected harness of modulator valve (2)
Repair
Defective controller
Controller replacement
Damaged or worn clutch disk (seized clutch)
T/M disassembly & repair
Malfunctioning pressure sensor
Replacement
Clutch pressure regulator valve stuck
Repair
Large time lag at a certain shift lever position only.
Main oil pressure is too low at all the shift lever positions.
Main oil pressure rises too slowly at all the shift lever positons.
Possible cause
Large time lag at all the shift lever positions.
Symptoms / check point
Check before starting work. 1. Check the error code No. shown on the MODM.
Time lag jsut after using the inching brake (check setting condition).
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.
01-10 95ZV-2 Troubleshooting Torque Converter and Transmission Group
Solution
Defective torque converter pump
Pump replacement
Malfunctioning modulator valve (1) (stuck in high pressure position)
Disassembly & repair
Malfunctioning modulator valve (2) (stuck in ON position)
Disassembly & repair
Restricted suction line-pinched, internally defective
Repair
Defective controller
Controller replacement
Internally leaked clutch oil
T/M disassembly & repair
Malfunctioning inching pressure switch
Switch replacement
Harness of modulator valve (1) disconnected
Repair
Malfunctioning pressure sensor
Replacement
01-11 95ZV-2 Troubleshooting Torque Converter and Transmission Group
Pump produces an abnormal (shrieking) noise.
Pump is extremely heated.
Clutch oil pressure is too low at a certain shift lever position.
Silver power (Aluminum) is on the line filter and strainer.
Torque converter oil is milky and cloudy in color.
Torque converter oil is discolored or emits nasty smell.
Temperature of the torque converter oil is too high.
Large time lag at a certain shift lever position only.
Machine moves even if the shift lever is set to the neutral position. ∗
Solution
Air drawn into suction line of torque converter
Tightening suction hose band
Broken torque converter turbine and pump
T/C disassembly & repair
Torque converter internal pressure too low
Regulator valve check
Seized clutch
T/M disassembly & repair
Clutch slipping
T/M disassembly & repair
Internally leaking clutch oil
T/M disassembly & repair
Restricted suction line-pinched, internally defective
Replace hose
Harness of modulator valve (1) disconnected
Disassembly & repair
Modulator valve spool sticking in OFF position
Disassembly & repair
Defective controller
Replacement
∗ If the seized clutch is Forward or Reverse clutch. Remarks
Output power is low at a certain shift lever position only.
Possible cause
Output power is low at all the shift lever positons.
Check before starting work. 1. Check the parking brake and service brake for dragging. 2. Check the torque converter oil level. 3. Check that no unusual load is applied to the hydraulic line (like excessive pilot pressure). 4. Check that the engine speed is standard value. 5. Check the error code No. shown on the MODM.
Symptoms / check point
6. Low power (Defective torque converter or transmission)
Overheating.
Engine speed at no load or during stall test is too low.
Thermometer in T/C out line indicates less than 250ºF/120ºC when gauge or light indicates overheat.
Service or parking brake is excessively hot/discolored.
Pump produces an abnormal (shrieking) noise.
Pump is extremely heated.
Output power is too small at a certain shift lever position.
Foreigh material is on the filter-especially silver powder (Aluminum).
Torque converter oil is discolored or emits nasty smell.
Machine does not move at a certain shift lever position (or dragging is felt).
Torque converter inlet pressure is too low.
Clutch oil pressure is too low.
Possible cause
Torque converter oil is milky and cloudy in color.
Check before starting work. 1. Check the torque converter oil level. 2. Check the engine coolant for overheat. 3. Check the oil pressure-adjust to specification. 4. Check the error code No. shown on the MODM.
Symptoms / check point
7. Torque converter oil is overheating.
Less difference in torque converter oil temperature between cooler inlet and outlet.
01-12 95ZV-2 Troubleshooting Torque Converter and Transmission Group
Solution
Air drawn into suction line of torque converter
Tightening hose band
Internally torque converter leakage
T/C disassembly & repair
Damaged torque converter
T/C disassembly & repair
Torque converter pump discharge amount too small
T/C pump disassembly & repair
Seized clutch
T/M disassembly & repair
Clutch slipping
T/M disassembly & repair
Scale deposited in water line of torque converter cooler
Cooler cleaning
Restricted suction line-pinched, internally defective
Replace hose
Wrong oil viscosity is used.
Replace w/proper oil
Service or parking brake dragging
Test/repair brake circuit
Operator is using too high gear for loading.
Train operator
Incorrect indication of gauge (no alarm)
Test/replace gauge or sensor
Alarm switch defective (gauge in normal zone)
Replace switch
Contamination in oil cooler (oil side)
Replace cooler
Engine speed too low / Engine power too low
See E/G Trouble shooting
01-13 95ZV-2 Troubleshooting Torque Converter and Transmission Group
8. Machine moves reverse when starting to climb up on a slope using inching brake.
Possible cause Large time lag in clutch engagement
After pedal release, too much time is required to move.
Symptoms / check point
Check before starting work. 1. Check the error code No. shown on the MODM.
∗
Solution Refer to description of time lag (No.5) ∗
Inching set-up condition abnormal
Set-up normally
Defective inching sensor
Replacement
01-14 95ZV-2 Troubleshooting Torque Converter and Transmission Group
Not indicates "1" on input "1" correspunds to shift lever "A" (MODM).
One or more planetaries are excessively hot/parking brake is hot or discolored.
Speed indicator lamp does not change even if machine speed is changed.
Actual speed increase or reduction does not correspond with the set speed.
Speed is properly increased on a downward slope.
Spees is fixed to 3rd speed, and is not increased to 4th speed.
Possible cause
Speed is fixed to 2nd speed, and automatic speed change is not possible.
Check before starting work. 1. Manually change the speed from 1st speed to 4th (R:3rd) speed. If manual speed change is impossible, refer to "Machine does not move at a certain shift lever position." (No.2) 2. Check the error code No. shown on the MODM.
Symptoms / check point
9. Automatic speed change is not possible.
Solution
Defective shift lever "A" position or defective wiring to controller
Shift lever replacement or repairing wire
Damaged speed sensor or disconnected sensor
Sensor replacement or repairing wire
Speed sensor signal output error or improperly adjusted speed sensor
Sensor replacement or readjustment
Defective controller
Controller replacement
Low machine speed (engine output power too low)
Inspection & repair
Parking or service brakes dragging
Test/repair brake circuit
01-15 95ZV-2 Troubleshooting Torque Converter and Transmission Group
Possible cause
Downshift button does not work.
Check before starting work. 1. Check that the downshift button is being used at the 2nd and the auto forward/ reverse speed position. At the other positions, shifting down is not possible. 2. Check the fuses. 3. Check the error code No. shown on the MODM.
Symptoms / check point
10. Downshift button does not work.
Solution
Defective downshift button
Downshift button replacement
Disconnected downshift button or wiring
Repair wire
Defective controller
Replacement
Defective 1st or 2nd solenoid valve or wiring failure
Inspection & repair / Refer to (No.2)
01-16 95ZV-2 Troubleshooting Hydraulic Group
Multiple control vale
Pump
Pump is extremely heated.
Main relief valve produces a noise.
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.
Main relief pressure is too low when the boom or bucket is operating.
No main relief pressure built.
Boom and bucket move with no load, though they do not move when loaded.
Either the boom or bucket does not move.
Possible cause
Steering is not possible either.
Check before starting work. 1. Check the oil level. 2. Check that the loading control lock lever is fully released. 3. Check that the pilot valve in-line filter is not clogged. 4. Check the error code No. shown on the MODM.
Symptoms / check point
1. Boom and/or bucket do not move.
Boom and bucket do not move normally while the engine runs idle but appears to move normally while it runs at full speed.
Hydraulic Group
Broken pump drive shaft
Pump replacement
Internally damaged steering pump.
Disassembly & repair
Internally damaged main pump.
Disassembly & repair
Internally damaged pilot pump.
Disassembly & repair
Main relief valve internal oil leakage or low setting pressure
Disassembly & readjustment
Overload relief valve internal oil leakage or low setting pressure
Disassembly & readjustment
Multiple control valve spool sticking
Plunger & replacement
Defective reducing valve (for pilot)
Disassembly & readjustment
Internally damaged cylinder
Disassembly & repair
∗ Exchange of the overlord relief valve means that the valves should be changed between the rod and bottom sides. Remarks
Solution
01-17 95ZV-2 Troubleshooting Hydraulic Group
Pump makes noise (shrieking).
Oil is foamy or milky looking after operation.
Bucket drifts down when full.
Pump is extremely heated.
Main relief valve produces a noise.
Only bucket "roll back" operation is abnormal.
Either the boom and bucket does not operate properly.
Both the boom and bucket do not operate properly.
Steering system operates properly.
Possible cause
Steering system does not operate properly.
Check before starting work. 1. Check the oil level. 2. Check that the loading control lock lever is fully released. 3. Check that the engine speed is standard value. 4. Check that the machine does not move if the shift lever of the transmission is at the natural position. Dragging/seized clutches reduce power available to hydraulics. 5. Check that the machine rolls freely in neutral. If the brakes, service or parking, drag it reduces the power available to hydraulics when the machine is moving. (Static testing will show normal hydraulic power and speed.) 6. Check that the pilot valve filter is not clogged. 7. Check the error code No. shown on the MODM.
Symptoms / check point
2. Boom and/or bucket have low power, or move too slowly.
Solution
Internally damaged steering pump.
Disassembly & repair
Internally damaged main pump.
Disassembly & repair
Main relief valve internal oil leakage or low setting pressure
Disassembly & readjustment
Overload relief valve internal oil leakage (bucket bottom side)
Disassembly & readjustment
Internally damaged cylinder.
Disassembly & repair
Oil is cold, wrong oil viscosity (too thick).
Warm up hydraulics Replace oil w/proper oil
Suction side air leak-clamp, hose, o-rings
Check & repair suction line
Suction line pinched or internally defective.
Check & repair suction line
Defective reducing valve (for pilot)
Disassembly & readjustment
Bucket or boom spool does not move smoothly.
Disassembly & repair
Solution
Internal boom cylinder piston seal oil leakage
Seal replacement
Internal bucket cylinder piston seal oil leakage
Seal replacement
Internal oil leakage from multiple control valve main spool
Disassembly & repair
Internal oil leakage from multiple control valve overload relief valve
Disassembly & repair
∗ This test may cause a serious accident. The test must be done carefully.
Remarks
Front wheels drift down when the front wheels are lifted off the ground by means of the bucket cylinder.
Excessive drift of bucket.
Possible cause
Excessive drift of boom.
Symptoms / check point
Check before starting work. 1. Check the error code No. shown on the MODM.
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 instructions on "Measuring Cylinder Drift".
When the piping for cylinder rod side is removed, pressurized oil spouts out. ∗ (The bucket hight should be 20~30 mm from the ground.)
3. Excessive cylinder drift
In the case that the overlord relief valve is switched or replaced, excessive drift stops.
01-18 95ZV-2 Troubleshooting Hydraulic Group
Boom is spongy just after quick lowering.
Boom cannot support the lifted front wheels, or the lifted front wheels soon drop.
Boom and bucket are strong enough if the engine runs at the full speed while dumping or lowering.
Bucket is spongy just after dumping.
Overload relief pressure is too low.
In case that the overload relief valves are switched ∗, the boom and bucket are strong enough to support the front wheels.
Possible cause
Bucket cannot support the lifted front wheels, or the lifted front wheels soon drop.
Check before starting work. 1. Check the error code No. shown on the MODM.
Symptoms / check point
4. Boom and/or bucket are spongy. (Holding bucket against the ground is not possible-front wheels off the ground.)
During digging operation, the bucket tilts back even though the lever is at the neutral position.
01-19 95ZV-2 Troubleshooting Hydraulic Group
Solution
Internal oil leakage from overload relief valve for bucket rod side
Disassembly & repair
Internal oil leakage from make-up valve for bucket rod side
Disassembly & repair
Make-up valve does not open on bucket rod side
Disassembly & repair
Internal oil leakage from make-up valve for boom rod side
Disassembly & repair
Make-up valve opening impossible on boom rod side
Disassembly & repair
Remarks
∗ Regarding check point above, switching the overload relief valves means that the valves should be changed between the rod and bottom sides of the bucket circuit.
Boom
Bucket
Check the relays and lines for lift kickout and lower kickout.
Remove the connector of the sensor assy and check that the harness (RLg) from chassis side supplies 5 V, harness (BY) is ground and harness (BrR) is conductive until MODM (Starter switch ON condition).
Magnet coil resistance value is indicated as infinity or 0 Ω.
Possible cause
Remove the connector of the proximity switch, and connect the wire harness, from the pilot valve to the ground. Check that the lever is held properly.
Check before starting work. 1. Check the fuses. 2. For bucket / Check that the distance between the proximity switch and detection bar is properly adjusted. 5±2 mm (0.2±0.08 in) 3. For boom / Check that the rod and link are properly connected with the sensor assy and the bracket of the boom. 4. Check all the connectors of the electrical power line to be sure they are properly connected. 5. Check the error code No. shown on the MODM.
Symptoms / check point
5. Bucket leveler does not work. Boom lift kickout and lower kickout does not work.
LED lamp of the proximity switch does not light (starter switch ON & metal plate in front of proximity switch face).
01-20 95ZV-2 Troubleshooting Hydraulic Group
Solution
Defective proximity switch
Proximity switch replacement
Broken detent solenoid coil inside pilot valve
Magnet replacement
Disconnected electrical power line
Repair
Defective sensor assy
Replacement
Broken detent solenoid coil inside pilot valve
Replacement
Disconnected electrical power line for lift kickout and lower kickout
Repair
01-21 95ZV-2 Troubleshooting Hydraulic Group
Internally damaged Orbitrol
®
Sticking stop valve spool
Pump is extremely heated.
If the overload relief valves are exchanged ∗, steering problem switches sides.
Overload relief pressure is too low.
Steering relief pressure is too low.
Increasing the engine speed enables smooth operation.
Steering is not possible at both the idling and full speeds.
Steering relief valve produces a noise.
Steering is possible in either the right or left direction.
Steering is not possible (or hard) in both the right and left directions.
Boom is too slow in rising.
Steering wheel is too loose (too light).
Possible cause
Steering wheel does not rotate or is heavy to rotate.
Check before starting work. 1. Check the oil level in the hydraulic tank. 2. Check that the stop bolts for the stop valves are properly adjusted. 3. Check operating conditions. Full brake application & heavy loading may create hard steering even when steering system is normal. 4. Measure steering wheel force to see if it is greater than normal. 5. Check that the pilot valve in-line filter is not clogged. 6. Check the error code No. shown on the MODM.
Symptoms / check point
6. Steering is not possible or hard to steer.
Solution Disassembly & repair Disassembly & repair
Internally damaged steering pump (deteriorated performance)
Disassembly & repair
Malfunctioning steering valve or flow control spool
Disassembly & repair
Defective main relief valve
Disassembly & repair
Defective overload relief valve (One side only)
Disassembly & repair
Defective steering cylinder
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
Defective steering pilot line reducing valve
Disassembly & repair
Steering plunger stuck
Disassembly & repair
Remarks
∗ Regarding check point above, exchange of the overload relief valve means that the valves should be changed between the left and right sides. The problem will also switch sides (weak steering to the left will, after exchange, become weak steering to the right).
Steering cylinders or circuit recently repaired.
Shock is noticed only when steering fully to right or left.
Shock is applied to the machine after quick steering.
Possible cause
Machine sways after quick steering.
Symptoms / check point
7. Machine sways, or has a shock during steering
While the machine is travelling straight, the machine sways even if the steering wheel is held steady.
01-22 95ZV-2 Troubleshooting Hydraulic Group
Solution
Loose steering cylinder pin ∗
Pin replacement or shim add
Tire having different diameter
Use of equal diameter tires
Large difference in air pressure of tires
Air pressure adjustment
Steering stopper bolt or bolts for stop valve misadjusted or missing
Adjust stopper bolts
Air trapped in steering cylinders
Steer full L & R several times to purge air
Remarks
∗ Have an operator quickly move the steering wheel right and left a few degrees. If the cylinder pin moves back & forth replace the pin & bushing. If the cylinders jump up & down add shims.
01-23 95ZV-2 Troubleshooting Hydraulic Group
At upper position of lower kickout setting, ELS works.
Without pressing ELS switch, if functions.
Possible cause
Pressing ELS switch, it does not function.
Check before starting work. 1. Check the error code No. shown on the MODM.
Symptoms / check point
8. ELS (Efficient Loading System) does not work. (Excavating and scooping tractive power does not become up during ELS working condition)
Solution
ELS switch defective
Repair
Solenoid valve coil or wiring failure
Disassembly & repair
Solenoid valve spool stuck
Disassembly & repair
Relief valve set pressure is extremely low.
Disassembly & repair
Main controller failure
Replacement
Kickout sensor defective or link, rod bent
Replacement or repair
Speed sensor failure
Replacement
Pump defective
Refer to (No.1)
01-24 95ZV-2 Troubleshooting Hydraulic Group
9. Ride control does not work.
Reducing valve chattering.
Damping condition too hard.
Damping condition too soft.
It takes a time to function.
Possible cause
Ride control does not work.
Symptoms / check point
Check before starting work. 1. Check the error code No. shown on the MODM.
Solution
Ride control switch or wiring defective
Replacement
Check valve (main spool) stuck
Disassembly & repair
Malfunctioning reducing valve
Disassembly & repair
Malfunctioning solenoid valve (2 pieces)
Disassembly & repair or replacement
Accumulator piston seal failure
Disassembly & repair
Accumulator gas pressure low
Check & charge gas
Bleeder valve loosened
Retighten
Bucket fully roll-back till touching with stopper
Make a clearance between stoppers
Check valve defective
Replacement
Speed sensor defective
Replacement
Controller defective
Replacement
01-25 95ZV-2 Troubleshooting Hydraulic Group
10. Fan motor rotates abnormally or does not rotate.
For reverse fan (OPT)
Reverse fan rotates slow or extremely slow.
OPT: Reverse fan does not rotates.
Fan motor makes noise.
Fan motor does not rotates.
Fan motor rotates faster than specified speed.
Possible cause
Fan motor rotates slow or extremely slow.
Symptoms / check point
Check before starting work. 1. Check the error code No. shown on the MODM.
Solution
Sensor (for E/G water or T/C oil or HYD. oil temperature) failure
Replacement
Safety valve setting pressure low
Check & adjust or repair
Proportional solenoid valve struck or not enough to move
Check & repair
Wiring or connector failure
Check & repair
Main controller malfunction
Replacement
Check valve failure
Replacement
Adjusting screw loosened (proportional solenoid valve)
Readjust
Fan motor damaged (bearing, shoe, etc.)
Replacement
Wiring or connector failure
Repair
Main spool stuck
Repair
Reverse fan solenoid valve stuck
Repair
01-26 95ZV-2 Troubleshooting Hydraulic Group
Noise may vary with engine speed or circuit being used.
Possible cause
Pump emits a shrieking sound.
Symptoms / check point
Check before starting work. 1. Check the error code No. shown on the MODM.
Increasing the engine speed emits a whining sound. (Hydraulics slow)
11. Abnormal noise in hydraulic system.
Solution
Air drawn into pump suction line
Hose band tightening & inspection
Internally broken pump
Disassembly & repair
High-pressure hose contact with chassis-loose sheet metal
Hose clamp check & repair
Suction hose pinched or internally defective
Inspect or replace hose
Suction line or strainer restricted
Drain & inspect tank
Engine cooling water (torque converter oil) overheats. (Fan motor does not switch to high speed.)
Oil milky white
Hydraulic cylinder packings leak repeatedly.
Hydraulic oil is mixed with the torque converter oil.
Hydraulic oil is foaming in the tank.
Boom or bucket moves too slow.
Possible cause
When the boom lever is switched from "DOWN" to "NEUTRAL", the boom will continue to lower. ∗
Symptoms / check point
Check before starting work. 1. Check the error code No. shown on the MODM.
When the bucket lever is set to "Roll-back" position, the bucket will be dumped slightly down first and then tilt back.
12. Others
When the boom lever is set to "UP" position, the boom will drop slightly first and then rise.
01-27 95ZV-2 Troubleshooting Hydraulic Group
Solution
Defective (incompletely closed) load check valve in multiple control valve boom line
Disassembly & repair
Defective (incompletely closed) load check valve in multiple control valve bucket line
Disassembly & repair
Clogged orifice of adapter in boom line ∗
Disassembly & repair
Malfunctioning multiple control valve or pilot valve is sticking.
Disassembly & repair
Air drawn into pump suction line
Tightening hose band
Damaged hydraulic oil pump (Seal)
Repair
Excessive hydraulic oil temp, due to cooler problems or improper operation
Test cooling Change operation
Water in hydraulic oil
Drain & replace oil
Defective thermo sensor
Check & repair refer to (No.10)
Defective relief valve of fan motor
Remarks
∗ Very cold or thick oil will also cause this symptom. If the problem stops when the oil warms up or the proper viscosity oil is used the orifice is normal. Clogged adapter orifice will cause slow boom response in both up and down directions.
01-28 95ZV-2 Troubleshooting Brake Group
Brake pedal stroke is large.
Brake is hard to work when the right pedal is depressed.
When the pedal is pressed, the brake oil pressure greatly deffers between the front axle brake and rear axle brake.
Possible cause
Both the right and left pedals have low braking resistance when pressed.
Check before starting work. 1. Check the Nitrogen gas pressure in the accumulator. 2. Check the brake piping for leakage. 3. Check the error code No. shown on the MODM.
Symptoms / check point
1. Brake does not work well. (In the worst case, the brake does not work at all.)
Measure the wear of the brake disk using calipers. The obtained wear value is less than the specified limit value.
Brake Group
Solution
Worn brake disk
Disassembly & repair
Defective accumulator
Disassembly & repair
Sticking brake valve spool
Disassembly & repair
Damaged brake oil pipe
Pipe replacement
Damaged brake piston seals one wheel
Seal replacement
Defective shaft between left and right pedals
Disassembly & repair
Defective pedal stroke adjustment
Disassembly & repair
01-29 95ZV-2 Troubleshooting Brake Group
2. Brake is dragging when released.
Manual rotation of the tire is not possible.
Pressing brake pedal is spongy feeling.
Either the front or rear axle causes dragging.
Possible cause
Brake is dragging.
Check before starting work. 1. Check the error code No. shown on the MODM.
Symptoms / check point
How to check dragging. 1. Check that the cover of the planetary gear is too hot (more than 100ºC [212ºF]). 2. Jack up the tires, and check that manual rotation (by hand) of the tire is not possible.
Solution
Stepping on brake pedal during traveling (Riding the brakes)
Instruction for operator
Insufficient return of brake pedal
Disassembly & repair
Incomplete air bleeding from the brake oil circuit
Disassembly, repair & air bleeding
Distorted brake disk due to seizure
Disassembly & repair
Insufficient return of brake piston
Disassembly & repair
Non-returned brake piston after replacement of brake disk
Disassembly & repair
Defective pedal stroke adjustment
Disassembly & repair
Defective brake valve
Disassembly & repair
01-30 95ZV-2 Troubleshooting Brake Group
3. Stepping on the brake pedal sounds the buzzer.
Parking brake is not released.
External pipe is only, leaking.
Too much time is required for accumulator charging.
Unloader valve on-load perssure is too low.
Buzzer sounds when the pedal is repeatedly depressed.
Pedal resistance is too low when depressed.
Possible cause
Buzzer sounds each time the brake pedal is stepped on.
Check before starting work. 1. Check the accumulator Nitrogen gas pressure. 2. Step on the pedal, and check that oil is not leaking. 3. Check the error code No. shown on the MODM.
Symptoms / check point
Conditions for buzzer sounding. 1. Low accumulator pressure [3.9 MPa (40 kgf/cm2) (569 psi) or less].
Solution
Insufficient pressure in accumulator
Adjust gas pressure
Low unloader valve switching pressure
Inspection & readjustment
Delay in working unloader valve
Inspection & readjustment
Large amount of oil leakage from brake piping
Disassembly & repair
Defective low oil pressure warning switch
Replace switch
Defective pilot pump
Replace pump
Brake oil piping damaged or loose
Repair / tightening
01-31 95ZV-2 Troubleshooting Brake Group
4. Accumulator pressure does not rise, or too slow in rising.
Low accumulator pressure in a certain accumulator only.
Possible cause
Low accumulator pressure in all two accumulators.
Symptoms / check point
Check before starting work. 1. Check the error code No. shown on the MODM.
Solution
Low unloader valve switching pressure
Inspection & readjustment
Defective unloader valve
Disassembly & repair
Internally damaged accumulator
Disassembly & repair
Defective pilot pump
Replace pump
Heavy movement of solenoid valve manual release knob.
Coil of the solenoid valve has extremely high or zero resistance.
Turning on/off the parking brake switch activates the link under the cylinder.
Turning on/off the parking brake switch causes a solenoid valve emitting noise.
Parking brake remains unreleased.
Possible cause
Brake does not work even if the parking swtich is turned to "ON" position.
Check before starting work. 1. Check the fuses of the electrical system. 2. Check the main accumulator pressure. 3. Check the error code No. shown on the MODM.
Symptoms / check point
5. Parking brake does not work. (or: Releasing the parking brake is not possible.)
Turning the manual release knob of the solenoid valve counterclockwise releases the parking brake.
01-32 95ZV-2 Troubleshooting Brake Group
Solution
Defective coil of parking solenoid valve
Solenoid valve replacement
Sticking spool of parking solenoid valve
Solenoid valve replacement
Oil leaking from line between solenoid valve and parking brake cylinder
Inspection & repair
Defective parking brake switch
Switch replacement
Disconnected or defective electrical line
Repair cable
Sticking parking brake cylinder
Inspection & repair
Defective link between parking brake cylinder and brake drum
Inspection & repair
Worn brake lining
Readjustment
Accumulator pressure in accumulator is low.
Inspection & repair
01-33 95ZV-2 Troubleshooting Electrical Group
T/M (transmission) solenoid valve does not operate based on the speed set by the shift lever.
Hour meter does not operate.
Pointers of all the gauges are deflected to their limits.
One of the gauges does not indicate properly. ∗
All the gauge pointers do not move.
One of the gauge pointers does not move.
Pointer of the speedometer does not move.
During operation, two or more monitor lamps light improperly. ∗
During operation, one of the monitor lamps lights improperly. ∗
Two or more monitor lamps will not light after setting the starter key to ON.
Possible cause
One of the monitor lamps will not light after setting the starter key to ON.
Check before starting work. 1. Check the fuses. 2. Lamp test Turn the starter switch key to "ON" position and leave it there for 3 seconds. Check the indicator lamps. 3. Check the error code No. shown on the MODM.
Symptoms / check point
1. Instrument panel does not indicate properly.
Speed indicated on the instrument panel does not correspond with the speed set by the shift lever.
Electrical Group
Solution
Bulb of monitor lamp burnt out
Bulb replacement
Defective sensor or improper wiring
Sensor replacement
Disconnected or defective electrical circuit
Repairing cable
Loose connector
Connector check & re-connection
T/M controller failure alarm turned on
Inspection & repair
Defective controller
Controller replacement
Defective inside mechanism of gauge or meter
Replacement
Defective board of instrument panel
Replacement
T/M solenoid valve improperly connected.
Properly connect
Gauge circuit grounded improperly.
Inspection & repair
Remarks
∗ If the gauge and warning lamps do not agree there probably is a defect in the wiring. Stop immediately and diagnose the defect.
Parking brake remains unreleased regardless of the parking brake switch position.
Coil of the solenoid valve has extremely low resistance.
Fuse blows off if the machine sways during travelling.
Possible cause
Fuse blows off immediately after replacing.
Symptoms / check point
Check before starting work. 1. Check the error code No. shown on the MODM.
Both the forward and reverse shift lever position enable the engine to start.
2. Fuse for controller is blown.
In the solenoid valve continuity test, changing the positive and negative sides to each other and both or them are continuity.
01-34 95ZV-2 Troubleshooting Electrical Group
Solution
Controller power line contacts with chassis. (Wire pinched by other components, etc.)
Inspection & repair
Controller power line occasional contacts with chassis.
Inspection & repair
Clutch solenoid valve coil short-circuited
Solenoid valve replacement
Clutch solenoid valve diode failed
Solenoid valve replacement
Neutral or controller failure or kickout relay power line contacts with chassis.
Inspection & repair
Neutral or controller failure or kickout relay power line occasional contacts with chassis.
Inspection & repair
Parking brake solenoid valve power line contacts with chassis.
Inspection & repair
Parking brake solenoid valve power line occasional contacts with chassis.
Inspection & repair
Neutral relay power line contacts with chassis.
Inspection & repair
01-35 95ZV-2 Troubleshooting Electrical Group
Error code (for chassis) Failure code (Input side) Code
Failure
Detection condition (In case of)
CN121
Shift lever F & R switch malfunction
Shift lever F & R contact ON at the same time Failure continues for more than 3 seconds
CN122
Shift lever 1•2•3•A switch malfunction (1)
Shift lever any of more than two 1•2•3•A contact ON at the same time Failure continues for more than 3 seconds
CN123
Shift lever 1•2•3•A switch malfunction (2)
All 1•2•3•A signal OFF continues for more than 3 seconds
CN141
Shift-up switch malfunction
Switch is ON for more than 10 seconds
CN142
Shift-down switch malfunction
Switch is ON for more than 10 seconds
CN143
Shift-up switch & shift-down switch malfunction
Shift-up switch & shift-down switch contact ON at the same time Failure continues for more than 3 seconds
CN145
Kick-down switch malfunction
Switch is ON for more than 10 seconds
CN146
Shift hold switch malfunction
Switch is ON for more than 10 seconds
CN151
T/M oil pressure switch malfunction (This applies to the model 115ZV-2/135ZV-2 only)
Signal OFF continues for more than 10 seconds during engine running
CN152
T/M oil pressure sensor malfunction (This applies to the model 95ZV-2 only)
T/M pressure below 294 kPa (3.0 kgf/cm2) (43 psi) continues for more than 10 seconds during engine running
CN161
Machine speed sensor malfunction (1)
Input circuit is disconnected for more than 3 seconds
CN162
Machine speed sensor malfunction (2)
Input value is over 70 km/h (44 mile/h) for more than 3 seconds
CN163
E/G speed sensor 1 (ECM output) malfunction (1)
No E/G speed sensor input for more than 3 seconds when E/G speed sensor selection is OFF (Input circuit is disconnected)
CN164
E/G speed sensor 1 (ECM output) malfunction (2)
Input value is more than 3,000 min-1 for more than 3 seconds when E/G speed sensor selection is OFF
CN165
E/G speed sensor 2 (Sensor output) malfunction (1)
No E/G speed sensor input for more than 3 seconds when E/G speed sensor selection is ON (Input circuit is disconnected)
CN167
E/G speed sensor 2 (Sensor output) malfunction (2)
Input value is more than 3,000 min-1 for more than 3 seconds when E/G speed sensor selection is ON
CN213
Inching sensor malfunction (1)
Voltage is lower than 0.2 V for more than 3 seconds
CN214
Inching sensor malfunction (2)
Voltage is larger than 4.6 V for more than 3 seconds
CN232
S/S potentiometer malfunction (1)
Voltage is lower than 0.1 V for more than 3 seconds
CN234
S/S potentiometer malfunction (2)
Voltage is larger than 4.9 V for more than 3 seconds
CN236
S/S shift switch (F & R contact) malfunction
Failure continues for more than 3 seconds
CN251
Secondary secondary steering oil pressure sensor malfunction(1)
Voltage is lower than 0.2 V for more than 3 seconds
CN252
Secondary steering oil pressure sensor malfunction (2)
Voltage is larger than 4.6 V for more than 3 seconds
CN254
Low secondary steering oil pressure
Oil pressure sensor detects secondary steering oil pressure below 306 kPa (3.1 kgf/cm2) (44 psi) for more than 3 seconds during engine running
CN262
Kickout potentiometer malfunction (1)
Voltage is lower than 0.2 V for more than 3 seconds
CN263
Kickout potentiometer malfunction (2)
Voltage is larger than 4.6 V for more than 3 seconds
CN271
Efficient loading system hydraulic oil pressure senVoltage is lower than 0.2 V for more than 3 seconds sor malfunction (1)
CN272
Efficient loading system hydraulic oil pressure senVoltage is larger than 4.6 V for more than 3 seconds sor malfunction (2)
CN312
Brake oil pressure sensor 1 malfunction (1)
CN313
Brake oil pressure sensor 1 malfunction (2)
Voltage is larger than 4.6 V for more than 3 seconds
CN315
Brake oil pressure sensor 2 malfunction (1)
Voltage is lower than 0.2 V for more than 3 seconds
Voltage is lower than 0.2 V for more than 3 seconds
CN316
Brake oil pressure sensor 2 malfunction (2)
Voltage is larger than 4.6 V for more than 3 seconds
CN321
E/G coolant temperature sensor malfunction (1)
Input voltage is larger than 3.56 V for more than 3 seconds
CN323
E/G coolant temperature sensor malfunction (2)
Input voltage is lower than 0.263 V for more than 3 seconds
CN341
T/M oil temperature sensor malfunction (1)
Input voltage is larger than 3.56 V for more than 3 seconds
CN342
T/M oil temperature sensor malfunction (2)
Input voltage is lower than 0.263 V for more than 3 seconds
01-36 95ZV-2 Troubleshooting Electrical Group
Code
Failure
Detection condition (In case of)
CN351
Hydraulic oil temperature sensor malfunction (1)
Input voltage is larger than 3.56 V for more than 3 seconds
CN352
Hydraulic oil temperature sensor malfunction (2)
Input voltage is lower than 0.263 V for more than 3 seconds
CN381
Fuel level sensor malfunction
Input signal corresponds to "any other pattern" in fuel level indication table
CN391
Air temperature probe malfunction (1)
Input voltage is larger than 4.35 V for more than 3 seconds
CN392
Air temperature probe malfunction (2)
Input voltage is lower than 0.13 V for more than 3 seconds
CN412
Abnormal brake oil pressure (1)
Brake oil pressure sensor 1 detects pressure below 4,081 kPa (41.6 kgf/ cm2) (592 psi) for more than 1 second during engine running
CN413
Abnormal brake oil pressure (2)
Brake oil pressure sensor 2 detects pressure below 4,081 kPa for (41.6 kgf/cm2) (592 psi) more than 1 second during engine running
CN414
Abnormal brake oil pressure difference
Brake oil pressure difference switch is in abnormal condition for more than 1 second
CN415
Abnormal brake oil amount
Brake oil amount switch is in abnormal condition for more than 1 second
CN421
Abnormal engine oil pressure
Engine oil pressure switch is OFF for more than 2 seconds during engine running
CN431
Abnormal engine coolant temperature (1)
Engine coolant temperature switch is ON for more than 2 seconds
CN432
Abnormal engine coolant temperature (2)
Engine coolant temperature sensor is in 101 deg. C (214 deg. F) condition for more than 2 seconds
CN451
Abnormal T/M oil temperature (1)
T/M oil temperature switch is ON for more than 2 seconds
CN452
Abnormal T/M oil temperature (2)
T/M oil temperature sensor is in 122 deg. C (252 deg. F) condition for more than 2 seconds
CN461
Abnormal hydraulic oil temperature
Hydraulic oil temperature sensor is in 100 deg. C (212 deg. F) condition for more than 2 seconds
CN471
Clogged T/M oil filter
30 minutes after starter switch is ON, T/M oil filter switch is ON for more than 2 seconds when T/M oil temperature sensor detects oil temperature more than 60 deg. C (140 deg. F)
CN481
Clogged air cleaner element
Air cleaner switch is ON for more than 2 seconds
CN491
Abnormal cooling water level in radiator
Radiator cooling water level switch is OFF for more than 2 seconds when the engine is off.
CN496
Abnormal hydraulic oil level
Hydraulic oil level switch is in abnormal condition for more than 30 seconds
CN497
Abnormal brake disc oil temperature (This applies to the model 135ZV-2 only)
Brake disc oil temperature switch is ON for more than 1 second
CN498
Abnormal disc wear (This applies to the model 135ZV-2 only)
Brake disc wear switch is ON for more than 1 second
CN801
CAN disconnect
CAN line is disconnected
CN802
Abnormal engine coolant temperature (CAN)
No engine coolant temperature data received for more than 3 seconds
CN912
Abnormal MCU voltage (1)
Voltage is larger than 30±1 V
CN913
Abnormal MCU voltage (2)
Voltage is lower than 22±0.5 V for more than 10 seconds during engine running
Note This table applies to the 95/115/135ZV-2 units.
Fuel level display table Input
Output
1/8
1/4
1/2
3/4
F
x
x
x
x
x
x
x
x
x
x
x
x
—
x
x
—
—
x
—
—
—
—
—
—
—
—
—
—
—
Other than above : No input signal given x : Input signal given
E
: Lamp on — : Lamp off
1/4
1/2
3/4
F
—
—
—
—
—
—
—
—
—
—
—
—
— —
: Lamp flashing
—
01-37 95ZV-2 Troubleshooting Electrical Group
Failure code (Output side) Code CN512
Failure
Detection condition
F solenoid valve malfunction
F solenoid valve is short-circuited or disconnected
CN514
R solenoid valve malfunction
R solenoid valve is short-circuited or disconnected
CN516
1st solenoid valve malfunction
1st solenoid valve is short-circuited or disconnected
CN518
2nd solenoid valve malfunction
2nd solenoid valve is short-circuited or disconnected
CN521
3rd solenoid valve malfunction
3rd solenoid valve is short-circuited or disconnected
CN524
4th solenoid valve malfunction
4th solenoid valve is short-circuited or disconnected
CN526
D solenoid valve malfunction
D solenoid valve is short-circuited or disconnected
CN528
H solenoid valve malfunction
H solenoid valve is short-circuited or disconnected
CN531
LU solenoid valve malfunction
LU solenoid valve is short-circuited or disconnected
CN534
Auto-brake solenoid valve malfunction
Auto-brake solenoid valve is short-circuited or disconnected
CN536
Speed change control solenoid valve malfunction (1)
Speed change control solenoid valve is short-circuited
CN537
Speed change control solenoid valve malfunction (2)
Speed change control solenoid valve is disconnected
CN621
S/S solenoid valve R malfunction (1)
S/S solenoid valve R is short-circuited
CN622
S/S solenoid valve R malfunction (2)
S/S solenoid valve R is disconnected
CN623
S/S solenoid valve L malfunction (1)
S/S solenoid valve L is short-circuited
CN624
S/S solenoid valve L malfunction (2)
S/S solenoid valve L is disconnected
CN631
Pressure increase solenoid valve malfunction
Pressure increase solenoid valve is short-circuited or disconnected
CN641
Ride control solenoid valve malfunction
Ride control solenoid valve is short-circuited or disconnected
CN681
Efficient loading system selection solenoid valve malfunction
Efficient loading system selection solenoid valve is short-circuited or disconnected
CN693
Lower kickout relay malfunction (1)
Lower kickout relay (coil) is short-circuited
CN694
Lower kickout relay malfunction (2)
Lower kickout relay (coil) is disconnected
CN712
Cooling fan solenoid valve malfunction (1)
Cooling fan solenoid valve is short-circuited
CN713
Cooling fan solenoid valve malfunction (2)
Cooling fan solenoid valve is disconnected
CN721
Hour meter drive malfunction
Hour meter drive is short-circuited
01-38 95ZV-2 Troubleshooting Electrical Group
EG111 Red
Engine Control Module (ECM) - critical internal failure.
EG113 Yellow
Engine Timing Actuator Circuit - shorted high.
EG114 Yellow
Engine Timing Actuator Circuit - shorted low.
EG115 Red
Engine Speed / Camshaft Position Sensor Circuit - lost both of two signals from the magnetic pickup sensor.
EG121 Yellow
Engine Speed / Position Sensor Circuit - lost one of two signals from the magnetic pickup sensor.
EG122 Yellow
Intake Manifold Pressure Sensor #1 Circuit - shorted high.
EG123 Yellow
Intake Manifold Pressure Sensor #1 Circuit - shorted low.
EG124 Yellow
Intake Manifold Pressure - above normal operation.
EG131 Red
Accelerator Pedal Position Sensor Circuit - shorted high.
EG132 Red
Accelerator Pedal Position Sensor Circuit - shorted low.
EG133 Red
Remote Accelerator Pedal Position Sensor Circuit - shorted high.
EG134 Red
Remote Accelerator Pedal Position Sensor Circuit - shorted low.
EG135 Yellow
Engine Oil Pressure Sensor Circuit - shorted high.
EG141 Yellow
Engine Oil Pressure Sensor Circuit - shorted low.
EG143 Yellow
Engine Oil Pressure Low - warning.
EG144 Yellow
Engine Coolant Temperature Sensor Circuit - voltage above normal or shorted high.
EG145 Yellow
Engine Coolant Temperature Sensor Circuit - voltage below normal or shorted low.
EG146 Yellow
Engine Coolant Temperature High - warning.
EG151 Red
Engine Coolant Temperature High - critical.
EG153 Yellow
Intake Manifold Air Temperature Sensor Circuit - voltage above normal or shorted high.
EG154 Yellow
Intake Manifold Air Temperature Sensor Circuit - voltage below normal or shorted low.
EG155 Red
Intake Manifold Air Temperature Sensor High - critical.
EG166 Yellow
Rack Position Sensor #1 Circuit - shorted high.
EG172 Red
Rack Actuator Position #1 Circuit - grounded circuit.
EG173 Yellow
Rack Actuator - mechanically stuck open.
QST30 (135ZV-2)
QSK19 (115ZV-2)
QSX15 (95ZV-2)
QSM11 (92ZV-2)
QSM11 (90ZV-2)
QSC8.3 (85ZV-2)
QSC8.3 (80ZV-2)
DESCRIPTION
QSB6.7 (70ZV-2) (70TMV-2)
FAULT CODE/ LAMP
QSB4.5 (60ZV-2)
Error code (for engine)
EG184 Yellow
Engine Control Module Identification Input State Error.
EG185 Yellow
Engine Control Module Network Communication Error.
EG187 Yellow
Sensor Supply Voltage #2 Circuit - shorted low.
EG212 Yellow
Engine Oil Temperature Sensor Circuit - shorted high.
EG213 Yellow
Engine Oil Temperature Sensor Circuit - shorted low.
EG214 Red
Engine Oil Temperature High - Critical.
EG221 Yellow
Ambient Air Pressure Sensor Circuit - shorted high.
EG222 Yellow
Ambient Air Pressure Sensor Circuit - shorted low.
EG227 Yellow
Sensor Supply Voltage #2 Circuit - shorted high.
EG231 Yellow
Engine Coolant Pressure Sensor Circuit - shorted high.
EG232 Yellow
Engine Coolant Pressure Sensor Circuit - shorted low.
EG233 Yellow
Engine Coolant Pressure Low - warning.
EG234 Red
Engine Speed High - critical.
EG238 Yellow
Sensor Supply Voltage #3 Circuit - shorted low.
EG254 Red
Fuel Shutoff Valve Circuit - shorted low.
EG255 Yellow
Fuel Shutoff Valve Circuit - shorted high.
EG259 Red
Fuel Shutoff Valve - stuck open.
EG261 Yellow
Fuel Temperature High - warning.
EG263 Yellow
Fuel Temperature Sensor Circuit - shorted high.
EG265 Yellow
Fuel Temperature Sensor Circuit - shorted low.
EG266 Red
Engine Fuel Temperature - data valid but above normal operational range - most severe level.
EG271 Yellow
Fuel Control Actuator Circuit - shorted low.
EG272 Yellow
Fuel Control Actuator Circuit - shorted high.
EG281 Yellow
Injection Pump Mechanical System - signal not in range from ECM.
EG284 Yellow
Engine Speed / Position Sensor #1 (Crankshaft) Supply Voltage Circuit - shorted low.
EG285 Yellow
SAE J1939 Data Link Multiplexing PGN Timeout Error.
EG286 Yellow
SAE J1939 Data Link Multiplexing Configuration Error.
QST30 (135ZV-2)
QSK19 (115ZV-2)
QSX15 (95ZV-2)
QSM11 (92ZV-2)
QSM11 (90ZV-2)
QSC8.3 (85ZV-2)
QSC8.3 (80ZV-2)
DESCRIPTION
QSB6.7 (70ZV-2) (70TMV-2)
FAULT CODE/ LAMP
QSB4.5 (60ZV-2)
01-39 95ZV-2 Troubleshooting Electrical Group
EG287 Red
SAE J1939 Multiplexing Accelerator Pedal Sensor System Error.
EG295 Yellow
Ambient Air Pressure Sensor Circuit - data incorrect.
EG299 Yellow
Engine stopped not using Starter Switch.
EG311 Yellow
Injector Solenoid Valve Cylinder #1 Circuit - grounded circuit.
EG312 Yellow
Injector Solenoid Valve Cylinder #5 Circuit - grounded circuit.
EG313 Yellow
Injector Solenoid Valve Cylinder #3 Circuit - grounded circuit.
EG314 Yellow
Injector Solenoid Valve Cylinder #6 Circuit - grounded circuit.
EG315 Yellow
Injector Solenoid Valve Cylinder #2 Circuit - grounded circuit.
EG319 Yellow
Real Time Clock - power Interrupt.
EG321 Yellow
Injector Solenoid Valve Cylinder #4 Circuit - grounded circuit.
EG322 Yellow
Injector Solenoid Valve Cylinder #1 Circuit - open circuit.
EG323 Yellow
Injector Solenoid Valve Cylinder #5 Circuit - open circuit.
EG324 Yellow
Injector Solenoid Valve Cylinder #3 Circuit - open circuit.
EG325 Yellow
Injector Solenoid Valve Cylinder #6 Circuit - open circuit.
EG331 Yellow
Injector Solenoid Valve Cylinder #2 Circuit - open circuit.
EG332 Yellow
Injector Solenoid Valve Cylinder #4 Circuit - open circuit.
EG334 Yellow
Coolant Temperature Sensor Circuit - data erratic, intermittent, or incorrect.
EG341 Yellow
Engine Control Module - data lost.
EG342 Red
Engine Control Module - out of calibration.
EG343 Yellow
Engine Control Module - warning internal hardware failure.
EG346 Yellow
Engine Control Module - warning software error.
EG351 Yellow
Injector Power Supply.
EG352 Yellow
Sensor Supply Voltage #1 Circuit - shorted low.
EG378 Yellow
Fueling Actuator #1 Circuit - open circuit.
EG379 Yellow
Fueling Actuator #1 Circuit - grounded circuit.
EG386 Yellow
Sensor Supply Voltage #1 Circuit - shorted high.
EG387 Yellow
Accelerator Pedal Position Sensor Supply Voltage Circuit - shorted high.
QST30 (135ZV-2)
QSK19 (115ZV-2)
QSX15 (95ZV-2)
QSM11 (92ZV-2)
QSM11 (90ZV-2)
QSC8.3 (85ZV-2)
QSC8.3 (80ZV-2)
DESCRIPTION
QSB6.7 (70ZV-2) (70TMV-2)
FAULT CODE/ LAMP
QSB4.5 (60ZV-2)
01-40 95ZV-2 Troubleshooting Electrical Group
EG394 Yellow
Timing Actuator #1 Circuit - open circuit.
EG395 Yellow
Timing Actuator #1 Circuit - grounded circuit.
EG396 Yellow
Fueling Actuator #2 Circuit - open circuit.
EG397 Yellow
Fueling Actuator #2 Circuit - grounded circuit.
EG398 Yellow
Timing Actuator #2 Circuit - open circuit.
EG399 Yellow
Timing Actuator #2 Circuit - grounded circuit.
EG415 Red
Engine Oil Pressure Low - critical.
EG418 Yellow
Water in Fuel Indicator High - maintenance.
EG419 Yellow
Intake Manifold Boost Pressure Imbalance.
EG423 Yellow
Fuel Timing Pressure or Timing Actuator Stuck.
EG428 Yellow
Water in Fuel Sensor Circuit - shorted high.
EG429 Yellow
Water in Fuel Sensor Circuit - shorted low.
EG431 Yellow
Accelerator Pedal Idle Validation Circuit - data incorrect.
EG432 Red
Accelerator Pedal Idle Validation Circuit - out of calibration.
EG433 Yellow
Intake Manifold Pressure Sensor Circuit - data incorrect.
EG434 Yellow
Voltage to ECM less than 6 V
EG435 Yellow
Engine Oil Pressure Switch Circuit - data incorrect.
EG441 Yellow
Battery #1 Voltage Low - warning.
EG442 Yellow
Battery #1 Voltage High - warning.
EG443 Yellow
Accelerator Pedal Position Sensor Supply Voltage Circuit - shorted low.
EG449 Yellow
Fuel Pump Delivery Pressure High - warning.
EG451 Yellow
Injector Metering Rail #1 Pressure Sensor Circuit - shorted high.
EG452 Yellow
Injector Metering Rail #1 Pressure Sensor Circuit - shorted low.
EG465 Yellow
Turbocharger #1 Wastegate Control Circuit - shorted high.
EG466 Yellow
Turbocharger #1 Wastegate Control Circuit - shorted low.
EG482 Yellow
Fuel Pressure Low - warning.
EG483 Yellow
Injector Metering Rail #2 Pressure Sensor Circuit - shorted high.
QST30 (135ZV-2)
QSK19 (115ZV-2)
QSX15 (95ZV-2)
QSM11 (92ZV-2)
QSM11 (90ZV-2)
QSC8.3 (85ZV-2)
QSC8.3 (80ZV-2)
DESCRIPTION
QSB6.7 (70ZV-2) (70TMV-2)
FAULT CODE/ LAMP
QSB4.5 (60ZV-2)
01-41 95ZV-2 Troubleshooting Electrical Group
EG484 Yellow
Injector Metering Rail #2 Pressure Sensor Circuit - shorted low.
EG485 Yellow
Injector Metering Rail #2 Pressure High - warning.
EG486 Yellow
Injector Metering Rail #2 Pressure Low - warning.
EG488 Yellow
Intake Manifold Temperature High - warning.
EG491 Yellow
Turbocharger #2 Wastegate Control Circuit - shorted high.
EG492 Yellow
Turbocharger #2 Wastegate Control Circuit - shorted low.
EG496 Yellow
Engine Speed / Position Sensor #2 (Camshaft) Supply Voltage.
EG524 Yellow
OEM Alternate Droop Switch Validation - data incorrect.
EG527 Yellow
Auxiliary Input / Output #2 Circuit - shorted high.
EG528 Yellow
OEM Alternate torque validation switch - data incorrect.
EG529 Yellow
Auxiliary Input / Output #3 Circuit - shorted high.
EG546 Yellow
Fuel Delivery Pressure Sensor Circuit - shorted high.
EG547 Yellow
Fuel Delivery Pressure Sensor Circuit - shorted low.
EG551 Yellow
Accelerate Pedal Idle Validation Circuit - shorted low.
EG553 Yellow
Injector Metering Rail #1 Pressure High - warning level.
EG554 Yellow
Fuel Pressure Sensor Error.
EG559 Yellow
Injector Metering Rail #1 Pressure Low - data valid but below normal operational range - moderately severe level.
EG596 Yellow
Electrical Charging System Voltage High - warning level.
EG598 Red
Electrical Charging System Voltage Low - critical level.
EG689 Yellow
Crankshaft Engine Speed Signal Error.
EG731 Yellow
Mechanical Timing Misalignment.
EG753 Yellow
Crankshaft Position Sensor and Camshaft Position Sensor - data erratic, intermittent, or in correct.
EG757 Yellow
Electronic Control Module Data Lost.
EG758 Yellow
Injector Metering Rail #2 Pressure Malfunction.
EG778 Yellow
Engine Speed Sensor (Camshaft) - data erratic, intermittent, or incorrect.
EG951 None
Cylinder Power Imbalance Detected.
EG1117 None
Power Lost with Ignition ON - data erratic, intermittent, or incorrect.
QST30 (135ZV-2)
QSK19 (115ZV-2)
QSX15 (95ZV-2)
QSM11 (92ZV-2)
QSM11 (90ZV-2)
QSC8.3 (85ZV-2)
QSC8.3 (80ZV-2)
DESCRIPTION
QSB6.7 (70ZV-2) (70TMV-2)
FAULT CODE/ LAMP
QSB4.5 (60ZV-2)
01-42 95ZV-2 Troubleshooting Electrical Group
EG1376 Orange
Engine Camshaft Speed / Position Sensor - data erratic, intermittent, or incorrect.
EG1595 Yellow
Remote Accelerator Pedal Position Sensor 1 Circuit - voltage above normal or shorted high.
EG1597 Orange
Engine Control Module Critical Internal Failure - bad intelligent device or component.
EG1845 Orange
Water in Fuel Indicator Sensor Circuit - voltage above normal or shorted to high source.
EG1846 Orange
Water in Fuel Indicator Sensor Circuit - voltage below normal or shorted to low source.
EG1852 Yellow
Water in Fuel Indicator - data valid but above normal operational range moderately severe level.
EG1911 Yellow
Injector Metering Rail 1 Pressure - above normal operating range.
EG2185 Yellow
Sensor Supply Voltage #4 Circuit - shorted high.
EG2186 Yellow
Sensor Supply Voltage #4 Circuit - shorted low.
EG2215 Yellow
Fuel Pump Delivery Pressure - data valid but below normal operational range moderately severe level.
EG2249 Yellow
Fuel Pump Delivery Pressure Sensor Circuit - shorted low.
EG2261 Orange
Fuel Pump Delivery Pressure - data valid but above normal operational range least severe level.
EG2262 Orange
Fuel Pump Delivery Pressure - data valid but below normal operational range least severe level.
EG2265 Yellow
Fuel Priming Pump Control Signal Circuit - shorted high.
EG2266 Yellow
Fuel Priming Pump Control Signal Circuit - shorted low.
EG2311 Yellow
Fueling Actuator #1 Circuit Error - condition exists.
EG2321 None
Engine Speed Sensor #1 - data erratic, intermittent, or incorrect.
EG2322 None
Engine Speed Sensor #2 - data erratic, intermittent, or incorrect.
EG2697 Orange
Accelerator Pedal Position Sensor Circuit and Idling Position Detection Switch Circuit - data erratic, intermittent, or incorrect.
EG2963 None
Engine Coolant Temperature High - warning.
EG2964 None
Intake Manifold Temperature High - warning.
EG2973 Yellow
Intake Manifold Pressure Sensor Circuit - data erratic, intermittent, or incorrect.
(09D20E)
QST30 (135ZV-2)
Remote Accelerator Pedal Position Sensor 1 Circuit - voltage below normal or shorted low.
QSK19 (115ZV-2)
EG1361 Yellow
QSX15 (95ZV-2)
Accelerator Pedal Position Sensor 1 Circuit - voltage below normal or shorted low.
QSM11 (92ZV-2)
EG1359 Yellow
QSM11 (90ZV-2)
Accelerator Pedal Position Sensor 1 Circuit - voltage above normal or shorted high.
QSC8.3 (85ZV-2)
EG1358 Yellow
QSC8.3 (80ZV-2)
DESCRIPTION
QSB6.7 (70ZV-2) (70TMV-2)
FAULT CODE/ LAMP
QSB4.5 (60ZV-2)
01-43 95ZV-2 Troubleshooting Electrical Group
01-44 95ZV-2 Troubleshooting Operator Station Group
Operator Station Group ∗ Error code table
Air conditioner Fault diagnosis procedure
Display
Hearing check
Error code check ∗
Phenomenon check
Basic check In accordance with fault phenomenon
1) Control mechanism 2) V-belt 3) Sight glass 4) Piping connection
Refrigerant cycle check - Pressure check - Gas leak check
Electrical system check
Repair/check
End
80V2E01012
Failure mode
E-
No failure
E11
Wire breakage in inside air sensor
E12
Short-circuit in inside air sensor
E13
Wire breakage in outside air sensor
E14
Short-circuit in outside air sensor
E15
Wire breakage in water temperature sensor
E16
Short-circuit in water temperature sensor
E18
Short-circuit in insolation sensor
E21
Wire breakage in vent sensor
E22
Short-circuit in vent sensor
E43
Abnormality in vent damper
E44
Abnormality in air mixing damper
E45
Abnormality in inside/outside air
E51
Abnormality in refrigerant pressure
01-45 95ZV-2 Troubleshooting Operator Station Group Basic check 1. Check of control mechanism Operate the switch arranged on the control panel, to check that it is operable smoothly and securely. 2. Check of V-belt Check that the V-belt is tensioned properly, and that it is not damaged. 3. Check of refrigerant level through sight glass When the air bubble is observed a lot through sight glass, the refrigerant is probably insufficient. In such a case, therefore, perform the checking with using a gauge manifold.
Sight glass
Receiver joint
Receiver drier
95ZVE01003
4. Check of piping connection At the piping connection where the oil stain is seen, there is probably a refrigerant leakage. In such a case, remove the stain, and then check for gas leakage.
Cooling failure
Normal air flow rate
With diagnostic display: E51 (refrigerant high/ lower pressure error)
With diagnostic display: E44 (A/M servo motor error)
Without diagnostic display
Air flow rate failure
<Trouble shooting charts>
Examine the cause of over-voltage before taking the corrective measure.
See D-2 .
See D-1 .
See C-3 .
Check the wiring. Replace the servo motor with a new one. Remove the foreign matter.
Replace the V-belt with a new one. Replace the compressor with a new one. Repair the magnet switch, or replace it with a new one. Check the wiring.
Operation of low-pressure function
Servomotor failure Blocked foreign matter
Wiring failure, disconnection, disengaged connector
Magnet clutch failure Clutch engagement failure due to electrical system failure
Broken or slipped belt Compressor failure(locking)
Insufficient refrigerant.
See C-3 . See C-4 . See C-5 .
High pressure both at high-pressure side and low-pressure side Low pressure both at high-pressure side and low-pressure side
See C-2 .
Too low pressure at high-pressure side(Pressure is not increased to approx. 981kPa[10kgf/cm2] or over) Too low pressure at low-pressure side(Pressure is decreased to approx. 49kPa[0.5kgf/cm2] or less
Close the window and door. Adjust the inside/outside air changeover damper. Re-set the link.
∗ Examine the cause before taking the corrective measure,and then replace the fuse with that of the same capacity. See B-1 . Replace the blower main relay with a new one. Replace the blower motor with a new one. Correct the interference. Replace the panel with a new one. Earth the body securely. Check the wiring. Replace the motor with a new one.
Too high pressure at low-pressure side(approx. 294kPa[3kgf/cm2] or over)
Disengaged A/M link
Mixing of outside air
Operation of BLC protective function due to locked motor
Blown fuse Blower main relay failure Blower motor failure Interference of blower with case Blower switch failure Body earth failure Wiring failure, disconnected connector
Operation of BLC over-voltage protective function
Check the battery charging system. Correct the contact failure. Replace the blower motor with a new one. Replace the BLC with a new one.
See A-1 .
See C-1 .
Pressure error
Normal pressure
Rotation failure for all modes
Blower is rotated only when the fan switch is selected to High-speed position.
Slow rotation
Decreased supply voltage Battery terminal contact failure Blower motor rotation failure BLC failure
Adhesion of dust to surface of evaporator
Deformed or damaged blower Frosting in evaporator
Existence of obstacle at vicinity of suction port
Clean the filter. Clean the filter. Remove the obstacle. Replace the blower with a new one. Stop the air compressor, to melt the ice. Examine the cause before taking the corrective measure. Clean the surface of evaporator.
Operation of high-pressure cut function
Compressor normal rotation failure
Compressor normal rotation
Blower motor rotation failure
Blower motor rotation
Normal rotation
Clogged inner air filter Clogged outer air filter
01-46 95ZV-2 Troubleshooting Operator Station Group
80V2E01013
C-2
C-1
B-1
A-1
Voltage not applied to magnet clutch
Voltage applied to magnet clutch Check for characteristic.
Thermister(frosting sensor) characteristic failure
Clogging of dust or mud, etc. in fin.
Excessively opened expansion valve
Replace the valve with a new one. Correction Contact failure in pressure needle valve
Replace the compressor with a new one.
Valve failure
Foreign matter caught by suction valve
Broken suction valve
Discharge the refrigerant to proper level.
Over-filled refrigerant Broken head gasket
Fully discharge the refrigerant, and execute the evacuation, and fill the refrigerant again to proper level.
Mixing of air during refrigerating cycle
Compressor failure
Discharge the refrigerant to proper level.
Over-filled refrigerant
Insufficiently cooled condenser
Clean(Washing with water) the fin.
Check the wiring.
Unusually high outside air temperature
Perform the checking, referring to the wiring diagram.
Evaporator
Sort-circuit wiring
Replace the blower motor with a new one.
Replace the magnet clutch with a new one. Thermister (frosting sensor)
12 ± 5 mm (0.5 ± 0.2 in)
Adjust the gap (12 ± 5 mm) (0.5 ± 0.2 in).
Replace the thermister(frosting sensor) with a new one.
Correction
Replace the clutch relay with a new one.
Erroneous wiring
Locked blower motor
Magnet clutch failure
Adjustment failure of gap between the thermister(frosting sensor) and evaporator
Check the short-circuit.
Check the clutch circuit.
Thermister(frosting sensor) wiring failure
Magnet clutch circuit failure
01-47 95ZV-2 Troubleshooting Operator Station Group
85V2U72008
C-5
C-4
C-3
Over-filled refrigerant
Clogging of dust or mud, etc. in fin.
Discharge the refrigerant to proper level.
Clean(washing with water) the fin.
Execute the evacuation fully after replacing the valve and receiver with a new one respectively.
Temporary clogging(mixing of moisture content) due to frozen valve
Insufficiently cooled condenser
Replace the valve with a new one.
Relieved gas from pressure needle valve
to A-1
Replace the valve with a new one.
Replacement
Replacement
Clogged valve(mixing of foreign matter)
Clogging due to foreign matter in the course of piping
Clogged receiver & drier
Perform the leak test and repair the location of failure before filling the refrigerant.
Gas leakage
Execute the evacuation fully after replacing the valve and receiver with a new one respectively.
Clogging(mixing of moisture content) due to frozen valve
Fill the refrigerant to proper level.
Replace the valve with a new one.
Relieved gas from pressure needle valve
Limited amount of refrigerant filled
Replace the valve with a new one.
Clogged valve(mixing of foreign matter)
Suction/discharge valve failure
Locked piston
Replace the compressor with a new one.
Perform the leak test and repair the location of failure before filling the refrigerant.
Gas leakage
Swash plate shoe seizure
Fill the refrigerant to proper level.
Limited amount of refrigerant filled
Frosted evaporator
Expansion valve failure
Clogging during refrigerating cycle
Limited refrigerant
Unusually low outside air temperature
Expansion valve failure
Compressor failure
Limited refrigerant
Unusually low outside air temperature
01-48 95ZV-2 Troubleshooting Operator Station Group
80V2E01015
D-2
D-1
2
C-4
Replacement
High/low-pressure switch failure
Excessively low pressure [981 kPa(10kgf/cm )or lower]
Replacement
Thermo-sensor failure
C-1
Replacement
Excessively high pressure [2452 kPa(25kgf/cm2)or over]
Replace the control panel with a new one.
Compressor clutch relay failure
High-pressure error
Replace the control panel with a new one.
Blower switch failure
Re-charging
Battery voltage drop
Air conditioner switch failure
Replacement
Rare-short in coil
Disassembling/repair
Remove the oil.
Foreign matter caught between rotor and stator
Replace the key with a new one.
Stained clutch surface due to oil
Repair or replacement Slippage due to broken key or key insertion failure
Excessive air gap between rotor and stator
Slipped clutch
Replacement
Disconnected stator coil
01-49 95ZV-2 Troubleshooting Operator Station Group
80V2E01016
Leakage of water in operator's cab
Heating failure
Normal wind force
Insufficient wind force
Fill the coolant to proper level. Replace the heater core with a new one.
Limited engine cooling water Broken heater core
Replacement
Cleaning
Check the wiring.
Servo motor failure
Remove the foreign matter.
Foreign matter caught
Wiring failure, disconnection, disconnected connector
Re-set the link.
Disengaged temperature controller link
IN side and OUT side reversed.
The temperature controller LED is not operated properly.
Clogged drain hole
Repair or replacement
Clogged or bent piping Excessively low outside air temperature
Discharge the air.
The air is mixed in hot-water circuit.
Note: Do not fail to check that the pump pressure is normal, and that the heater hose is not connected with
The temperature controller LED is operated properly.
Normal water temperature
Low water temperature
Same as "Cooling failure"
01-50 95ZV-2 Troubleshooting Operator Station Group
85V2U72009
(without inside air sensor error)
Without diagnostic display
(short-circuit inside air sensor)
setting temperature
With diagnostic display: E12
higher or lower than
(disconnected inside air sensor)
With diagnostic display: E11
(inside air/outside air servo motor abnormal)
With diagnostic display: E45
(inside air/outside air servo motor normal)
Without diagnostic display
(blow-off servo motor abnormal)
With diagnostic display: E43
Room temperature
changeover failure
Outside air/inside air
failure
Blow-off changeover
(blow-off servo motor normal)
Without diagnostic display
Cooling failure, heating failure
Short-circuit inside air sensor
Perform the checking in accordance with the paragraph "Cooling failure/heating failure".
Replacement
Check the wiring.
Replacement
Disconnected inside air sensor Short-circuit harness
Re-check the wiring.
Remove the foreign matter.
Foreign matter caught
Disconnected harness, disengaged connector
Replacement
Re-check the wiring
Wiring failure, disconnection, disconnected connector Servo motor failure
Re-set the link.
Remove the foreign matter.
Foreign matter caught
Disengaged link
Replacement
Check the wiring.
Wiring failure, disconnection, disconnected connector Servo motor failure
Re-set the link.
Disengaged link
01-51 95ZV-2 Troubleshooting Operator Station Group
80V2E01018
01-52 95ZV-2 Troubleshooting
MEMO
03-1
Measurement for Performance Check 03 Cautions on Safety ............................................................................................................................................ 03-2 Standard Measurement Values for Performance Check ................................................................................... 03-3 Preparation for Performance Check ................................................................................................................. 03-6 Engine ............................................................................................................................................................... 03-8 Measuring engine speed ............................................................................................................................. 03-8 Clutch Oil Pressure and Time Lag .................................................................................................................. 03-12 Measuring clutch oil pressure ................................................................................................................... 03-12 Hydraulic Cylinder ........................................................................................................................................... 03-15 Cylinder natural drift .................................................................................................................................. 03-15 Boom Cycle Time ............................................................................................................................................ 03-17 Full Steering Time ........................................................................................................................................... 03-19 Loading/Steering Circuit Relief Valve .............................................................................................................. 03-21 Loading circuit relief valve setting pressures ............................................................................................ 03-21 Steering circuit relief valve setting pressures ............................................................................................ 03-26 Stop Valve ....................................................................................................................................................... 03-32 Stop valve adjustment procedure ............................................................................................................. 03-32 Fan Revolution ................................................................................................................................................ 03-33 Service Brake .................................................................................................................................................. 03-34 Service brake performance check ............................................................................................................ 03-34 Parking Brake ................................................................................................................................................. 03-35 Parking brake performance check ............................................................................................................ 03-35 Brake Circuit Oil Pressure ............................................................................................................................... 03-36 Unloader valve setting pressure ............................................................................................................... 03-36 Brake valve oil pressure ............................................................................................................................ 03-39 Accumulator Circuit Charging Time ................................................................................................................ 03-41 Number of Brake Pedal Applications .............................................................................................................. 03-43 Declutch Engagement ..................................................................................................................................... 03-44
03-2 95ZV-2 Measurement for Performance Check Cautions on Safety
Cautions on Safety WARNING Unexpected movement of the machine may cause an accident resulting in injury or death. Therefore, to provide repair service with the engine running, be sure to observe the following items: - Park the machine on level ground. - Apply the parking brake. - Block the tires with chocks to prevent the tires from moving. - Determine the signals between the service man. - Prohibit any person from walking into dangerous areas. - Near articulation areas of the machine - Under the machine - Around the engine - In front of or behind the machine
WARNING Operation under the boom or the bucket may lead to severe accidents. Make sure to apply the safety lock of the boom and the bucket control lever provided in the cab, remove the starter key, and attach a "DO NOT OPERATE!" tag to the cab.
CAUTION Be careful not to be burnt by bursting high pressure oil. Release the pressure remaining inside the circuit and open the cap of the hydraulic tank before removing the plug from the pressure measurement port so that the internal pressure of the hydraulic tank is released and burst of the high pressure oil can be prevented.
WARNING Entering the articulation area of the machine body while the engine is running may cause severe accidents. Make sure to stop the engine, pull out the starter key, and attach a "DO NOT OPERATE!" tag to the cab before entering the articulation area.
CAUTION Touching the fan or the V belt of the engine or the hot area while the engine is running may cause severe accidents. Make sure to stop the engine before opening the engine room access panel.
03-3 95ZV-2 Measurement for Performance Check Standard Measurement Values for Performance Check
Standard Measurement Values for Performance Check Measurement conditions Temperature of torque converter oil: 50~80°C (120~180°F) Temperature of hydraulic oil: 50~80°C (120~180°F) Temperature of engine coolant: 50~80°C (120~180°F) Standard measurement values for performance check
Item Measurement item
System
Engine speed (min-1) (rpm)
Engine
(S/N 9001~9250)
Minimum no-load speed, Low Idle (LI)
850±50
Maximum no-load speed, High Idle (HI)
2,040±50
Maximum speed in torque converter stall mode
2,000±100
1,800±100
Maximum speed in multiple control valve relief mode
2,010±100
1,670±100
Maximum speed in torque converter stall plus multiple control valve relief mode
1,460 +150 - 100
1,250 +150 - 100
Minimum no-load speed, Low Idle (LI) Engine speed (min-1) (rpm) (S/N 9251~)
850±50
Maximum no-load speed, High Idle (HI)
2,040±50
1,800±50
Maximum speed in torque converter stall mode
2,020±100
1,800±100
Maximum speed in multiple control valve relief mode
2,010±100
2,010±100
Maximum speed in torque converter stall plus multiple control valve relief mode
1,530 +150 - 100
1,300 +150 - 100
Main pressure MPa (kgf/cm2) (psi) Transmission
Fuel efficient mode
Normal
Engine speed
Remarks
725 in hibernate mode
725 in hibernate mode
Idling (LI)
2.4±0.2 (24±2) (341±28)
Maximum (HI)
3.0±0.2 (31±2) (441±28) 1st speed
2.2±0.2 (22±2) (313±28)
Except 1st speed
2.4±0.2 (24±2) (341±28)
1st speed
2.5±0.2 (25±2) (356±28)
Except 1st speed
2.9±0.2 (30±2) (427±28)
Idling (LI)
Clutch pressure MPa (kgf/cm2) (psi) Maximum (HI) Clutch time lag (sec)
Neutral→Forward 1st speed (engine speed: 1,500 min-1 (rpm))
0.3±0.1
Before wheels move
03-4 95ZV-2 Measurement for Performance Check Standard Measurement Values for Performance Check
Standard measurement values for performance check
Item Measurement item
System
Cylinder drift (when boom and bucket are horizontal and with no load) (mm/min) (in/min)
Boom rising time (no load) (sec)
Hydraulic line
Full steering time (sec)
Relief valve setting pressure MPa (kgf/cm2) (psi)
Fan maximum revolution (HI) min-1 (rpm)
Fan minimum revolution (LI) min-1 (rpm)
Boom cylinder
3 (1/8) or less
Bucket cylinder
4 (5/32) or less Idling (LI)
Engine speed
Engine speed
Remarks
23±3.0 -1
1,500 min (rpm)
10.5±1.0
Maximum (HI)
6.7±0.5
Idling (LI)
5.0±0.5 -1
1,500 min (rpm)
2.4±0.3
Full accelerated engine speed
2.4±0.5
Loading line main relief pressure (HI)
20.6±0.5 (210±5) (2,986±71)
Loading line overload relief pressure (LI)
23.5±0.5 (240±5) (3,417±71)
Steering line main relief pressure (HI)
20.6±0.5 (210±5) (2,986±71)
Steering line overload relief pressure (LI)
+10 24.5 +1.0 0 (250 0 ) +142 (3,555 0 )
Run engine at lowest possible speed while setting
Pilot line reducing pressure (LI)
3.5 (36) (512)
Run engine at lowest possible speed while setting
Engine water temp. <80ºC (180ºF) T/C oil temp. <110ºC (230ºF) Hydraulic oil temp. <90ºC (195ºF)
910 +75 - 200
Engine water temp. >95ºC (205ºF) T/C oil temp. >115ºC (240ºF) Hydraulic oil temp. >95ºC (205ºF)
1,300 +100 - 50
Engine water temp. <60ºC (140ºF) Engine idle revolution
750 +50 - 200
Run engine at lowest possible speed while setting
03-5 95ZV-2 Measurement for Performance Check Standard Measurement Values for Performance Check
Item Measurement item
System
Performance of service brake
Performance of parking brake
Shift lever position
2nd speed reverse
Engine speed
Maximum (HI)
Shift lever position
3rd speed reverse
Engine speed
Maximum (HI)
Off (Cut-out)
11.8±0.5 (120±5) (1,706±71)
On (Cut-in)
6.9±1.0 (70±10) (995±142)
Low-pressure alarm switch setting pressure (For brake accumulator circuit)
Brake
Auto brake reducing pressure (LI) The time from the low-pressure alarm is turned off till the unloading valve cuts off pressure
Accumulator charge time (sec)
Engine speed (LI)
Number of brake pedal applications
Run engine 1 minute high idle, then stop the engine. (Turn key switch "ON" with engine off.) Step on the brake pedal and release, and check the number of times until the low-pressure alarm is turned on.
Declutch engagement (cm) (in)
Engine: Maximum speed/ Declutch pedal: Quick release (Distance the loader rolls back before moving forward.)
Note These are the standard measurement values for the machines at the time when delivered from the factory.
Remarks
Slowly increase the engine speed, and check that the machine does not move at the maximum engine speed.
↑
Unloader valve setting pressure Brake line setting pressure MPa (kgf/cm2) (psi)
Standard measurement values for performance check
Before brake check, be sure to disconnect the cable connector of parking brake solenoid valve.
3.9±0.5 (40±5) (569±71) 3.5 (36) (512)
The same as pilot line reducing pressure (LI)
16
at least 10 times
Repeat stepping on the brake pedal as follows: On: 5 sec. Off: 5 sec.
15 (6) or less
1/5 slope (approx. 11º), unladen, 1st speed
03-6 95ZV-2 Measurement for Performance Check Preparation for Performance Check
Preparation for Performance Check WARNING Unexpected movement of the machine may cause an accident resulting in injury or death. Therefore, to provide repair service with the engine running, be sure to observe the following items: - Park the machine on level ground. - Apply the parking brake. - Block the tires with chocks to prevent the tires from moving. - Determine the signals between the service men. - Prohibit any person from walking into dangerous areas. - Near articulation area of the machine - Under the machine - Around the engine - In front of or behind the machine
CAUTION Do not touch the fan or V-belt of the engine or a high temperature section if the engine is running. An accident resulting in injury may occur. Be sure to stop the engine before you open the side cover of the engine room. Keep all guards in place. Avoid high temperature components even when the engine is stopped.
Preparation of measurement units - To measure pressure, be sure to prepare the hose, adapter, and wrench for pressure port plug in addition to the measurement instruments. - Check operation of the measurement instruments. Carefully handle the instruments. If something comes in contact with an instrument or large shock is applied to an instrument, the instrument may be damaged. In addition, periodic inspection of the instruments is also important. If the zero point of an instruments is not properly adjusted, the value indicated by the instrument may be wrong. Cautions regarding measurement - Take safety precautions before starting measurement work, and carefully measure and record the valves. - Measure a value three times or more. If the obtained values greatly differs from each other, an error has been made in measuring the value. Measure the value again. Calculate the average value from the various readings. Warm-up - If the machine is too cold, measured values may be wrong. To prevent incorrect readings, be sure to warm up the machine until the torque converter oil, hydraulic oil, and engine coolant are heated to the specified temperature.
03-7 95ZV-2 Measurement for Performance Check Preparation for Performance Check Procedure for warm-up Gauge
Engine water temperature 97ºC(206ºF)
T/C. T/M oil temperature 110ºC(230ºF)
100ºC(212ºF)
35ºC(95ºF)
103ºC(217ºF)
100ºC(212ºF)
120ºC(248ºF)
50ºC(122ºF)
125ºC(257ºF)
Indication
White
Red
Red
White
Resistance between S and E (Ω)
120~125
75~80
Resistance between S and V (Ω)
120~125
85~90
Resistance between E and V (Ω)
170~190
130~150
1. Torque converter oil temperature Perform torque converter stall operation by referring to "Stall speed measurement procedure". Check the approximate temperature using the temperature gauge in the instrument panel. 2. Hydraulic oil temperature Perform multiple control valve relief operation by referring to "Engine speed measurement procedure in multiple control valve relief mode". Check the approximate temperature using the contact thermometer attached to the outside surface of the hydraulic tank. 3. Engine coolant temperature Warming up the torque converter oil and hydraulic oil also warms up the engine. Check the engine coolant temperature using the temperature gauge in the instrument panel.
03-8 95ZV-2 Measurement for Performance Check Engine
Engine WARNING Unexpected movement of the machine may cause an accident resulting in injury or death. Therefore, to provide repair service with the engine running, be sure to observe the following items: - Park the machine on level ground. - Apply the parking brake. - Block the tires with chocks to prevent the tires from moving. - Determine the signals between the service men. - Prohibit any person from walking into dangerous areas. - Near articulation area of the machine - Under the machine - Around the engine - In front of or behind the machine
CAUTION Do not touch the fan or V-belt of the engine or hightemperature section if the engine is running. An accident resulting in injury may occur. Be sure to stop the engine before you open the access panel of the engine room. Keep all guards in place. Avoid high temperature components even when the engine is stopped. Use a photo tachometer when checking engine revolution.
Measuring engine speed
Measurement conditions Temperature of torque converter oil: 50~80ºC (120~180ºF) Temperature of hydraulic oil: 50~80ºC (120~180ºF) Temperature of engine coolant: 50~80ºC (120~180ºF) 1. Press the brake pedal. Set and confirm the transmission shift lever is neutral position. 2. Set and confirm the parking brake to the "ON" position. 3. Lower the bucket onto the ground. 4. Set the boom and bucket control lever to "Neutral position". 5. Set the shift lever to the forward position. Note To avoid "Hibernate mode". In "Hibernate mode", decrease the engine speed 850 min-1 to 725 min-1 under following condition. When the transmission shift lever is placed in "N" position, the engine coolant temperature is higher than 60ºC, and the engine speed is held at 950 min-1 or less for 10 seconds. 6. Record low idle speed. 7. Set and confirm the transmission shift lever is neutral.
Measurement instrument
8. Set the declutch ON/OFF switch to ON. Press the brake pedal all the way to the floor.
- Tachometer (MODM)
Note To avoid "fuel saving mode at idle time". In "fuel saving mode at idle time", not activated promptly and engine may not reach the maximum revolution. Press the brake pedal all the way to the floor with the declutch ON/OFF switch to ON, release this mode.
Standard measurement value Low idle (min-1): 850±50 High idle (min-1): 2,040±50
9. Gradually increase the engine speed. Measure the speed (high Idle) when the accelerator pedal is fully pressed down. 10. Record high idle speed.
03-9 95ZV-2 Measurement for Performance Check Engine Stall speed measurement procedure
WARNING Unexpected movement of the machine for abnormal brake performance may cause an accident resulting in injury or death. Before measuring, make sure that the machine has sufficient brake performance.
IMPORTANT In the stall mode, the torque converter oil temperature rises rapidly. Therefore, long stall operation may damage the seals, and the damaged seal may cause oil leakage. This is why stall test should be limited to 20 seconds. The torque converter oil temperature should not be exceeded 120°C (250°F). To repeat the stall operation, be sure to wait more than 10 seconds with medium engine speed before next stall operation so that the torque converter oil is cooled enough. 1. Press the brake pedal. Set and confirm the transmission shift lever is neutral position. 2. Set and confirm the parking brake to the "ON" position.
Engine speed measurement procedure in multiple control valve relief mode
IMPORTANT When the relief valve is activated, the oil temperature rises rapidly. Therefore, long relief operation may damage the seals or cause the spool to stick inside the valve. This is why relief operation should be limited to 10 seconds. To repeat the relief operation, be sure to wait more than 10 seconds with medium engine speed before next relief operation, and cool the inside of the valve. Using this cycle safely warms up cold oil. 1. Press the brake pedal. Set and confirm the transmission shift lever is neutral position. 2. Set and confirm the parking brake to the "ON" position. 3. Lower the boom to the lowest limit. Roll back the bucket fully until the bucket contacts to the stopper. 4. Set the declutch ON/OFF switch to ON. Press the brake pedal all the way to the floor.
4. Set the parking brake to the "OFF" position.
Note To avoid "fuel saving mode at idle time". In "fuel saving mode at idle time", not activated promptly and engine may not reach the maximum revolution. Press the brake pedal all the way to the floor with the declutch ON/OFF switch to ON, release this mode.
5. Set the declutch ON/OFF switch to OFF.
5. Set the engine speed to HI.
6. Press the brake pedal all the way to the floor, and then set the transmission shift lever to the forward 3rd speed position.
6. Place the bucket control lever in roll back position. Measure the engine speed.
3. Lower the boom to the lowest limit. Roll back the bucket fully until the bucket contacts to the stopper.
7. Gradually increase the engine speed. Measure the engine speed when the accelerator pedal is fully pressed down. 8. Record the engine speed at T/C stall. (During stall speed measurement, do not operate the steering system, boom, bucket, etc.)
97ZV03002
03-10 95ZV-2 Measurement for Performance Check Engine Maximum speed in torque converter stall plus multiple control valve relief mode.
WARNING Unexpected movement of the machine for abnormal brake performance may cause an accident resulting in injury or death. Before measuring, make sure that the machine has sufficient brake performance.
IMPORTANT In the stall mode, the torque converter oil temperature rises rapidly. Therefore, long stall operation may damage the seals, and the damaged seal may cause oil leakage. This is why stall test should be limited to 20 seconds. The torque converter oil temperature should not be exceeded 120°C (250°F). To repeat the stall operation, be sure to wait more than 10 seconds with medium engine speed before next stall operation so that the torque converter oil is cooled enough.
1. Press the brake pedal. Set and confirm the transmission shift lever is neutral position. 2. Set and confirm the parking brake to the "ON" position. 3. Lower the boom to the lowest limit. Roll back the bucket fully until the bucket contacts to the stopper. 4. Set the parking brake to the "OFF" position. 5. Set the declutch ON/OFF switch to OFF. 6. Press the brake pedal all the way to the floor, and then set the transmission shift lever to the 3rd speed position. 7. Gradually increase the engine speed. 8. Place the bucket control lever in roll back position. 9. Measure the engine speed when the accelerator pedal is fully pressed down.
IMPORTANT When the relief valve is activated, the oil temperature rises rapidly. Therefore, long relief operation may damage the seals or cause the spool to stick inside the valve. This is why relief operation should be limited to 10 seconds. To repeat the relief operation, be sure to wait more than 10 seconds with medium engine speed before next relief operation, and cool the inside of the valve. Using this cycle safely warms up cold oil.
97ZV03002
03-11 95ZV-2 Measurement for Performance Check Engine Cause of extremely high or low measurement value and solution Minimum no-load speed (LI) or maximum no-load speed (HI) low
Possible cause Insufficient warm up Malfunctioning accelerator pedal or harness
Solution Warm up
Clean
Defective fuel pump
Repair
Defective fuel injection nozzle
Repair
Insufficient compression pressure
Possible cause
Solution
Relief valve pressure too low
Adjustment or disassembly
Defective pump / pump seals
Disassembly & repair
Inspection & repair
Clogged fuel filter
Valve clearances incorrect
The engine speed is too high in multiple control valve relief mode.
Adjustment Repair
The engine speed is too low in multiple control valve relief mode.
Possible cause
Solution
Engine low power
Inspection & repair
Extremely high relief pressure of multiple control valve
Adjustment
The engine speed is too high in torque converter stall mode.
Possible cause
Solution
Slipping transmission clutch or defect inside of transmission
Disassembly & repair
Defect inside torque converter
Disassembly & repair
The engine speed is too low in torque converter stall mode.
Caused by reduction in engine power Possible cause Clogged air cleaner element Improper type of fuel Clogged fuel filter or suction strainer Frozen fuel / wax build up Malfunctioning accelerator pedal or harness
The engine speed is too high in torque converter stall plus multiple control valve relief mode. Possible cause
Solution
Slipping transmission clutch or defect inside of transmission or T/C
Disassembly & repair
Relief pressure too low
Adjustment
Defective pump / pump seals
Disassembly & repair
The engine speed is too low in torque converter stall plus multiple control valve relief mode. Solution Cleaning Fuel replacement Clean or replace Use antifreeze mixture Inspection & repair
Defective fuel pump
Repair
Defective fuel injector nozzle
Repair
Insufficient compression pressure
Repair
Hydraulic load is extremely large
Inspection & repair
Malfunctioning torque converter
Inspection & repair
Possible cause
Solution
Engine low power
Inspection & repair
Extremely high relief pressure of multiple control valve or steering valve
Adjustment
Malfunctioning torque converter
Repair
03-12 95ZV-2 Measurement for Performance Check Clutch Oil Pressure and Time Lag
Clutch Oil Pressure and Time Lag Measuring clutch oil pressure WARNING Unexpected movement of the machine may cause an accident resulting in injury or death. Therefore, to provide repair service with the engine running, be sure to observe the following items: - Park the machine on level ground. - Apply the parking brake. - Block the tires with chocks to prevent the tires from moving. - Determine the signals between the service man. - Prohibit any person from walking into dangerous areas. - Near articulation areas of the machine - Under the machine - Around the engine - In front of or behind the machine
Gauge port 1. Location: Main pressure
Lock-up clutch High range Reverse clutch 2nd clutch clutch Low range 1st clutch 3rd clutch clutch
Measurement instrument - Pressure gauge - Tachometer (MODM) - Stop watch
L
Transmission oil pressure test port location
R
2
3
95V2E33001
2. Measuring port: PF 1/4 with O-ring. 3. Oil pressure gauge: 5 MPa (50 kgf/cm2) (1000 psi) with 2~3 m (6~10 ft.) hose Note Warm-up the engine before measuring the clutch oil pressure and time lag
03-13 95ZV-2 Measurement for Performance Check Clutch Oil Pressure and Time Lag
Standard measurement value 1st speed
2.2±0.2 (22±2) (313±28)
Except 1st
2.4±0.2 (24±2) (341±28)
1st speed
2.5±0.2 (25±2) (356±28)
Except 1st
2.9±0.2 (30±2) (427±28)
Low idle Clutch pressure MPa (kgf/cm2) (psi)
Engine speed High idle
Clutch time lag (sec)
Neutral→1st forward speed (engine speed: 1,500 min-1 (rpm))
0.3±0.1
Clutch oil pressure measurement procedure 1. Press the brake pedal, set and confirm the transmission shift lever is neutral position. 2. Set and confirm the parking brake to the "ON" position. 3. Depress the brake pedal. 4. Lower the bucket onto the ground. 5. Stop the engine. Attach the pressure gauge to the pressure measurement port. Place the gauge inside the operator's area, start the engine. 6. As the clutch oil pressure rises just after the engine is started, keep the engine to low idle before the pressure measurement. 7. Measure and record the pressure in each speed range. (Low idle 1st speed, low idle except 1st) 8. Set the declutch ON/OFF switch to ON. Press the brake pedal all the way to the floor. Note To avoid "fuel saving mode at idle time". In "fuel saving mode at idle time", not activated promptly and engine may not reach the maximum revolution. Press the brake pedal all the way to the floor with the declutch ON/OFF switch to ON, release this mode.
9. As the clutch oil pressure rise just after the engine is started, adjust the engine to high idle before the pressure measurement. 10. Measure and record the pressure in each speed range. (High idle 1st speed, high idle except 1st) Note 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.
03-14 95ZV-2 Measurement for Performance Check Clutch Oil Pressure and Time Lag
Time lag measurement procedure
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. 1. Press the brake pedal, set and confirm the transmission shift lever is neutral position. 2. Set and confirm the parking brake to the "ON" position.
Possible causes for low clutch 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 MCU
Replacement
Oil leakage from clutch
Disassembly & repair
Clutch time lag Possible cause
Solution
3. Depress the brake pedal. 4. Lower the boom to the lowest limit, and fully roll back the bucket until the bucket contacts to the stopper. 5. Set the parking brake switch to the "OFF" position. Do not apply the service brakes. 6. Set the transmission shift lever to the neutral 1st speed. 7. Keep the engine speed at 1,500 min-1 (rpm). 8. 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.
Defective pressure sensor
Replacement
Malfunctioning modulator valve (1) operation
Inspection & repair
Malfunctioning modulator valve (2) operation
Inspection & repair
Defective MCU
Replacement
Defective clutch
Disassembly & repair
03-15 95ZV-2 Measurement for Performance Check Hydraulic Cylinder
Hydraulic Cylinder Cylinder natural drift
5. Lock the boom and bucket control levers using the loading control lever lock. (Set to "lock position")
WARNING Standing under the boom or bucket during service work is dangerous. An accident resulting in injury or death may be caused. To prevent such an accident, be sure to lock the boom and bucket control levers in the cab, securely support the boom, and remove the starter key. In addition, hang a "DO NOT OPERATE!" tag on the steering wheel.
Measurement instrument
6. Stop the engine. 7. Attach vinyl tape to the cylinder rod at a point 100~150 mm (4~6 in) away from the cylinder head cover. 8. Measure the accurate distance from the cylinder head cover to the vinyl tape. This is distance "A" mm (in). Measure the distance again 5 minutes later. This is distance "B" mm (in). Cylinder drift (mm/min) A – B (mm) (in) = -------------(in/min) 5 (min)
- Scale 150~300 mm (1 ft.)
Reference
- Stop watch - Black vinyl "electrician's" type Note Warm-up the hydraulic oil before measuring cylinder drift.
Vinyl tape
Standard measurement value (mm/min) (in/min)
Scale 95ZV43009
Boom cylinder
3 (1/8) or less
Bucket cylinder
4 (5/32) or less
Measurement procedure
Drift rate depends on the viscosity of the hydraulic oil and its temperature. In other words, high temperature of the hydraulic oil reduces the viscosity. Reduction in oil viscosity increases oil leakage through the seals, and increases the drift rate. Cold thick oil reduces the drift rate.
1. Unload the bucket. 2. Press the brake pedal. Set and confirm the transmission shift lever is neutral position. 3. Set and confirm the parking brake switch to the "ON" position. 4. Keep the boom and bucket horizontal.
IMPORTANT At the completion of measurement, if the vinyl tape used for measurement is not removed from the cylinder rod, the tape may be caught by the rod seal. The tape will cause oil leakage from the rod seal. To prevent oil leakage, be sure to remove the vinyl tape.
03-16 95ZV-2 Measurement for Performance Check Hydraulic Cylinder
Possible causes of excessive cylinder drift
Boom cylinder
Bucket cylinder Bucket cylinder
Boom cylinder
Boom cylinder rod side flange
Bucket cylinder rod side flange
Possible cause
95ZV03002
Solution
Damaged cylinder piston seal / barrel
Disassembly & repair
Defective multiple control valve overload relief valve
Disassembly & repair
Oil leakage from multiple control valve bucket spool
Disassembly & repair
- Identifying defective part Pressure is applied to the bucket cylinder bottom side to support the bucket. There should be no pressure applied to the cylinder rod side. Keep the boom and bucket horizontal, and stop the engine. Carefully loosen the split flange (see the arrow) on the cylinder rod side. If the compressed oil spouts from the cylinder, judge that the piston seal and/or cylinder barrel is damaged. If the compressed oil spouts from the hose side, judge that the piston seal of the other cylinder is defective. If no compressed oil spouts from the cylinder, judge that the cause is the defective multiple control overload relief valve or oil leakage from the main spool of multiple control valve. Note If only a few drops come out per minute it is considered normal.
Possible cause
95ZV03003
Solution
Damaged cylinder piston seal / barrel
Disassembly & repair
Oil leakage from multiple control valve boom spool
Disassembly & repair
- Identifying defective part Just like the bucket cylinder, no pressure should be applied to the rod side of the boom cylinder when the weight of the boom is resting on the boom cylinders. Carefully loosen the split flange (see the arrow) for the pipe on the cylinder rod side. If the compressed oil spouts from the cylinder, judge that the piston seal and/or barrel of the boom cylinder is damaged. If the compressed oil spouts from the pipe side, judge that the piston seal of the other cylinder is defective. If no oil spouts from the split flange, judge that oil is leaking from the multiple control valve spool.
03-17 95ZV-2 Measurement for Performance Check Boom Cycle Time
Boom Cycle Time Measurement procedure
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.
1. Unload the bucket. 2. Press the brake pedal. Set and confirm the transmission shift lever is neutral position.
Measurement instrument
3. Set and confirm the parking brake switch to the "ON" position.
- Stop watch
4. Depress brake pedal.
- Tachometer (MODM)
5. Lower the boom to the lower limit, and roll back the bucket. 6. Set ELS switch to the OFF.
Warm-up the engine before measuring boom rising time.
Standard measurement value (sec)
Engine speed
Idling (LI)
23±3.0
1,500 min-1 (rpm)
10.5±1.0
Maximum (HI)
6.7±0.5
7. Set the shift lever to the forward position. Note To avoid "Hibernate mode". In "Hibernate mode", decrease the engine speed 850 min-1 to 725 min-1 under following condition. When the transmission shift lever is placed in "N" position, the engine coolant temperature is higher than 60ºC, and the engine speed is held at 950 min-1 or less for 10 seconds. 8. Adjust the engine speed to low idle (LI) speed. 9. Measure the time required for the boom from the lowest to the highest limit. 10. Set and confirm the transmission shift lever is neutral. 11. Adjust the engine speed to 1,500 min-1. 12. Measure the time required for the boom from the lowest to the highest limit. 13. Set the declutch ON/OFF switch to ON. Press the brake pedal all the way to the floor. Note To avoid "fuel saving mode at idle time". In "fuel saving mode at idle time", not activated promptly and engine may not reach the maximum revolution. Press the brake pedal all the way to the floor with the declutch ON/OFF switch to ON, release this mode.
03-18 95ZV-2 Measurement for Performance Check Boom Cycle Time Possible causes of slow boom cycle time:
14. Adjust the engine speed to high idle (HI). 15. Measure the time required for the boom from the lowest to the highest limit. Note Even if the boom kick out system is installed, the boom control lever should be held in the UP position until the boom rises to the highest limit.
97ZV03005
Possible cause
Solution
Damaged main pump / seals
Disassembly & repair
Damaged steering pump / seals
Disassembly & repair
Multiple control valve spool sticking
Disassembly & repair
Malfunctioning ELS valve
Disassembly & repair
Malfunctioning ELS switch or harness
Inspection & repair
Malfunctioning controller or harness
Inspection & repair
Internal oil leakage of boom cylinder
Inspection & repair
Malfunctioning steering valve
Disassembly & repair
How to determine the cause (damaged main pump or steering pump): Measure the full steering time. If normal the main pump is damaged. If steering time is also slow the steering pump is damaged.
Boom cylinder
To steering line
Multiple control valve
Steering valve ELS valve Steering pump
Main pump
Hydraulic tank 95ZV03004
03-19 95ZV-2 Measurement for Performance Check Full Steering Time
Full Steering Time Measurement procedure
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.
1. Adjust the stopper bolts of the front chassis so that the front chassis stopper contacts to the rear chassis. 2. Unload the bucket. 3. Press the brake pedal. Set and confirm the transmission shift lever is neutral position.
Measurement instrument
4. Set and confirm the parking brake switch to the "ON" position.
- Stop watch - Tachometer (MODM)
5. Lower the boom, and roll back the bucket. (Bucket and boom are not on to ground for steering)
Warm-up the engine before measuring full steering time.
6. Confirm the parking brake switch is in the “ON” position and release the brake pedal. 7. Set the shift lever to the forward position.
Standard measurement value (sec)
Engine speed
Idling (LI)
5±0.5
1,500 min-1 (rpm)
2.4±0.3
Full accelerated engine speed
2.4±0.5
Note To avoid "Hibernate mode". In "Hibernate mode", decrease the engine speed 850 min-1 to 725 min-1 under following condition. When the transmission shift lever is placed in "N" position, the engine coolant temperature is higher than 60ºC, and the engine speed is held at 950 min-1 or less for 10 seconds. 8. Adjust the engine speed to low idle (LI) speed. 9. Measure and record the time required for full steering. 10. Set and confirm the transmission shift lever is neutral. 11. Adjust the engine speed to 1,500 min-1. 12. Measure and record the time required for full steering. 13. Gradually increase the engine speed. Accelerator pedal is fully pressed down.
03-20 95ZV-2 Measurement for Performance Check Full Steering Time 14. Measure and record time required for full steering. - From full left to full right or - From full right to full left Turn the steering wheel as fast as possible during the test.
Possible causes for slow steering times: Possible cause
Solution
Damaged steering pump / seals
Disassembly & repair
Malfunctioning steering valve flow control plunger or steering spool
Disassembly & repair
IMPORTANT After measuring, return the stopper bolts. (Refer to "Stop valve" in Check & Adjustment.)
Flow control plunger
(G) P MR
Pb
Steering valve
97ZV03007
Full steering
Pa
T
95ZV03005
03-21 95ZV-2 Measurement for Performance Check Loading/Steering Circuit Relief Valve
Loading/Steering Circuit Relief Valve Loading circuit relief valve setting pressures WARNING Unexpected movement of the machine may cause an accident resulting in injury or death. Therefore, to provide repair service with the engine running, be sure to observe the following items: - Park the machine on level ground. - Apply the parking brake. - Block the tires with chocks to prevent the tires from moving. - Determine the signals between the service man. - Prohibit any person from walking into dangerous areas. - Near articulation areas of the machine - Under the machine - Around the engine - In front of or behind the machine
CAUTION Be careful, you may get burned if the high pressure oil spouts out. To prevent such an accident, be sure to release the residual pressure from the pipe, and open the cap of the hydraulic tank before removing the plug from the pressure measurement port.
CAUTION Do not touch the fan or V-belt of the engine or a hightemperature section if the engine is running. An accident resulting in injury may occur. Be sure to stop the engine before you open the access panel of the engine room. Keep all guards in place. Avoid high temperature components even when the engine is stopped.
Measurement instruments Pressure gauge 30 MPa (300 kgf/cm2) (5,000 psi) (for loading line with 3 m (10 ft.) hose and steering line with 1.5~3 m (4~10 ft.) hose) 5 MPa (50 kgf/cm2) (1,000 psi) (for pilot line) with 2~3 m (6~10 ft.) hose Note For safety, route the gauge to an area where it may be safely read by the person doing the test.
Gauge port Gauge port location Main relief pressure
(1), (2), (3)
Overload relief pressure
(1), (2), (3)
Pilot line pressure (Reducing valve)
(4)
Port size
(1), (2), (3) G (PF) 1/4 with O-ring
(4) G (PF) 3/8 with O-ring
03-22 95ZV-2 Measurement for Performance Check Loading/Steering Circuit Relief Valve
Standard measurement value MPa (kgf/cm2) (psi) Loading line main relief pressure (at maximum speed)
20.6±0.5 (210±5) (2,986±71)
Loading line overload relief pressure (at idling speed)
23.5±0.5 (240±5) (3,413±71)
Pilot line
3.5 (36) (512)
Measuring loading circuit main relief pressure 1. Unload the bucket. 2. Press the brake pedal. Set and confirm the transmission shift lever is neutral position. 3. Set and confirm the parking brake switch to the "ON" position.
Hydraulic oil temp 50±5ºC (120±9ºF)
4. Depress the brake pedal.
Reference
5. Lower the boom to the lowest limit.
Releasing residual pressure from tank and pipes
6. Attach the pressure gauge 30 MPa (300 kgf/cm2) (5,000 psi) to the bucket cylinder bottom side (2).
Keep the bottom surface of the bucket horizontal, and stop the engine when the bucket is approximately 30 cm (1 ft.) above the ground. Tilt down the bucket until it comes in contact with the ground. Place the bucket control lever in the roll back position, and then lower the boom. Push down on, then open the cap of the hydraulic tank to release the residual pressure.
7. Set the declutch ON/OFF switch to ON. Press the brake pedal all the way to the floor. Note To avoid "fuel saving mode at idle time". In "fuel saving mode at idle time", not activated promptly and engine may not reach the maximum revolution. Press the brake pedal all the way to the floor with the declutch ON/OFF switch to ON, release this mode. 8. Move the bucket control lever to the roll back position. Hold the lever at that position. 9. Increase the engine speed to the maximum, and measure and record the pressure using the pressure gauge. Adjusting main relief pressure Loosen the lock nut and adjust the pressure by the adjusting screw. Turn clockwise the adjusting screw to raise the set pressure, or turn counterclockwise the adjusting screw to lower the set pressure.
IMPORTANT At the completion of check and adjustment of main relief valve pressure, be sure to tighten the lock nut.
03-23 95ZV-2 Measurement for Performance Check Loading/Steering Circuit Relief Valve Main relief valve
Bucket cylinder
Cap Lock nut
(2) Note (1) North America equipped M/c's have a quick connector in port (3) for testing. K97V2J43003
Multiple control valve
Make-up valve
Overload relief valve
Main relief valve
Overload relief valve
(3) 95ZV43002
Valve assembly
(4) (PPI)
(Z2) (PA) (PARKING)
(Z)
(Z1) ACF
(ACCF)
(ACCR)
(TA) (T)
(P)
Reducing valve (for pilot) 85V2E43006
Adjusting screw
95ZV43004
03-24 95ZV-2 Measurement for Performance Check Loading/Steering Circuit Relief Valve
Measuring loading circuit overload relief pressure 1. Attach the pressure gauge to the port (3). ((1) for the rod side, (2) for the bottom side, (3) for the both sides.) 2. Adjust the main relief valve pressure to 24.5 MPa (250 kgf/cm2) (3,555 psi) + 1/4 additional turn, so the pressure is above the overload relief pressure. Bucket cylinder bottom side (gauge port (2) or (3)) 1. Lower the boom to the lowest limit. 2. Move the bucket control lever to the roll back position.
Adjusting overload relief pressure Loosen the lock nut and adjust the pressure by the adjusting screw. Turn clockwise the adjusting screw to raise the set pressure, or turn counterclockwise the adjusting screw to lower the set pressure.
IMPORTANT At the completion of check and adjustment of overload relief valve pressure, be sure to reset the main relief valve to the original condition. Overload relief valve
3. Set the shift lever to the forward position. Lock nut
Note To avoid "Hibernate mode". In "Hibernate mode", decrease the engine speed 850 min-1 to 725 min-1 under following condition. When the transmission shift lever is placed in "N" position, the engine coolant temperature is higher than 60ºC, and the engine speed is held at 950 min-1 or less for 10 seconds. 4. Keep the engine speed at low idle. 5. Hold the bucket control lever at the roll back position and record the pressure. Bucket cylinder rod side (gauge port (1) or (3)) 1. Keep the boom horizontal. 2. Move the bucket control lever to the dump position, hold and then measure and record the pressure.
Adjusting screw
95ZV43005
03-25 95ZV-2 Measurement for Performance Check Loading/Steering Circuit Relief Valve
Measuring pilot circuit relief pressure
Reducing valve
WARNING Trapped pressure in brake circuit could cause serious injury when the plug is removed. Fully release all residual accumulator pressure before servicing.
Lock nut
1. Attach the pressure gauge to the port (4). 2. Set the shift lever to the forward position. Note To avoid "Hibernate mode". In "Hibernate mode", decrease the engine speed 850 min-1 to 725 min-1 under following condition. When the transmission shift lever is placed in "N" position, the engine coolant temperature is higher than 60ºC, and the engine speed is held at 950 min-1 or less for 10 seconds.
3. Keep the engine speed at low idle (when the brake line pressure is normal) and then measure and record the pressure.
Adjusting pilot line pressure Loosen the lock nut and adjust the pressure by the adjusting screw. Turn clockwise the adjusting screw to raise the pilot line pressure.
IMPORTANT After the completion of the adjustment of the pilot line pressure, be sure to tighten the lock nut.
Adjusting screw
90ZVE43004
03-26 95ZV-2 Measurement for Performance Check Loading/Steering Circuit Relief Valve
Steering circuit relief valve setting pressures WARNING Unexpected movement of the machine may cause an accident resulting in injury or death. Therefore, to provide repair service with the engine running, be sure to observe the following items: - Park the machine on level ground. - Apply the parking brake. - Block the tires with chocks to prevent the tires from moving. - Determine the signals between the service man. - Prohibit any person from walking into dangerous areas. - Near articulation areas of the machine - Under the machine - Around the engine - In front of or behind the machine
Measurement instruments Pressure gauge 30 MPa (300 kgf/cm2) (5,000 psi) (for loading line with 3 m (10 ft.) hose and steering line with 1.5~3 m (4~10 ft.) hose) 5 MPa (50 kgf/cm2) (1,000 psi) (for pilot line) with 2~3 m (6~10 ft.) hose Note For safety, route the gauge to an area where it may be safely read by the person doing the test.
Gauge port Gauge port location
Port size
Main relief pressure
CAUTION Be careful, you may get burned if the high pressure oil spouts out. To prevent such an accident, be sure to release the residual pressure from the pipe, and open the cap of the hydraulic tank before removing the plug from the pressure measurement port.
CAUTION Do not touch the fan or V-belt of the engine or a hightemperature section if the engine is running. An accident resulting in injury may occur. Be sure to stop the engine before you open the access panel of the engine room. Keep all guards in place. Avoid high temperature components even when the engine is stopped.
(1), (2)
G (PF) 1/4 with O-ring
(3)
Rc (PT 1/8)
Overload relief pressure Reducing pressure
03-27 95ZV-2 Measurement for Performance Check Loading/Steering Circuit Relief Valve
Standard measurement value MPa (kgf/cm2) (psi) Steering line main relief pressure (at maximum speed)
20.6±0.5 (210±5) (2,986±71)
Steering line overload relief pressure (at idling speed)
24.5 +1.0 0 (250 +100 ) (3,555 +1420 )
Pilot line
3.5 (36) (512)
Measuring steering circuit main relief pressure 1. Unload the bucket. 2. Press the brake pedal. Set and confirm the transmission shift lever is neutral position. 3. Set and confirm the parking brake switch to the "ON" position.
Hydraulic oil temp: 50±5ºC (120±9ºF) 4. Depress the brake pedal. Reference Releasing residual pressure from tank and pipes Steer the machine in a straight position. Keep the bottom surface of the bucket horizontal, and stop the engine when the bucket is approximately 30 cm (1 ft.) above the ground.
5. Attach the pressure gauge to the gauge port ((1) or (2)). 6. Set the declutch ON/OFF switch to ON. Press the brake pedal all the way to the floor. Note To avoid "fuel saving mode at idle time". In "fuel saving mode at idle time", not activated promptly and engine may not reach the maximum revolution. Press the brake pedal all the way to the floor with the declutch ON/OFF switch to ON, release this mode. 7. In case the pressure gauge is installed to (1), steer the machine to the left until the front and rear chassis contact each other. Continue to hold the steering wheel fully turned. 8. Increase the engine speed to high idle, and measure and record the pressure. Note Because the stop valve is installed into the steering line, oil pressure does not reach the set point when the steering is fully turned. When measuring oil pressure, be sure to apply the articulation stopper or screw the stopper (bolt) in until the front and rear chassis contact each other.
WARNING If the machine begins to move with the articulation stopper applied, it may cause an accident resulting in injury or death. After the measurement, be sure to disconnect and store the articulation stopper.
03-28 95ZV-2 Measurement for Performance Check Loading/Steering Circuit Relief Valve Reducing valve
Adjusting steering line main pressure
Adjusting screw Steering cylinder
Lock nut
(2)
(A)
Note North America equipped M/c's have quick connectors at ports (1) and (2).
(3)
(1)
70ZV43007
115ZV43006a
(B)
Steering valve Loosen the lock nut and adjust the pressure by the adjusting screw. Main relief valve
Turn clockwise the adjusting screw to raise the steering line main pressure.
Overload relief valve 95ZV43006
03-29 95ZV-2 Measurement for Performance Check Loading/Steering Circuit Relief Valve
Measuring steering circuit overload relief pressure
Main relief valve
Lock nut Adjusting screw
Stopper (bolt)
95ZV43007
Port B To steering valve
Port A From pilot valve
Spool
Installed on front chassis
Check valve Installed on rear chassis 90V2U42003
1. Attach the pressure gauge to the port ((1) for the left turn, (2) for the right turn). 2. Adjust the main relief valve pressure to 25.5 MPa (260 kgf/cm2) (3,697 psi) + 1/4 additional turn, so the pressure is above the overload relief pressure. 3. Steer the machine until the front and rear chassis contact each other. Continue to hold the steering wheel fully turned. Note Because the stop valve is installed into the steering line, oil pressure does not reach the set point when the steering is fully turned. When measuring oil pressure, be sure to apply the articulation stopper or screw the stopper (bolt) in until the front and rear chassis contact each other. 4. Set the shift lever to the forward position. Note To avoid "Hibernate mode". In "Hibernate mode", decrease the engine speed 850 min-1 to 725 min-1 under following condition. When the transmission shift lever is placed in "N" position, the engine coolant temperature is higher than 60ºC, and the engine speed is held at 950 min-1 or less for 10 seconds. 5. Keep the engine speed at low idle, and measure and record the pressure. Raise the engine speed to 1,000 min-1 if fail to do.
03-30 95ZV-2 Measurement for Performance Check Loading/Steering Circuit Relief Valve
Measuring pilot circuit relief pressure (reducing pressure)
Adjusting overload relief pressure Lock nut Adjusting screw
Adjusting screw Lock nut
95ZV43008
(T)
Loosen the lock nut and adjust the pressure by the adjusting screw. (A)
Turn clockwise the adjusting screw to raise the set pressure, or turn counterclockwise the adjusting screw to lower the set pressure.
(3) (TS)
WARNING (B)
If the machine begins to move with the articulation stopper applied, it may cause an accident resulting in injury or death. After the measurement, be sure to disconnect and store the articulation stopper.
115ZV43007
1. Attach the pressure gauge to the port (3).
IMPORTANT At the completion of check and adjustment of overload relief valve pressure, be sure to reset the main relief valve to the original condition.
Gauge port plug width across flat 5 mm 2. Move the bucket control lever to the roll back position. 3. Set the shift lever to the forward position. Note To avoid "Hibernate mode". In "Hibernate mode", decrease the engine speed 850 min-1 to 725 min-1 under following condition. When the transmission shift lever is placed in "N" position, the engine coolant temperature is higher than 60ºC, and the engine speed is held at 950 min-1 or less for 10 seconds. 4. Keep the engine speed at low idle and record the pressure. 5. Hold the bucket control lever at the roll back position and record the pressure.
03-31 95ZV-2 Measurement for Performance Check Loading/Steering Circuit Relief Valve Adjusting pilot line pressure Loosen the lock nut and adjust the pressure by the adjusting screw. Turn clockwise the adjusting screw to raise the pilot line pressure.
IMPORTANT After the completion of the adjustment of the pilot line pressure, be sure to tighten the lock nut.
03-32 95ZV-2 Measurement for Performance Check Stop Valve
Stop Valve Stop valve adjustment procedure
Reference dimension Front chassis
Stop valve (rear chassis)
Stopper (bolt)
(L.H, R.H)
Front chassis
Rear chassis
Reference dimension 23~27.5 mm (0.9~1.1 in) Stopper (bolt) length
Reference dimension 28~48 mm (1.1~1.9 in) Clearance between machine body and stopper
115ZV43005
115ZV43004
Articulation angle ( º)
WARNING When the machine turns, the clearance in the articulation area closes. As a result, people may be caught, leading to a severe accident. To prevent such an accident, observe the following items strictly when adjusting the steering stopper. - Stop the engine before starting adjustment of the stopper bolt. - When confirming the operation after setup, keep proper distance from the articulation area of the machine. The stop valve works when the spool is pushed in 3 mm (0.118 in). Adjust the stopper bolt by using the following procedure. - Adjust the stopper (bolt) length so that the clearance between the machine body and the stopper becomes the reference dimension "28~48 mm (1.102~1.890 in)" shown in the table below.
37
36
35
Clearance between machine body and stopper (mm) (in)
28 38 48 (1.102) (1.496) (1.890)
Stopper (bolt) length (mm) (in)
23 25 27.5 (0.906) (0.984) (1.083)
*The target value should be the articulation angle "36º". - After adjustment, turn the steering wheel slowly at a rate of 5 sec or more per turn, and confirm the clearance between the machine body and the stopper. - When adjustment is completed, tighten the lock nut of the stopper (bolt). : 90 N-m (9.2 kgf-m) (67 lb-ft)
03-33 95ZV-2 Measurement for Performance Check Fan Revolution
Fan Revolution Measuring number of fan maximum revolutions
CAUTION Do not touch the fan or V-belt of the engine or a hightemperature section if the engine is running. An accident resulting in injury may occur. Be sure to stop the engine before you open the side cover of the engine room. Keep all guards in place. Avoid high temperature components even when the engine is stopped.
Measurement instrument
1. Disconnect the cable connector of proportional relief valve. 2. Measure the number of tan revolutions while the engine at high idle. 3. If the maximum number of revolutions is not correct, adjust it using the proportional relief valve. Loosen lock nut and turn the adjusting screw clockwise to increase the number of fan revolution.
- Tachometer (Photo tachometer) Adjusting screw Fan motor (1)
MB
Lock nut
MA
Make-up valve (3)
Proportional relief valve
Safety valve (4) Proportional relief valve (2)
MCU (Engine water temp. sensor T/C oil temp. sensor Hydraulic oil temp. sensor)
95V2E03002
Possible causes by extremely high or low measurement value and solution. Fan speed is low Possible cause Defective proportional relief valve
To return filter
From unloader valve
Solution Replacement
Defective fan motor
Replacement
Inappropriate set proportional relief valve pressure
Adjust set pressure
Hydraulic circuit diagram 95V2E03001
High revolution is high Possible cause
Solution
Inappropriate set proportional relief valve pressure
Adjust set pressure
03-34 95ZV-2 Measurement for Performance Check Service Brake
Service Brake Service brake performance check
Method 2
Method 1
If no test course available as described "Method 1", carry out the following method.
WARNING
IMPORTANT
Separate the test course by using rope etc. and keep persons away from the test course. In addition, post persons in several positions near the course to warn others and avoid an accident while checking the service brake performance.
The following method is easy and simple, however it is not an accurate way, because the braking force and rim-pull may vary on each machine. Confirm engine & transmission performance via using a stall test. See page 03-3. Reconfirm the brake performance by the method 1 as soon as possible.
Condition 1. Test course Level, straight, dry and the paved ground. 2. Run the machine and depress the brake pedal at 35 km/h (22 mph). Measure and record the braking distance.
Standard measurement value
WARNING Unexpected movement of the machine may cause an accident resulting in injury or death. Before starting brake performance check, be sure to observe the following items: - Place the machine on level ground. - Check that there is enough clearance for brake performance check around the machine. - During performance check, prohibit any person to walking near the machine. 1. Lower the boom to the lowest limit, and roll back the bucket fully until the bucket contacts to the stopper.
Braking distance 20 m (22 1/4 yard) or shorter Possible causes of extremely long braking distance
2. Set the parking brake switch to the "OFF" position. Possible cause
Solution
Low brake line pressure
Check and repair
Friction plate wear
Check and repair
Brake valve malfunction
Check and repair
Note The brake performance check methods 1 and 2 are based on the law and the regulation in Japan. When checking the service brake performance, follow the law and/or local regulation in your country, state, or province.
3. Set the declutch switch to OFF, and then depress the brake pedal all the way to the floor. 4. Set the shift lever to 2nd reverse speed. 5. Gradually increase the engine speed. The machine should not move at the maximum engine speed. Possible cause of machine moving during brake performance check. Possible cause
Solution
Low brake line pressure
Check and repair
Friction plate wear
Check and repair
Brake valve malfunction
Check and repair
03-35 95ZV-2 Measurement for Performance Check Parking Brake
Parking Brake Parking brake performance check
Method 2
Method 1
If no test course available as described "Method 1", carry out the following method.
WARNING
IMPORTANT
Unexpected movement of the machine may cause an accident resulting in injury or death. Before starting brake performance check, be sure to observe the following items: - Check that there is enough clearance for brake performance check around the machine. - During performance check, prohibit any person to walking near the machine.
The following method is easy and simple, however it is not an accurate way, because the braking force and rim-pull may vary on each machine. Confirm engine & transmission performance via stall test. See page 03-3. Reconfirm the brake performance by the method 1 as soon as possible.
WARNING Unexpected movement of the machine may cause an accident resulting in injury or death. Before starting brake performance check, be sure to observe the following items: - Place the machine on level ground. - Check that there is enough clearance for brake performance check around the machine. - During performance check, prohibit any person to walking near the machine.
Condition 1. Test course 1/5 slope (Approx. 11º 19') 2. Bucket empty 3. Parking switch ON
1. Set the parking brake switch to the "ON" position.
Standard measurement value
2. Disconnect the cable connector of parking brake solenoid valve.
No movement on 1/5 slope. 3. Place the shift lever to the 3rd reverse position. Possible cause of machine moving during brake performance check Possible cause
4. Gradually increase the engine speed. The machine should not move at the maximum speed.
Solution
Wear or breakage of brake disc
Check and repair
Parking brake switch malfunction
Check and repair
Parking brake solenoid valve malfunction
Check and repair
Note The brake performance check methods 1 and 2 are based on the law and the regulation in Japan. When checking the service brake performance, follow the law and/or local regulation in your country, state, or province.
IMPORTANT If the machine begins to move with the parking brake applied, the brake discs are worn. At the completion of parking brake test, be sure to connect the connector of electrical line to the solenoid valve again. Possible cause
Solution
Wear or breakage of brake disc
Check and repair
Parking brake switch malfunction
Check and repair
Parking brake solenoid valve malfunction
Check and repair
03-36 95ZV-2 Measurement for Performance Check Brake Circuit Oil Pressure
Brake Circuit Oil Pressure Unloader valve setting pressure WARNING Unexpected movement of the machine may cause an accident resulting in injury or death. Therefore, to provide repair service with the engine running, be sure to observe the following items: - Park the machine on level ground. - Apply the parking brake. - Block the tires with chocks to prevent the tires from moving. - Determine the signals between the service men.
(PPI)
(Z2)
(Z)
(Z1)
(PA)
ACF
(ACCF)
(ACCR)
(PARKING) (TA)
(T)
(P)
ACF port
Valve assembly
85V2E53001
WARNING
Injection Hazard Depress brake pedal 80~100 times to completely discharge the brake accumulators prior to removing these test plugs. 135ZV52035
Brake line main pressure is regulated by the unloader valve.
03-37 95ZV-2 Measurement for Performance Check Brake Circuit Oil Pressure Method 1
Measurement procedure
Refer to "Brake Main pressure 1" "Brake Main pressure 2" of MODM "Input/Output Monitor" for information.
1. Lower the boom to the lowest limit, and tilt the bucket down to the ground. Then set the parking brake switch to the "ON" position.
Method 2 If the pressure gauge is not available as described "Method 2", apply the "Method 1".
Measurement instrument Hydraulic pressure gauge 20 MPa (200 kgf/cm2) (3,000 psi)
2. Stop the engine. Repeatedly depress and release the brake pedal till you feel light brake to discharge accumulator pressure. 3. Remove one of the ACF port plug on the valve assembly and attach the pressure gauge to the port. 4. Start the engine, and keep the speed at low idle. Measure and record the pressure when the pointer of the pressure gauge stops rising (cut-out pressure).
Gauge port ACF port on valve assembly Rc (PT) 1/8
Standard measurement value Cut-out
11.8±0.5 MPa (120±5 kgf/cm2) (1,706±71 psi)
Cut-in
6.9±1.0 MPa (70±10 kgf/cm2) (995±142 psi)
5. Keep the engine at low idle, and repeatedly depress and release the brake pedal to reduce the accumulator pressure. Measure and record the pressure when the pointer of the pressure gauge stops and then starts rising again (cut-in pressure).
03-38 95ZV-2 Measurement for Performance Check Brake Circuit Oil Pressure Tightening torque : ACF port plug: 11.3 N-m (1.15 kgf-m) (8.3 lb-ft) : Lock nut (22): 16.7 N-m (1.7 kgf-m) (12.3 lb-ft) : Cap nut (24): 78.5 N-m (8.0 kgf-m) (57.86 lb-ft)
Adjusting unloader valve setting pressure (S/N 9001~9048) 24 22 21
Fan motor port
Pump port Unloader valve 70ZV53001
(S/N 9049~)
21
22 Fan motor port
Pump port Unloader valve
K115ZV53002
1. Remove cap nut (24) and loosen lock nut (22). (Nut (24) is not equipped on S/N 9049~.) 2. Adjust the pressure by adjusting screw (21). Turn the screw clockwise to raise the pressure. Note In a case that the "ON" or "OFF" pressure does not match the standard setting pressure, set the "ON" (cutin) pressure to the standard setting pressure.
03-39 95ZV-2 Measurement for Performance Check Brake Circuit Oil Pressure
Brake valve oil pressure
Gauge port
Size of air bleeder port: Rc (PT) 3/8 (In case of the bleeder valve: M10x1.0)
Force
19
Pe
da
la ng
le
Remove air bleeder nipple fitting on the axle housing, and then install the pressure gauge to the bleeder position.
15 0 m m
45
Air bleeder nipple fitting [59 N-m (6.0 kgf-m) (43 lb-ft)]
85V2E53002
85ZVE53001
Method 1 Refer to "Brake Pedal Output Oil Pressure" of MODM "Input/Output Monitor" for information. Method 2 If the pressure gauge is not available as described "Method 2", apply the "Method 1".
Measurement instrument Hydraulic pressure gauge 10 MPa (105 kgf/cm2) (1,500 psi)
Measurement procedure Check to be sure the brake valve is fully released. Press down the brake pedal to check that the oil pressure rises in proportion to the pedal angle. Release the brake pedal to check that the oil pressure drops to zero in proportion to the pedal angle. In addition, visually check for brake oil leakage.
03-40 95ZV-2 Measurement for Performance Check Brake Circuit Oil Pressure
Brake valve performance
Output oil pressure (brake port)
MPa (kgf/cm2) (psi)
4.10 (42) (595)
4 (40) (580)
2 (20) (290)
0.80 (8.2) (116)
0.36 (3.7) (52) 0
3.9 5
7.4
10
15
Pedal stroke
18.5 19 95V2E53001
Refer to the curve shown in the above figure. When the measured value does not match the performance curve, check the following points. Possible cause Malfunctioning brake valve
Solution Repair or replacement
Brake line oil pressure low (Pump, reducing valve malfunction)
Check and repair
IMPORTANT After measuring oil pressure, be sure to tighten the air bleeder valve. Also be sure to bleed air.
03-41 95ZV-2 Measurement for Performance Check Accumulator Circuit Charging Time
Accumulator Circuit Charging Time WARNING Unexpected movement of the machine may cause an accident resulting in injury or death. Therefore, to provide repair service with the engine running, be sure to observe the following items: - Park the machine on level ground. - Apply the parking brake. - Block the tires with chocks to prevent the tires from moving. - Determine the signals between the service men. - Prohibit any person from walking into dangerous areas. - Near articulation areas of the machine - Under the machine - Around the engine - In front of or behind the machine
(PPI) (PA)
(Z2)
(Z) (Z1) (ACCF)
(ACCR) (PI)
(TA) (P) (T)
ACF port
CAUTION Be careful, you may get burned if the high pressure oil spouts out. To prevent such an accident, be sure to release the residual pressure from the pipe, and open the cap of the hydraulic oil tank before removing the plug and hose from the pressure measurement port.
Valve assembly 95V2E03003
Measurement instrument - Hydraulic pressure gauge 20 MPa (200 kgf/cm2) (3,000 psi) - Stop watch
Gauge installation position - Valve assembly ACF port size Rc (PT) 1/8
03-42 95ZV-2 Measurement for Performance Check Accumulator Circuit Charging Time
Standard measurement valve (sec) Engine speed : Low idle Unloader valve pressure 3.9 MPa (40 kgf/cm2) (569 psi)
→
11.8 MPa (120 kgf/cm2) (1,706 psi)
16
Measurement procedure 1. Lower the boom to the lowest limit, and tilt down the bucket to the ground. 2. Set the parking brake switch to the "ON" position. 3. Stop the engine. Repeatedly depress and release the brake pedal to discharge accumulator pressure. 4. Attach the pressure gauge to the valve assembly ACF port. 5. Start the engine, and keep the engine speed at low idle speed. 6. Measure and record the time from the low pressure alarm is turned off 3.9±0.5 MPa (40±5 kgf/cm2) (569±71 psi) till the pointer of the pressure gauge stops rising 11.8±0.5 MPa (120±5 kgf/cm2) (1,706±71 psi). Possible causes of extremely high measurement value and solution The accumulator charging time is too long.
Possible cause
Solution
Defective unloader valve
Disassembly & repair
Oil leakage from pipe
Check & repair
Defective pilot pump
Disassembly & repair
03-43 95ZV-2 Measurement for Performance Check Number of Brake Pedal Applications
Number of Brake Pedal Applications Standard measurement value
WARNING Unexpected movement of the machine may cause an accident resulting in injury or death. Therefore, to provide repair service with the engine running, be sure to observe the following items: - Park the machine on level ground. - Apply the parking brake. - Block the tires with chocks to prevent the tires from moving. - Determine the signals between the service men. - Prohibit any person from walking into dangerous areas. - Near articulation areas of the machine - Under the machine - Around the engine - In front of or behind the machine
Run engine 1 minute high idle, then stop the engine. Turn the key to the "ON" position. Step on the brake pedal and release, and check the number of times until the low pressure alarm is turned on 3.9±0.5 MPa (40±5 kgf/cm2) (569±71 psi)
at least 10 times
Measurement procedure 1. Lower the boom to the lowest limit, and tilt down the bucket to the ground. 2. Set the parking brake switch to the "ON" position. 3. Run engine 1 minute high idle, then stop the engine. 4. Turn the starter switch to "ON".
CAUTION Do not touch the fan or V-belt of the engine or a high temperature section if the engine is running. An accident resulting in injury may occur. Be sure to stop the engine before you open the side cover of the engine room. Keep all guards in place. Avoid high temperature components even when the engine is stopped.
5. Depress the right brake pedal all the way to the floor, and hold down the pedal for 5 seconds. Release the pedal, and wait for 5 seconds to depress the pedal again. Repeat. 6. Count and record the number of pedal applications until the low pressure alarm buzzer starts to sound.
Possible causes of extremely low measurement value and solution Possible cause
Solution
Insufficient accumulator pressure due to defective unloader valve
Check & repair
Insufficient accumulator gas (N2) pressure
Charging
Insufficient accumulator pressure due to defective pilot pump
Check & repair
Defective brake valve
Check & repair
Defective service brake piston seal
Check & repair
Oil leakage from pipe
Check & repair
03-44 95ZV-2 Measurement for Performance Check Declutch Engagement
Declutch Engagement Standard measurement value
WARNING Brake performance check on a slope is dangerous work. An accident resulting in injury or death may occur. Before starting declutch engagement test observe the following: - Check that the slope is smooth. - Check that the brake works well. - Prohibit any person from walking into the dangerous. - Determine the signs between the service men. - Do not enter the area near the moving machine.
1/5 slope (approx. 11º19'), unloaded bucket, engine maximum speed at 1st speed position, quickly released inching pedal
15 cm (6 in) or less
Cause of extremely high measurement value and solution Possible cause
Solution
Too much delay in resetting declutch switch
Check and replace declutch switch
Too much time lag in engaging clutch
Refer to "Time lag measurement procedure".
Measurement procedure 1. Park the machine on level ground. 2. Attach the measurement rod to the step. 3. Position the boom approximately 50 cm (11/2ft.) above the ground. Roll the bucket fully back until the bucket contacts to the stopper. 4. Stop the machine on a 1/5 slope (approx. 11°19') so that the machine is in the climbing direction (bucket up hill). 97ZV03010
Measurement rod attached to step
Measurement instrument - Chalk - Scale (approx. 1 m) (3 ft.) or tape measure - Thin rod (approx. 1 m) (3 ft.) used as measurement rod - Vinyl tape - Assistant / operator - Nylon tie straps (2 or 3)
Warm-up the engine before measuring declutch engagement
5. Set the inching cut-off switch to ON. 6. Set the parking brake switch to the "OFF" position. 7. Press the inching brake pedal (left pedal) all the way to floor. 8. Mark the ground at the pointer position with chalk or tape. Increase the engine speed to its maximum, and set the transmission shift lever to the 1st forward speed. 9. Quickly release the inching brake pedal, and mark the point at which the machine stops rolling back (using the pointer) and starts moving up the slope. 10. Measure and record the distance on the slope.
03-45 95ZV-2 Measurement for Performance Check
MEMO
Maintenance Log Date
Machine hours
Service performed
Date
Machine hours
Service performed
Date
Machine hours
Service performed
Date
Machine hours
Service performed
Notes