80ZV 2 (EU Trouble)

93209-00460
May 25, 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 meth-
ods. Please read this manual to ensure correct troubleshooting and good repair service.
This manual will be periodically reviewed and revised for more satisfactory content. If you have any opinion or
requests, please inform us.
Safety Precautions
The most important point in providing repair service is safety. To ensure safety, observe the general cautions
described below.
- This manual is intended for properly trained and equipped service technicians.
- Any work on the machine must be performed by the trained personnel only.
- Carefully read this manual to thoroughly understand the operation method before you operate or repair the
machine.
- Be sure to wear appropriate clothes and protectors, such as safety boots, hard hat and goggles.
- Place the machine on level and solid ground, and place chocks against the wheels to prevent movement.
- Remove the cable from the battery before starting the service work, and attach a "DO NOT OPERATE!" tag to the
steering wheel.
- Be sure to release the internal pressure before you remove a pipe, such as the hydraulic oil, air, or engine cool-
ant pipe.
- 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 crib-
bing 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 kgf (40 lbs) or more), be sure to use a crane or other lifting device.
- Just after stopping operation, be careful not to directly touch a hot component. You may get burned.
- Contact tire manufacturer's local dealer for tire servicing and changing.
- Always store the tools in good condition, and use them properly.
- 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
Shows the condition or procedure that will be useful

Reference
or efficient in doing service work.
Shows the weight of a part or unit. The weight

should be considered in selecting wire rope or cable
Weight
for slinging work or determining the working pos-
ture.
Tightening Shows the tightening torque of a section that should

torque be carefully tightened during assembly work.
Shows the type of coating or adhesive and the coat-

Coating
ing section.
Oil or
Shows the oil or water supply port and the refill
water
amount.
supply
Shows the oil or water drain port and the drain

Drainage
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 dam-
aged or the performance of the product will be reduced.
The message shows the preventive measures.
Abbreviation
To save space, abbreviations are used in sentences. To understand the contents of this manual, refer to the follow-
ing abbreviation list.
E/G ........... Engine RH ........... Right hand side 3rd ............3rd speed
T/C ........... Torque converter LH ........... Left hand side 4th ............4th speed
T/M ........... Transmission H ........... High M/C ............Machine
SOL ........... Solenoid valve L ........... Low min-1 ............RPM
SW ........... Switch GND ........... Ground ELS ............Efficient loading system
F ........... Front or Forward OPT ........... Option MODM ........Machine operation diag-
A/M ........... Auto/Manual Assy ........... Assembly nostic module
B ........... Battery 1st ........... 1st speed MCU............Machine control unit
R ........... Rear or Reverse 2nd ........... 2nd speed
CONTENTS
TROUBLESHOOTING ......................................................01-1
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
Quick Troubleshooting Table

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
01-2
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
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 ................................................................................................................................... 01-45

Air conditioner ........................................................................................................................................... 01-45
01-3
80ZV-2 Troubleshooting
Cautions Regarding Troubleshooting
Cautions Regarding Troubleshooting

Important points The following questions will be helpful in determining of
the cause. Answer the questions to prevent an incorrect
The important points for troubleshooting is to carefully diagnosis.
read the operation manual and shop manual to get
enough information on the operation, circuits, structure, 1. Did the problem occur suddenly ?
and function of each component. If you have enough 2. When did the operator notice the problem ?
knowledge of each component and system, you can 3. Is there any past problem that may be the cause of
easily determine the cause of the problem. this problem ?
4. When the problem occurred, what kind of work was
There may be various causes for each problem, there- the operator doing ?
fore experience will be needed to determine which is the 5. Has the machine had the same kind of problem
actual cause of the problem. before ?
6. Has the machine been repaired or inspected
It is necessary to know the normal operation of each recently ?
component. In addition, it is also important to know the 7. Does the machine have any other problem ?
abnormal condition when a problem occurs. This chap-
ter shows various examples of past problems, and Troubleshooting
describes possible causes and remedies for each prob-
lem.
- Check before determination of cause
A problem may be caused by poor daily mainte-
Before starting troubleshooting nance, such as lack of grease, low or improper oil or
a clogged filter. Be sure to check the machine for oil
To prevent incorrect diagnosis, talk with the persons level, appearance, unpleasant odor, etc. to prevent
concerned, particularly with the operator, to get enough time loss due to other unnecessary tests.
information on the problem. If possible, check the
machine by repeating the symptom. - Inspection procedure
As a rule, check the easy-to-be-repaired system first
If the problem cannot be repeated, do not provide any (excluding the cases where the cause can be easily
repair service. determined based on the past experiences).
For instance, assume that the operator complains that This machine is controlled by electrical, hydraulic,
the boom power is low, and the rim-pull is also low. In and mechanical systems. The most easy-to-be-
this case, there are two possible causes ; low hydraulic repaired system is the electrical system. Check the
power and low rim-pull. The remedies against both electrical system first. If no problem is detected in
causes are much different from each other. the electrical system, check the hydraulic system,
and then the mechanical system.
If you hastily determine the wrong cause without check-
ing the actual condition of the problem, it will take too Note
much time and expense to solve the problem. As a Check the error code on the MODM at first !
result, you will not be trusted by the user.
01-4
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 troubleshoot-
ing table. From the problem explained by the user and
the check points written in the table, you can immedi-
ately 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 pos-
sible cause to prevent an incorrect diagnosis.
In this case, start from the most easily checked
item.
01-5
Safety Precautions
Safety Precautions
DANGER WARNING
Entering the articulation area of the machine body Service work under the machine may cause an acci-
while the engine is running may cause severe accident resulting in injury or death. To prevent such an
dents. accident, be sure to observe the following items.
Make sure to stop the engine, pull out the starter key, - Park the machine on level ground.
and attach a "DO NOT OPERATE!" tag to the cab - Apply the parking brake.
before entering the articulation area. - Block the tires with chocks to prevent the tires from
moving.
- Stop the engine.
WARNING - Give signals to the person in the cab during the
Unexpected movement of the machine may cause an work.
accident resulting in injury or death.
Therefore, to provide repair service with the engine

CAUTION
running, be sure to observe the following items. Do not touch the fan or V-belt of the engine or a high-
temperature section if the engine is running.
- Park the machine on level ground.
- Apply the parking brake. An accident resulting in injury may occur.
- Block the tires with chocks to prevent the tires from
moving. Be sure to stop the engine before you open the side
- Determine the signals between the service man. cover of the engine room.
- Prohibit any person from walking into dangerous
areas. Avoid high temperature components even when the
- Near articulation areas of the machine engine is stopped.
- Under the machine
- Around the engine
- In front of or behind the machine CAUTION
Be careful not to be burnt by bursting high pressure
oil.
WARNING
Standing under the boom or bucket during service Release the pressure remaining inside the circuit and
work is dangerous. An accident resulting in injury or open the cap of the hydraulic tank before removing
death may be caused. the plug from the pressure measurement port so that
the internal pressure of the hydraulic tank is released
To prevent such an accident, be sure to observe the and burst of the high pressure oil can be prevented.
following items.

- Apply the parking brake.
moving.
- Place a stand under the boom to support it.
- Apply the safety look of the boom and bucket con-
trol lever provided in the cab.
- Remove the starter key, and attach a "DO NOT
OPERATE!" tag to the cab.
01-6
Torque Converter and Transmission Group
1. Machine dose not move in any

shift lever position.
Check before starting work.

1. Check that the parking brake is released.
Setting the declutch ON/OFF switch to OFF allows normal operation.

2. Check the error code No. shown on the
MODM.
3. Check the transmission oil level.
4. Check the fuses of the MCU system.
Symptoms / check point
Torque converter oil becomes milky and cloudy in color.

5. Check the 70 A fusible link.
Low clutch oil pressure at all the shift lever positions.
(If the 70 A fusible link is off, no electrical

circuits will operate except horn circuit and Temperature of the torque converter oil is too high.
Pump produces an abnormal (shrieking) noise.

hazard flasher [opt.].) Filter of the torque converter is clogged.
Pump is extremely heated.

F5 fuse blows.
Possible cause 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 clutch pressure regulator valve 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 defec-

tive. Replace hose
01-7
Machine moves at a certain shift lever position, but hesitates to move at any other posi-
2. Machine dose not move at a cer-
Machine does not move at a certain shift lever position, but moves at all the other posi-
Clutch oil pressure is low at a certain position only. At all the other positions, the pres-
tain shift lever position.
Clutch can be engaged at a certain shift lever position, though the clutch will not be
(OR:Machine moves only in a cer-
tain shift lever position.)
Torque converter oil looks and smells as if it was scorched (black).

Even when pressing solenoid valve, machine does not move.

Clutch oil pressure is always high despite shift lever position.
MODM.
Machine may move even when shift lever is in "NEUTRAL".

Resistance of the solenoid valve coil is infinite Ω.

24V power is not supplied to the solenoid valve.
engaged at any other position.

sure is normal.
F5 fuse blows.
tions.
tions.

Clutch slipping Disassembly & repair
Seized clutch Disassembly & repair
Clutch oil leaks internally. Disassembly & repair
Solenoid valve replace-
Coil of clutch solenoid valve is defective.
ment
Harness of clutch solenoid valve disconnected Repair cable
Clutch solenoid valve sticking in OFF position
ment
Clutch solenoid valve sticking in ON position
ment
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
ment
Short circuited clutch solenoid or wiring Repair cable
01-8
3. Machine moves at the neutral
When the lever is shifted to the reverse position, the machine does not move reverse
position.
(Example: Machine moves for-
When the lever is shifted to the forward position, the machine moves forward.
ward at the neutral position.)

1. Check that the ground is level.
2. Check the error code No. shown on the Symptoms / check point
MODM.
Oil is black and smells scorched.

(as if the brake is applied).

T/M disassembly &
Seized clutch on forward side ∗
repair
Malfunctioning forward solenoid valve Solenoid valve
(sticking at ON position) ∗ 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
01-9
4. Large shock at starting or chang-

ing speed / direction
Even if the solenoid valve for trimmer is pressed, the solenoid valve does not work.
MODM.
Main oil pressure rises too quickly at all the shift lever positions.
Temperature of the torque converter oil is too high.

Large shock at a certain shift lever position only.
Large shock at all the shift lever positions.
Line filter is clogged.

Malfunctioning control valve regulator valve (stuck) Disassembly & repair
Malfunctioning trimmer plug (stuck) Disassembly & repair
Defective solenoid valve for trimmer Solenoid valve replace-
(Disconnected coil or stuck) ment
Damaged or worn clutch disk (seized clutch) T/M disassembly & repair
01-10
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.
MODM.
Time lag just after using the inching brake (check setting condition).
Main oil pressure rises too slowly at all the shift lever positions.
Main oil pressure is too low at all the shift lever positions.
Large time lag at a certain shift lever position only.
Large time lag at all the shift lever positions.

Defective torque converter pump Pump replacement
Malfunctioning control valve regulator valve (stuck) Disassembly & repair
Malfunctioning trimmer plug (stuck) Disassembly & repair
Control valve spring breakage or excessive wear-out Spring replacement
Malfunctioning trimmer solenoid valve (spool stuck) Disassembly & repair
Internally leaked clutch oil T/M disassembly & repair
Malfunctioning inching pressure switch Switch replacement
01-11
6. Low power
(Defective torque converter or
transmission)

1. Check the parking brake and service brake
Machine moves even if the shift lever is set to the neutral position. ∗
for dragging.
2. Check the torque converter oil level.
Clutch oil pressure is too low at a certain shift lever position.

3. Check that no unusual load is applied to the
Silver powder (Aluminum) is on the line filter and strainer.

Output power is low at a certain shift lever position only.
Torque converter oil is discolored or emits nasty smell.

hydraulic line (like excessive pilot pres-
sure).
Temperature of the torque converter oil is too high.

Large time lag at a certain shift lever position only.
Output power is low at all the shift lever positions.
Torque converter oil is milky and cloudy in color.

4. Check that the engine speed is standard

value.
MODM.

Tightening suction hose
Air drawn into suction line of torque converter
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
∗ If the seized clutch is Forward or Reverse clutch.
Remarks
01-12
7. Torque converter oil is overheat-

ing.
Less difference in torque converter oil temperature between cooler inlet and outlet.
Thermometer in T/C out line indicates less than 250ºF/120ºC when gauge or light indicates overheat.
Machine does not move at a certain shift lever position (or dragging is felt).
1. Check the torque converter oil level.
2. Check the engine coolant for overheat.
Foreigh material is on the filter-especially silver powder (Aluminum).

3. Check the oil pressure-adjust to specifica-
tion.
Output power is too small at a certain shift lever position.

MODM.
Service or parking brake is excessively hot/discolored.

Torque converter oil is discolored or emits nasty smell.
Engine speed at no load or during stall test is too low.

Torque converter oil is milky and cloudy in color.

Torque converter inlet pressure is too low.
Clutch oil pressure is too low.
Overheating.
Air drawn into suction line of torque converter Tightening hose band
T/C disassembly &
Internally torque converter leakage
repair
T/C disassembly &
Damaged torque converter
repair
Torque converter pump discharge amount too small T/C pump disassem-
bly & repair
T/M disassembly &
Seized clutch
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
Test/repair brake cir-
Service or parking brake dragging
cuit
Operator is using too high gear for loading. Train operator
Test/replace gauge or
Incorrect indication of gauge (no alarm)
sensor
Alarm switch defective (gauge in normal zone) Replace switch
Contamination in oil cooler (oil side) Replace cooler
See E/G Trouble
Engine speed too low / Engine power too low
shooting
01-13
8. Machine moves reverse when

starting to climb up on a slope
using inching brake.

MODM.

After pedal release, too much time is required to move.

Refer to description of
Large time lag in clutch engagement ∗
time lag (No.5) ∗
Inching set-up condition abnormal Set-up normally
Defective inching sensor Replacement
01-14
9. Automatic speed change is not

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

Actual speed increase or reduction does not correspond with the set speed.
Speed indicator lamp does not change even if machine speed is changed.
Speed is fixed to 2nd speed, and automatic speed change is not possible.
1. Manually change the speed from 1st speed
to 4th speed. If manual speed change is
impossible, refer to "Machine does not
Speed is fixed to 3rd speed, and is not increased to 4th speed.

move at a certain shift lever position."
(No.2)

MODM.
Speed is properly increased on a downward slope.

Shift lever replacement or
Defective shift lever "A" position or defective wiring to controller
repairing wire
Sensor replacement or
Damaged speed sensor or disconnected sensor
repairing wire
Speed sensor signal output error or improperly adjusted speed Sensor replacement or
sensor readjustment
Low machine speed Inspection & repair
Parking or service brakes dragging Test/repair brake circuit
Engine power too low / Engine speed too low See E/G troubleshooting
Speed indicator lamp failure Replacement
01-15
10. Downshift button does not work.

1. Check that the downshift button is being
used at the 2nd forward/reverse speed
position.
At the other positions, shifting down is not
possible.
2. Check the fuses.
MODM.
Downshift button does not work.

Downshift button replace-
Defective downshift button
ment
Disconnected downshift button or wiring Repair wire
Defective controller Replacement
Inspection & repair /
1st or 2nd solenoid valve or wiring
Refer to (No.2)
01-16
Hydraulic Group
Hydraulic Group
1. Boom and/or bucket do not move.
Boom and bucket do not move normally while the engine runs idle but appears to move
Boom and bucket move with no load, though they do not move when loaded.
1. Check the oil level.
Bucket moves if the overload relief valves are exchanged with each other. ∗
2. Check that the loading control lock lever is
Cylinder does not operate, though oil is discharged from the return port.
Main relief pressure is too low when the boom or bucket is operating.
fully released.
3. Check that the pilot valve inline filter is not
clogged.
After warm-up, it is possible to operate the bucket and boom.

MODM.
Either the boom or bucket does not move.
Main relief valve produces a noise.

normally while it runs at full speed.
Steering is not possible either.
Pilot relief pressure is too low.

No main relief pressure built.
No pilot relief pressure built.

Pump
Broken pump drive shaft
replacement
Disassembly &
Internally damaged steering pump.
repair
Pump
Disassembly &
Internally damaged main pump.
repair
Disassembly &
Internally damaged pilot pump.
repair
Disassembly &
Multiple control valve
Main relief valve internal oil leakage or low setting pressure

readjustment
Disassembly &
Overload relief valve internal oil leakage or low setting pressure
readjustment
Plunger
Multiple control valve spool sticking
replacement
Disassembly &
Defective valve assembly (reducing valve for pilot)
readjustment
Disassembly &
Internally damaged cylinder
repair
∗ Exchange of the overload relief valve means that the valves should be changed between the rod and bottom sides.
Remarks
01-17
Hydraulic Group
2. Boom and/or bucket have low

power, or move too slowly.

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
Either the boom and bucket does not operate properly.

the shift lever of the transmission is at the
Both the boom and bucket do not operate properly.

natural position. Dragging/seized clutches
Only bucket "roll back" operation is abnormal.

reduce power available to hydraulics.
Oil is foamy or milky looking after operation.

Steering system does not operate properly.
5. Check that the machine rolls freely in neu-

tral. If the brakes, service or parking, drag it
Main relief valve produces a noise.

Steering system operates properly.
reduces the power available to hydraulics
Pump makes noise (shrieking).

when the machine is moving. (Static testing
Bucket drifts down when full.

will show normal hydraulic power and
speed.) Pump is extremely heated.
6. Check that the pilot valve filter is not
clogged.
MODM.

Internally damaged steering pump. Disassembly & repair
Internally damaged main pump. Disassembly & repair
Disassembly & readjust-
Main relief valve internal oil leakage or low setting pressure
ment
Overload relief valve internal oil leakage (bucket bottom side)
ment
Internally damaged cylinder. Disassembly & repair
Warm up hydraulics
Oil is cold, wrong oil viscosity (too thick). Replace oil w/proper oil
Check & repair suction
Suction side air leak-clamp, hose, o-rings line
Check & repair suction
Suction line pinched or internally defective. line
Defective valve assembly (reducing valve for pilot)
ment
Bucket or boom spool does not move smoothly. Disassembly & repair
01-18
Hydraulic Group
3. Excessive cylinder drift
Front wheels drift down when the front wheels are lifted off the ground by means of the
In the case that the overload relief valve is switched or replaced, excessive drift stops.
The maximum drift rate is measured according
When the piping for cylinder rod side is removed, pressurized oil spouts out. ∗
to instructions on "Measuring Cylinder Drift".

MODM. Symptoms / check point
(The bucket hight should be 20~30 mm from the ground.)

Excessive drift of bucket.
Excessive drift of boom.
boom cylinder.

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
Disassembly & repair
valve
∗ This test may cause a serious accident. The test must be done carefully.
Remarks
01-19
Hydraulic Group
4. Boom and/or bucket are spongy.
Boom and bucket are strong enough if the engine runs at the full speed while dumping
In case that the overload relief valves are switched ∗, the boom and bucket are strong
During digging operation, the bucket tilts back even though the lever is at the neutral
(Holding bucket against the
Bucket cannot support the lifted front wheels, or the lifted front wheels soon drop.
Boom cannot support the lifted front wheels, or the lifted front wheels soon drop.
ground is not possible-front
wheels off the ground.)

MODM.
Boom is spongy just after quick lowering.

Bucket is spongy just after dumping.
enough to support the front wheels.
Overload relief pressure is too low.
or lowering.
position.

Internal oil leakage from overload relief valve for bucket rod
side
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
∗ 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.
Remarks
01-20
Hydraulic Group
5. Bucket leveler does not work.
Remove the connector of the sensor assy and check that the harness (RLg) from chas-
sis side supplies 5 V, harness (BY) is ground and harness (BrR) is conductive until MCU
LED lamp of the proximity switch does not light (starter switch ON & metal plate in front
Remove the connector of the proximity switch, and connect the wire harness (black),
Boom lift kickout and lower kick-
out does not work.
from the pilot valve to the ground (blue). Check that the lever is held properly.
1. Check the fuses.
2. For bucket / Check that the distance
between the proximity switch and detection
Check the relays and lines for lift kickout and lower kickout.
Magnet coil resistance value is indicated as infinity or 0 Ω.

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
powerline to be sure they are properly con-
nected.
MODM.
of proximity switch face).
(Starter switch ON).

Proximity switch
Defective proximity switch
replacement
Bucket
Broken detent solenoid coil inside pilot valve Magnet replacement

Disconnected electrical power line Repair
Defective sensor assy Replacement
Boom
Broken detent solenoid coil inside pilot valve Replacement

Disconnected electrical power line for lift kickout and lower kick-
Repair
out
01-21
Hydraulic Group
6. Steering is not possible or hard to

steer.
If the overload relief valves are exchanged ∗, steering problem switches sides.
1. Check the oil level in the hydraulic tank.
2. Check that the stop bolts for the stop valves
Steering is not possible (or hard) in both the right and left directions.
Increasing the engine speed enables smooth operation (steering).

are properly adjusted.
3. Check operating conditions. Full brake
application & heavy loading may create
Steering is not possible at both the idling and full speeds.

hard steering even when steering system is
Steering is possible in either the right or left direction.

Steering wheel does not rotate or is heavy to rotate.
normal.
4. Measure steering wheel force to see if it is
greater than normal.
5. Check that the inline filter is not clogged.
Steering relief valve produces a noise.

Steering wheel is too loose (too light).
Overload relief pressure is too low.

MODM.
Steering relief pressure is too low.

Boom is too slow in rising.

®
Internally damaged Orbitrol Disassembly & repair
Sticking stop valve spool Disassembly & repair
Internally damaged steering pump (deteriorated performance) Disassembly & repair
Malfunctioning steering valve or flow control spool Disassembly & repair
Defective main relief valve or flow control spool stuck Disassembly & repair
Defective overload relief valve Disassembly & repair
Defective steering cylinder Disassembly & repair
Suction line is pinched or internally defective Check & repair
Steering spool stuck Disassembly & repair
Warm up hydraulics
Cold oil / viscosity too thick for weather
Replace oil w/proper oil
Defective steering pilot line reducing valve Disassembly & repair
∗ 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 switch sides also (weak steering to the left will, after exchange, become weak steering to the right).
Remarks
01-22
Hydraulic Group
7. Machine sways, or has a shock
While the machine is travelling straight, the machine sways even if the steering wheel is
during steering

MODM.
Shock is noticed only when steering fully to right or left.

Shock is applied to the machine after quick steering.
Steering cylinders or circuit recently repaired.

Machine sways after quick steering.
held steady.

Pin replacement or shim
Loose steering cylinder pin ∗
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 misadjusted or missing Adjust stopper bolts
Steer full L & R several
Air trapped in steering cylinders
times to purge air
∗ Have an operator quickly move the steering wheel right and left a few degrees. If the cylinder pin moves back & forth replace the pin &
bushing. If the cylinders jump up & down, add shims.
Remarks
01-23
Hydraulic Group
8. ELS (Efficient Loading System)

does not work.
(Excavating and scooping trac-
tive power does not become up
during ELS working condition.)


MODM.
At upper position of lower kickout setting, ELS works.

Pressing ELS switch, it does not function.
Without pressing ELS switch, if functions.

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
Hydraulic Group
9. Ride control does not work.

MODM.
Damping condition too hard.

Ride control does not work.
Damping condition too soft.
Reducing valve chattering.

It takes a time to function.

Ride control switch defective Replacement
Charge spool stuck Disassembly & repair
Malfunctioning reducing valve Disassembly & repair
Disassembly & repair or
Malfunctioning solenoid valve
replacement
Main spool stuck or moving slowly Disassembly & repair
Flow control spool stuck or moving slowly Disassembly & repair
Accumulator piston seal failure Disassembly & repair
Accumulator gas pressure low Check & charge gas
Depressure valve loosened Retighten
Make a clearance
Bucket fully roll-back till touching with stopper
between stoppers
Check valve defective Replacement
01-25
Hydraulic Group
10. Fan motor rotates abnormally or

does not rotate.

MODM.
Reverse fan rotates slow or extremely slow.

Fan motor rotates faster than specified speed.
Fan motor rotates slow or extremely slow.
OPT: Reverse fan does not rotates.

Fan motor does not rotates.
Fan motor makes noise.

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 stuck or not enough to move Check & repair
Wiring or connector failure Check & repair
Reducing valve defective Check & repair
Main controller malfunction Replacement
Check valve failure Replacement
Flow control valve stuck Repair
Adjusting screw loosened Readjust
Strainer clogged or spring (flow con.) damaged Clean or replacement
Fan motor damaged (bearing, shoe, etc.) Replacement
Wiring or connector failure Repair
For reverse fan (OPT)
Main spool stuck Repair

Reverse fan solenoid valve stuck Repair
01-26
Hydraulic Group
11. Abnormal noise in hydraulic sys-

tem.

Increasing the engine speed emits a whining sound-Hydraulics slow.

MODM.
Noise may vary with engine speed or circuit being used.

Pump emits a shrieking sound.

Hose band tightening &
Air drawn into pump suction line
inspection
Internally broken pump Disassembly & repair
Hose clamp check &
High-pressure hose contact with chassis-loose sheet metal
repair
Suction hose pinched or internally defective Inspect or replace hose
Suction line or strainer restricted Drain & inspect tank
01-27
Hydraulic Group
12. Others
When the boom lever is switched from "DOWN" to "NEUTRAL", the boom will continue
When the bucket lever is set to "Roll-back" position, the bucket will be dumped slightly
When the boom lever is set to "UP" position, the boom will drop slightly first and then
MODM.
Engine cooling water (torque converter oil) overheats.

Hydraulic oil is mixed with the torque converter oil.
Hydraulic cylinder packings leak repeatedly.
(Fan motor does not switch to high speed.)

Hydraulic oil is foaming in the tank.
Boom or bucket moves too slow.
down first and then tilt back.
Oil milky white

to lower. ∗
rise.

Defective (incompletely closed) load check valve in multiple
control valve boom line
Defective (incompletely closed) load check valve in multiple
control valve bucket line
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 Test cooling
improper operation Change operation
Water in hydraulic oil Drain & replace oil
Defective thermo sensing valve Disassembly & repair
Defective relief valve Check & repair
∗ 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.
Remarks
01-28
Brake Group
Brake Group
1. Brake does not work well.
When the pedal is pressed, the brake oil pressure greatly deffers between the front axle
Measure the wear of the brake disk using calipers. The obtained wear value is less than
(In the worst case, the brake does
not work at all.)
Both the right and left pedals have low braking resistance when pressed.
1. Check the Nitrogen gas pressure in the
accumulator.
2. Check the brake piping for leakage. Symptoms / check point
Brake is hard to work when the right pedal is depressed.

MODM.
Brake pedal stroke is large.

brake and rear axle brake.
the specified limit value.

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 Disassembly & repair
Defective pedal stroke adjustment Disassembly & repair
01-29
Brake Group
2. Brake is dragging when released.
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.

MODM.
Either the front or rear axle causes dragging.
Manual rotation of the tire is not possible.

Pressing brake pedal is spongy feeling.
Brake is dragging.

Stepping on brake pedal during traveling (Riding the brakes) Instruction for operator
Insufficient return of brake pedal Disassembly & repair
Disassembly, repair
Incomplete air bleeding from the brake oil circuit
& 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
Brake Group
3. Stepping on the brake pedal

sounds the buzzer.
Conditions for buzzer sounding.

1. Low accumulator pressure
[3.9 MPa (40 kgf/cm2) (569 psi) or less].

1. Check the accumulator Nitrogen gas pres-
Buzzer sounds each time the brake pedal is stepped on.
Buzzer sounds when the pedal is repeatedly depressed.

sure.
Too much time is required for accumulator charging.

2. Step on the pedal, and check that oil is not
leaking.
Pedal resistance is too low when depressed.
3. Check the error code No. shown on the Unloader valve on-load pressure is too low.
MODM.
Parking brake is not released.

External pipe is oily, leaking.

Insufficient pressure in accumulator Adjust gas pressure
Inspection &
Low unloader valve switching pressure
readjustment
Inspection &
Delay in working unloader valve
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
Brake Group
4. Accumulator pressure does not

rise, or too slow in rising.

MODM.
Low accumulator pressure in a certain accumulator only.

Low accumulator pressure in all two accumulators.

Inspection &
Low unloader valve switching pressure
readjustment
Defective unloader valve Disassembly & repair
Internally damaged accumulator Disassembly & repair
Defective pilot pump Replace pump
01-32
Brake Group
5. Parking brake does not work.
Turning the manual release knob of the solenoid valve counterclockwise releases the
(or: Releasing the parking brake
is not possible.)
Turning on/off the parking brake switch causes a solenoid valve emitting noise.
Turning on/off the parking brake switch activates the link under the cylinder.
Brake does not work even if the parking switch is turned to "ON" position.
1. Check the fuses of the electrical system.
2. Check the main accumulator pressure.
Coil of the solenoid valve has extremely high or zero resistance.

3. Check the error code No. shown on the Symptoms / check point
MODM.
Heavy movement of solenoid valve manual release knob.

Parking brake remains unreleased.
parking brake.

Solenoid valve
Defective coil of parking solenoid valve
replacement
Solenoid valve
Sticking spool of parking solenoid valve
replacement
Oil leaking from line between solenoid valve and parking brake
Inspection & repair
cylinder
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
Electrical Group
Electrical Group
1. Instrument panel does not indi-
Speed indicated on the instrument panel does not correspond with the speed set by the
T/M (transmission) solenoid valve does not operate based on the speed set by the shift
cate properly.
Two or more monitor lamps will not light after setting the starter key to ON.
One of the monitor lamps will not light after setting the starter key to ON.
1. Check the fuses.
2. Lamp test
Turn the starter switch key to "ON" position
During operation, two or more monitor lamps light improperly. ∗

During operation, one of the monitor lamps lights improperly. ∗
and leave it there for 3 seconds. Check the
indicator lamps.
Pointers of all the gauges are deflected to their limits.

MODM.
One of the gauges does not indicate properly. ∗

Pointer of the speedometer does not move.
One of the gauge pointers does not move.
All the gauge pointers do not move.
Hour meter does not operate.
shift lever.
lever.
Bulb of monitor lamp burnt out Bulb replacement
Defective sensor or improper wiring Sensor replacement
Disconnected or defective electrical circuit Repairing cable
Connector check &
Loose connector
re-connection
MCU failure alarm turned on Inspection & repair
Controller replace-
Defective controller
ment
Defective inside mechanism of gauge or meter Replacement
Defective board of instrument panel Replacement
T/M solenoid valve improperly connected. Properly connect
Gauge circuit grounded improperly. Inspection & repair
∗ If the gauge and warning lamps do not agree there probably is a defect in the wiring. Stop immediately and diagnose the defect.
Remarks
01-34
Electrical Group
2. Fuse for controller is blown.
In the solenoid valve continuity test, changing the positive and negative sides to each
Parking brake remains unreleased regardless of the parking brake switch position.
Both the forward and reverse shift lever position enable the engine to start.
MODM.
Fuse blows off when a certain speed or direction is selected.

Coil of the solenoid valve has extremely low resistance.

Fuse blows off if the machine sways during travelling.
Fuse blows off immediately after replacing.
other and both of them are continuity.

Controller power line contacts with chassis.
Inspection & repair
(Wire pinched by other components, etc.)
Controller power line occasional contacts with chassis. Inspection & repair
Solenoid valve
Clutch solenoid valve coil shortcircuited
replacement
Solenoid valve
Clutch solenoid valve diode failed
replacement
Neutral or controller failure or kickout relay power line contacts
Inspection & repair
with chassis.
Neutral or controller failure or kickout relay power line occa-
Inspection & repair
sional contacts with chassis.
Parking brake solenoid valve power line contacts with chassis. Inspection & repair
Parking brake solenoid valve power line occasional contacts
Inspection & repair
with chassis.
Neutral relay power line contacts with chassis. Inspection & repair
01-35
Electrical Group
Error code (for chassis)

Failure code (Input side)
Code Failure Detection condition (In case of)

Shift lever F & R contact ON at the same time
CN121 Shift lever F & R switch malfunction
Failure continues for more than 3 seconds
Shift lever any of more than two 1•2•3•A contact ON at the same time
CN122 Shift lever 1•2•3•A switch malfunction (1)
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
Shift-up switch & shift-down switch contact ON at the same time
CN143 Shift-up switch & shift-down switch malfunction
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
T/M oil pressure switch malfunction
CN151 Signal OFF continues for more than 10 seconds during engine running
(This applies to the model 115ZV-2/135ZV-2 only)
T/M oil pressure sensor malfunction T/M pressure below 294 kPa (3.0 kgf/cm2) (43 psi) continues for more than
CN152
(This applies to the model 95ZV-2 only) 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
No E/G speed sensor input for more than 3 seconds when E/G speed sen-
CN163 E/G speed sensor 1 (ECM output) malfunction (1)
sor selection is OFF (Input circuit is disconnected)
Input value is more than 3,000 min-1 for more than 3 seconds when E/G
CN164 E/G speed sensor 1 (ECM output) malfunction (2)
speed sensor selection is OFF
E/G speed sensor 2 (Sensor output) malfunction No E/G speed sensor input for more than 3 seconds when E/G speed sen-
CN165
(1) sor selection is ON (Input circuit is disconnected)
E/G speed sensor 2 (Sensor output) malfunction Input value is more than 3,000 min-1 for more than 3 seconds when E/G
CN167
(2) 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
Secondary steering oil pressure sensor malfunc-
CN251 Voltage is lower than 0.2 V for more than 3 seconds
tion(1)
Secondary steering oil pressure sensor malfunc-
CN252 Voltage is larger than 4.6 V for more than 3 seconds
tion (2)
Oil pressure sensor detects secondary steering oil pressure below
CN254 Low secondary steering oil pressure 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
Efficient loading system hydraulic oil pressure sen-
CN271 Voltage is lower than 0.2 V for more than 3 seconds
sor malfunction (1)
Efficient loading system hydraulic oil pressure sen-
CN272 Voltage is larger than 4.6 V for more than 3 seconds
sor malfunction (2)
CN312 Brake oil pressure sensor 1 malfunction (1) Voltage is lower than 0.2 V for more than 3 seconds
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
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
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
Brake oil pressure sensor 1 detects pressure below 4,081 kPa (41.6 kgf/
CN412 Abnormal brake oil pressure (1)
cm2) (592 psi) for more than 1 second during engine running
Brake oil pressure sensor 2 detects pressure below 4,081 kPa for (41.6
CN413 Abnormal brake oil pressure (2)
kgf/cm2) (592 psi) more than 1 second during engine running
Brake oil pressure difference switch is in abnormal condition for more than
CN414 Abnormal brake oil pressure difference
1 second
CN415 Abnormal brake oil amount Brake oil amount switch is in abnormal condition for more than 1 second
Engine oil pressure switch is OFF for more than 2 seconds during engine
CN421 Abnormal engine oil pressure
running
CN431 Abnormal engine coolant temperature (1) Engine coolant temperature switch is ON for more than 2 seconds
Engine coolant temperature sensor is in 101 deg. C (214 deg. F) condition
CN432 Abnormal engine coolant temperature (2)
for more than 2 seconds
CN451 Abnormal T/M oil temperature (1) T/M oil temperature switch is ON for more than 2 seconds
T/M oil temperature sensor is in 122 deg. C (252 deg. F) condition for more
CN452 Abnormal T/M oil temperature (2)
than 2 seconds
Hydraulic oil temperature sensor is in 100 deg. C (212 deg. F) condition for
CN461 Abnormal hydraulic oil temperature
more than 2 seconds
30 minutes after starter switch is ON, T/M oil filter switch is ON for more
CN471 Clogged T/M oil filter 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
Radiator cooling water level switch is OFF for more than 2 seconds when
CN491 Abnormal cooling water level in radiator
the engine is off.
CN496 Abnormal hydraulic oil level Hydraulic oil level switch is in abnormal condition for more than 30 seconds
Abnormal brake disc oil temperature
CN497 Brake disc oil temperature switch is ON for more than 1 second
(This applies to the model 135ZV-2 only)
Abnormal disc wear
CN498 Brake disc wear switch is ON for more than 1 second
(This applies to the model 135ZV-2 only)
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
Voltage is lower than 22±0.5 V for more than 10 seconds during engine
CN913 Abnormal MCU voltage (2)
running
Fuel level display table

Note
Input Output This table applies to the 95/115/135ZV-2 units.
1/8 1/4 1/2 3/4 F E 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 : Lamp on : Lamp flashing

x : Input signal given — : Lamp off
01-37
Electrical Group
Failure code (Output side)
Code Failure Detection condition

CN512 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
Speed change control solenoid valve malfunction
CN536 Speed change control solenoid valve is short-circuited
(1)
Speed change control solenoid valve malfunction
CN537 Speed change control solenoid valve is disconnected
(2)
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
Efficient loading system selection solenoid valve Efficient loading system selection solenoid valve is short-circuited or dis-
CN681
malfunction connected
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
Electrical Group
Error code (for engine)

These codes show the fault codes for the engine failure
displayed on the MODM error log monitor, or checked
by the diagnostic switch (option).
Please note that not all are used in the 80ZV-2 machine
application. Refer to Cummins Engine troubleshooting
fault codes list for more information.
QSK19 (115ZV-2)
QST30 (135ZV-2)
QSC8.3 (80ZV-2)
QSC8.3 (85ZV-2)
QSB4.5 (60ZV-2)
QSB6.7 (70ZV-2)
(70TMV-2)
QSM11 (90ZV-2)
QSM11 (92ZV-2)
QSX15 (95ZV-2)
FAULT
CODE/ DESCRIPTION
LAMP
EG111
Engine Control Module (ECM) - critical internal failure.
Red
EG113
Engine Timing Actuator Circuit - shorted high.
Yellow
EG114
Engine Timing Actuator Circuit - shorted low.
Yellow
EG115 Engine Speed / Camshaft Position Sensor Circuit - lost both of two signals from
Red the magnetic pickup sensor.
EG121 Engine Speed / Position Sensor Circuit - lost one of two signals from the
Yellow magnetic pickup sensor.
EG122
Intake Manifold Pressure Sensor #1 Circuit - shorted high.
Yellow
EG123
Intake Manifold Pressure Sensor #1 Circuit - shorted low.
Yellow
EG124
Intake Manifold Pressure - above normal operation.
Yellow
EG131
Accelerator Pedal Position Sensor Circuit - shorted high.
Red
EG132
Accelerator Pedal Position Sensor Circuit - shorted low.
Red
EG133
Remote Accelerator Pedal Position Sensor Circuit - shorted high.
Red
EG134
Remote Accelerator Pedal Position Sensor Circuit - shorted low.
Red
EG135
Engine Oil Pressure Sensor Circuit - shorted high.
Yellow
EG141
Engine Oil Pressure Sensor Circuit - shorted low.
Yellow
EG143
Engine Oil Pressure Low - warning.
Yellow
EG144 Engine Coolant Temperature Sensor Circuit - voltage above normal or shorted
Yellow high.
EG145 Engine Coolant Temperature Sensor Circuit - voltage below normal or shorted
Yellow low.
EG146
Engine Coolant Temperature High - warning.
Yellow
EG151
Engine Coolant Temperature High - critical.
Red
EG153 Intake Manifold Air Temperature Sensor Circuit - voltage above normal or
Yellow shorted high.
EG154 Intake Manifold Air Temperature Sensor Circuit - voltage below normal or
Yellow shorted low.
01-39
Electrical Group
QST30 (135ZV-2)
QSK19 (115ZV-2)
QSC8.3 (80ZV-2)
QSC8.3 (85ZV-2)
QSB4.5 (60ZV-2)
QSB6.7 (70ZV-2)
(70TMV-2)
QSM11 (90ZV-2)
QSM11 (92ZV-2)
QSX15 (95ZV-2)
FAULT
CODE/ DESCRIPTION
LAMP
EG155
Intake Manifold Air Temperature Sensor High - critical.
Red
EG166
Rack Position Sensor #1 Circuit - shorted high.
Yellow
EG172
Rack Actuator Position #1 Circuit - grounded circuit.
Red
EG173
Rack Actuator - mechanically stuck open.
Yellow
EG184
Engine Control Module Identification Input State Error.
Yellow
EG185
Engine Control Module Network Communication Error.
Yellow
EG187
Sensor Supply Voltage #2 Circuit - shorted low.
Yellow
EG212
Engine Oil Temperature Sensor Circuit - shorted high.
Yellow
EG213
Engine Oil Temperature Sensor Circuit - shorted low.
Yellow
EG214
Engine Oil Temperature High - Critical.
Red
EG221
Ambient Air Pressure Sensor Circuit - shorted high.
Yellow
EG222
Ambient Air Pressure Sensor Circuit - shorted low.
Yellow
EG227
Sensor Supply Voltage #2 Circuit - shorted high.
Yellow
EG231
Engine Coolant Pressure Sensor Circuit - shorted high.
Yellow
EG232
Engine Coolant Pressure Sensor Circuit - shorted low.
Yellow
EG233
Engine Coolant Pressure Low - warning.
Yellow
EG234
Engine Speed High - critical.
Red
EG238
Yellow
EG254
Fuel Shutoff Valve Circuit - shorted low.
Red
EG255
Fuel Shutoff Valve Circuit - shorted high.
Yellow
EG259
Fuel Shutoff Valve - stuck open.
Red
EG261
Fuel Temperature High - warning.
Yellow
EG263
Fuel Temperature Sensor Circuit - shorted high.
Yellow
EG265
Fuel Temperature Sensor Circuit - shorted low.
Yellow
EG266 Engine Fuel Temperature - data valid but above normal operational range - most
Red severe level.
EG271
Fuel Control Actuator Circuit - shorted low.
Yellow
EG272
Fuel Control Actuator Circuit - shorted high.
Yellow
01-40
Electrical Group
QST30 (135ZV-2)
QSK19 (115ZV-2)
QSC8.3 (80ZV-2)
QSC8.3 (85ZV-2)
QSB4.5 (60ZV-2)
QSB6.7 (70ZV-2)
(70TMV-2)
QSM11 (90ZV-2)
QSM11 (92ZV-2)
QSX15 (95ZV-2)
FAULT
CODE/ DESCRIPTION
LAMP
EG281
Injection Pump Mechanical System - signal not in range from ECM.
Yellow
EG284 Engine Speed / Position Sensor #1 (Crankshaft) Supply Voltage Circuit - shorted
Yellow low.
EG285
SAE J1939 Data Link Multiplexing PGN Timeout Error.
Yellow
EG286
SAE J1939 Data Link Multiplexing Configuration Error.
Yellow
EG287
SAE J1939 Multiplexing Accelerator Pedal Sensor System Error.
Red
EG295
Ambient Air Pressure Sensor Circuit - data incorrect.
Yellow
EG299
Engine stopped not using Starter Switch.
Yellow
EG311
Injector Solenoid Valve Cylinder #1 Circuit - grounded circuit.
Yellow
EG312
Yellow
EG313
Yellow
EG314
Yellow
EG315
Yellow
EG319
Real Time Clock - power Interrupt.
Yellow
EG321
Yellow
EG322
Injector Solenoid Valve Cylinder #1 Circuit - open circuit.
Yellow
EG323
Yellow
EG324
Yellow
EG325
Yellow
EG331
Yellow
EG332
Yellow
EG334
Coolant Temperature Sensor Circuit - data erratic, intermittent, or incorrect.
Yellow
EG341
Engine Control Module - data lost.
Yellow
EG342
Engine Control Module - out of calibration.
Red
EG343
Engine Control Module - warning internal hardware failure.
Yellow
EG346
Engine Control Module - warning software error.
Yellow
EG351
Injector Power Supply.
Yellow
EG352
Yellow
01-41
Electrical Group
QST30 (135ZV-2)
QSK19 (115ZV-2)
QSC8.3 (80ZV-2)
QSC8.3 (85ZV-2)
QSB4.5 (60ZV-2)
QSB6.7 (70ZV-2)
(70TMV-2)
QSM11 (90ZV-2)
QSM11 (92ZV-2)
QSX15 (95ZV-2)
FAULT
CODE/ DESCRIPTION
LAMP
EG378
Fueling Actuator #1 Circuit - open circuit.
Yellow
EG379
Fueling Actuator #1 Circuit - grounded circuit.
Yellow
EG386
Yellow
EG387
Accelerator Pedal Position Sensor Supply Voltage Circuit - shorted high.
Yellow
EG394
Timing Actuator #1 Circuit - open circuit.
Yellow
EG395
Timing Actuator #1 Circuit - grounded circuit.
Yellow
EG396
Fueling Actuator #2 Circuit - open circuit.
Yellow
EG397
Fueling Actuator #2 Circuit - grounded circuit.
Yellow
EG398
Timing Actuator #2 Circuit - open circuit.
Yellow
EG399
Timing Actuator #2 Circuit - grounded circuit.
Yellow
EG415
Engine Oil Pressure Low - critical.
Red
EG418
Water in Fuel Indicator High - maintenance.
Yellow
EG419
Intake Manifold Boost Pressure Imbalance.
Yellow
EG423
Fuel Timing Pressure or Timing Actuator Stuck.
Yellow
EG428
Water in Fuel Sensor Circuit - shorted high.
Yellow
EG429
Water in Fuel Sensor Circuit - shorted low.
Yellow
EG431
Accelerator Pedal Idle Validation Circuit - data incorrect.
Yellow
EG432
Accelerator Pedal Idle Validation Circuit - out of calibration.
Red
EG433
Intake Manifold Pressure Sensor Circuit - data incorrect.
Yellow
EG434
Voltage to ECM less than 6 V
Yellow
EG435
Engine Oil Pressure Switch Circuit - data incorrect.
Yellow
EG441
Battery #1 Voltage Low - warning.
Yellow
EG442
Battery #1 Voltage High - warning.
Yellow
EG443
Accelerator Pedal Position Sensor Supply Voltage Circuit - shorted low.
Yellow
EG449
Fuel Pump Delivery Pressure High - warning.
Yellow
EG451
Injector Metering Rail #1 Pressure Sensor Circuit - shorted high.
Yellow
EG452
Injector Metering Rail #1 Pressure Sensor Circuit - shorted low.
Yellow
01-42
Electrical Group
QST30 (135ZV-2)
QSK19 (115ZV-2)
QSC8.3 (80ZV-2)
QSC8.3 (85ZV-2)
QSB4.5 (60ZV-2)
QSB6.7 (70ZV-2)
(70TMV-2)
QSM11 (90ZV-2)
QSM11 (92ZV-2)
QSX15 (95ZV-2)
FAULT
CODE/ DESCRIPTION
LAMP
EG465
Turbocharger #1 Wastegate Control Circuit - shorted high.
Yellow
EG466
Turbocharger #1 Wastegate Control Circuit - shorted low.
Yellow
EG482
Fuel Pressure Low - warning.
Yellow
EG483
Injector Metering Rail #2 Pressure Sensor Circuit - shorted high.
Yellow
EG484
Injector Metering Rail #2 Pressure Sensor Circuit - shorted low.
Yellow
EG485
Injector Metering Rail #2 Pressure High - warning.
Yellow
EG486
Injector Metering Rail #2 Pressure Low - warning.
Yellow
EG488
Intake Manifold Temperature High - warning.
Yellow
EG491
Turbocharger #2 Wastegate Control Circuit - shorted high.
Yellow
EG492
Turbocharger #2 Wastegate Control Circuit - shorted low.
Yellow
EG496
Engine Speed / Position Sensor #2 (Camshaft) Supply Voltage.
Yellow
EG524
OEM Alternate Droop Switch Validation - data incorrect.
Yellow
EG527
Auxiliary Input / Output #2 Circuit - shorted high.
Yellow
EG528
OEM Alternate torque validation switch - data incorrect.
Yellow
EG529
Auxiliary Input / Output #3 Circuit - shorted high.
Yellow
EG546
Fuel Delivery Pressure Sensor Circuit - shorted high.
Yellow
EG547
Fuel Delivery Pressure Sensor Circuit - shorted low.
Yellow
EG551
Accelerate Pedal Idle Validation Circuit - shorted low.
Yellow
EG553
Injector Metering Rail #1 Pressure High - warning level.
Yellow
EG554
Fuel Pressure Sensor Error.
Yellow
EG559 Injector Metering Rail #1 Pressure Low - data valid but below normal operational
Yellow range - moderately severe level.
EG596
Electrical Charging System Voltage High - warning level.
Yellow
EG598
Electrical Charging System Voltage Low - critical level.
Red
EG689
Crankshaft Engine Speed Signal Error.
Yellow
EG731
Mechanical Timing Misalignment.
Yellow
EG753 Crankshaft Position Sensor and Camshaft Position Sensor - data erratic,
Yellow intermittent, or in correct.
EG757
Electronic Control Module Data Lost.
Yellow
01-43
Electrical Group
QST30 (135ZV-2)
QSK19 (115ZV-2)
QSC8.3 (80ZV-2)
QSC8.3 (85ZV-2)
QSB4.5 (60ZV-2)
QSB6.7 (70ZV-2)
(70TMV-2)
QSM11 (90ZV-2)
QSM11 (92ZV-2)
QSX15 (95ZV-2)
FAULT
CODE/ DESCRIPTION
LAMP
EG758
Injector Metering Rail #2 Pressure Malfunction.
Yellow
EG778
Engine Speed Sensor (Camshaft) - data erratic, intermittent, or incorrect.
Yellow
EG951
Cylinder Power Imbalance Detected.
None
EG1117
Power Lost with Ignition ON - data erratic, intermittent, or incorrect.
None
EG1358 Accelerator Pedal Position Sensor 1 Circuit - voltage above normal or shorted
Yellow high.
EG1359 Accelerator Pedal Position Sensor 1 Circuit - voltage below normal or shorted
Yellow low.
EG1361 Remote Accelerator Pedal Position Sensor 1 Circuit - voltage below normal or
Yellow shorted low.
EG1376 Engine Camshaft Speed / Position Sensor - data erratic, intermittent, or
Orange incorrect.
EG1595 Remote Accelerator Pedal Position Sensor 1 Circuit - voltage above normal or
Yellow shorted high.
EG1597 Engine Control Module Critical Internal Failure - bad intelligent device or
Orange component.
EG1845 Water in Fuel Indicator Sensor Circuit - voltage above normal or shorted to high
Orange source.
EG1846 Water in Fuel Indicator Sensor Circuit - voltage below normal or shorted to low
Orange source.
EG1852 Water in Fuel Indicator - data valid but above normal operational range -
Yellow moderately severe level.
EG1911
Injector Metering Rail 1 Pressure - above normal operating range.
Yellow
EG2185
Yellow
EG2186
Yellow
EG2215 Fuel Pump Delivery Pressure - data valid but below normal operational range -
Yellow moderately severe level.
EG2249
Fuel Pump Delivery Pressure Sensor Circuit - shorted low.
Yellow
EG2261 Fuel Pump Delivery Pressure - data valid but above normal operational range -
Orange least severe level.
EG2262 Fuel Pump Delivery Pressure - data valid but below normal operational range -
Orange least severe level.
EG2265
Fuel Priming Pump Control Signal Circuit - shorted high.
Yellow
EG2266
Fuel Priming Pump Control Signal Circuit - shorted low.
Yellow
EG2311
Fueling Actuator #1 Circuit Error - condition exists.
Yellow
EG2321
Engine Speed Sensor #1 - data erratic, intermittent, or incorrect.
None
EG2322
Engine Speed Sensor #2 - data erratic, intermittent, or incorrect.
None
EG2697 Accelerator Pedal Position Sensor Circuit and Idling Position Detection Switch
Orange Circuit - data erratic, intermittent, or incorrect.
EG2963
Engine Coolant Temperature High - warning.
None
01-44
Electrical Group
QST30 (135ZV-2)
QSK19 (115ZV-2)
QSC8.3 (80ZV-2)
QSC8.3 (85ZV-2)
QSB4.5 (60ZV-2)
QSB6.7 (70ZV-2)
(70TMV-2)
QSM11 (90ZV-2)
QSM11 (92ZV-2)
QSX15 (95ZV-2)
FAULT
CODE/ DESCRIPTION
LAMP
EG2964
Intake Manifold Temperature High - warning.
None
EG2973
Intake Manifold Pressure Sensor Circuit - data erratic, intermittent, or incorrect.
Yellow
(09D20E)
01-45
Operator Station Group
Air conditioner ∗ Error code table
Fault diagnosis procedure Display Failure mode

E- No failure
E11 Wire breakage in inside air sensor
Hearing check E12 Short-circuit in inside air sensor
E13 Wire breakage in outside air sensor
E14 Short-circuit in outside air sensor
Error code check ∗
E15 Wire breakage in water temperature sensor
E16 Short-circuit in water temperature sensor
Phenomenon check E18 Short-circuit in insolation sensor
E21 Wire breakage in vent sensor
E22 Short-circuit in vent sensor
Basic check
E43 Abnormality in vent damper
In accordance with fault phenomenon E44 Abnormality in air mixing damper
E45 Abnormality in inside/outside air
E51 Abnormality in refrigerant pressure
1) Control mechanism
2) V-belt
3) Sight glass
4) Piping connection
Refrigerant cycle Electrical system

check check
- Pressure check
- Gas leak check
Repair/check
End
80V2E01012
01-46
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.
<Trouble shooting charts>
Clogged inner air filter Clean the filter.

Clogged outer air filter Clean the filter.
Existence of obstacle at vicinity of suction port Remove the obstacle.
Normal rotation Deformed or damaged blower Replace the blower with a new one.
Frosting in evaporator Stop the air compressor, to melt the ice.
Examine the cause before taking the corrective measure. See A-1 .
Blower motor Adhesion of dust to surface of evaporator Clean the surface of evaporator.
rotation
Decreased supply voltage Check the battery charging system.

Battery terminal contact failure Correct the contact failure.
Slow rotation
Blower motor rotation failure Replace the blower motor with a new one.
Air flow rate
BLC failure Replace the BLC with a new one.
failure
Blower is rotated only
when the fan switch is Operation of BLC over-voltage protective function Examine the cause of over-voltage before taking the corrective measure.
selected to High-speed ∗ Examine the cause before taking the corrective measure,and then replace
position. Blown fuse the fuse with that of the same capacity. See B-1 .
Blower motor
rotation Blower main relay failure Replace the blower main relay with a new one.
failure Blower motor failure Replace the blower motor with a new one.
Rotation failure Interference of blower with case Correct the interference.
for all modes Blower switch failure Replace the panel with a new one.
Body earth failure Earth the body securely.
Without
Wiring failure, disconnected connector Check the wiring.
diagnostic
display Operation of BLC protective function due Replace the motor with a new one.
to locked motor
Normal pressure Mixing of outside air Close the window and door.
Adjust the inside/outside air changeover damper.
Disengaged A/M link Re-set the link.
Compressor
normal rotation
Too high pressure at low-pressure side(approx. 294kPa[3kgf/cm2] or over) See C-2 .
Too low pressure at high-pressure side(Pressure is not increased to approx. 981kPa[10kgf/cm2] or over) See C-3 .
Pressure error Too low pressure at low-pressure side(Pressure is decreased to approx. 49kPa[0.5kgf/cm2] or less See C-4 .
Cooling failure
Normal air High pressure both at high-pressure side and low-pressure side See C-5 .
flow rate Low pressure both at high-pressure side and low-pressure side Insufficient refrigerant.
Broken or slipped belt Replace the V-belt with a new one.

Compressor
Compressor failure(locking) Replace the compressor with a new one.
normal rotation
failure Magnet clutch failure Repair the magnet switch, or replace it with a new one. See D-1 .
Clutch engagement failure due to Check the wiring. See D-2 .
electrical system failure
Wiring failure, disconnection, disengaged connector Check the wiring.
With diagnostic display:
E44 (A/M servo motor Servomotor failure Replace the servo motor with a new one.
error) Blocked foreign matter Remove the foreign matter.
Operation of high-pressure cut

function See C-1 .
With diagnostic display:
E51 (refrigerant high/
Operation of low-pressure
lower pressure error) See C-3 .
function
80V2E01013
01-47
01-48
Magnet clutch circuit failure Check the clutch circuit. Replace the clutch relay with a new one.
Voltage applied to Thermister(frosting sensor) wiring failure Check the short-circuit. Correction
magnet clutch
Thermister(frosting sensor) characteristic failure Check for characteristic. Replace the thermister(frosting sensor) with a new one.
Adjustment failure of gap between the thermister(frosting sensor) and evaporator Adjust the gap(12 ± 5 mm).
A-1
12 ± 5 mm
Voltage not applied

to magnet clutch Magnet clutch failure Replace the magnet clutch
with a new one. Thermister
(frosting sensor)
Evaporator
Locked blower motor Replace the blower motor with a new one.
B-1 Erroneous wiring Perform the checking, referring to the wiring diagram.
Sort-circuit wiring Check the wiring.
Unusually high outside air temperature

Insufficiently cooled condenser Clogging of dust or mud, etc. in fin. Clean(Washing with water) the fin.
C-1
Over-filled refrigerant Discharge the refrigerant to proper level.
Mixing of air during refrigerating cycle Fully discharge the refrigerant, and execute the
evacuation, and fill the refrigerant again to
proper level.

Compressor failure Broken head gasket
C-2 Broken suction valve Replace the compressor with a new one.
Foreign matter caught by suction valve
Excessively opened expansion valve Valve failure Replace the valve with a new one.
Contact failure in Correction
pressure needle valve
80V2E01014
Unusually low outside air temperature
Limited refrigerant Limited amount of refrigerant filled Fill the refrigerant to proper level.
Gas leakage Perform the leak test and repair the location of
failure before filling the refrigerant.
C-3
Compressor failure Swash plate shoe seizure
Locked piston Replace the compressor with a new one.
Suction/discharge valve failure
Expansion valve failure Clogged valve(mixing of foreign matter) Replace the valve with a new one.
Relieved gas from pressure needle valve Replace the valve with a new one.
Clogging(mixing of moisture content) due to frozen valve Execute the evacuation fully after replacing the
valve and receiver with a new one respectively.
Unusually low outside air temperature

Limited refrigerant Limited amount of refrigerant filled Fill the refrigerant to proper level.
Gas leakage Perform the leak test and repair the location of
failure before filling the refrigerant.
Clogging during refrigerating cycle Clogged receiver & drier Replacement

C-4 Clogging due to foreign matter in the course of piping Replacement
Expansion valve failure Clogged valve(mixing of foreign matter) Replace the valve with a new one.
Relieved gas from pressure needle valve Replace the valve with a new one.
Temporary clogging(mixing of moisture content) Execute the evacuation fully after replacing the
due to frozen valve valve and receiver with a new one respectively.
Frosted evaporator to A-1
Insufficiently cooled condenser Clogging of dust or mud, etc. in fin. Clean(washing with water) the fin.
C-5
80V2E01015
01-49
01-50

Disconnected stator coil Replacement

Excessive air gap between rotor and stator Repair or replacement
Slipped clutch Slippage due to broken key or key insertion failure Replace the key with a new one.
Stained clutch surface due to oil Remove the oil.
D-1
Rare-short in coil Replacement
Battery voltage drop Re-charging
Foreign matter caught between rotor and stator Disassembling/repair
Air conditioner switch failure Replace the control panel with a new one.
Blower switch failure Replace the control panel with a new one.
Compressor clutch relay failure Replacement
D-2
Thermo-sensor failure Replacement
High/low-pressure switch failure Replacement
High-pressure error Excessively high pressure [2452 kPa(25kgf/cm2)or over] C-1
2
Excessively low pressure [981 kPa(10kgf/cm )or lower] C-4
80V2E01016
Insufficient Same as "Cooling failure"
wind force
Heating failure
Low water temperature
Normal wind
force
The air is mixed in hot-water circuit. Discharge the air.

Clogged or bent piping Repair or replacement
Normal water Excessively low outside air temperature
temperature
Limited engine cooling water Fill the coolant to proper level.
Broken heater core Replace the heater core with a
new one.
Note: Do not fail to check that the pump pressure is normal, and that the heater hose is not connected with
IN side and OUT side reversed.
The temperature
controller LED is Disengaged temperature controller link Re-set the link.
operated properly. Foreign matter caught Remove the foreign matter.
The temperature
Wiring failure, disconnection, disconnected connector Check the wiring.
controller LED is not
operated properly. Servo motor failure Replacement
Leakage of water in
Clogged drain hole Cleaning
operator's cabin
80V2E01017
01-51
01-52
Without diagnostic display

Disengaged link Re-set the link.
(blow-off servo motor normal)
Blow-off changeover Wiring failure, disconnection, disconnected connector Check the wiring.
failure
With diagnostic display: E43
Servo motor failure Replacement
(blow-off servo motor abnormal)
Foreign matter caught Remove the foreign matter.
Without diagnostic display

Disengaged link Re-set the link.
(inside air/outside air servo motor normal)
Outside air/inside air Wiring failure, disconnection, disconnected connector Re-check the wiring
changeover failure
Servo motor failure Replacement
(inside air/outside air servo motor abnormal)
Foreign matter caught Remove the foreign matter.

Disconnected harness, disengaged connector Re-check the wiring.
(disconnected inside air sensor)
Disconnected inside air sensor Replacement
Room temperature With diagnostic display: E12

Short-circuit harness Check the wiring.
higher or lower than (short-circuit inside air sensor)
setting temperature
Short-circuit inside air sensor Replacement
Without diagnostic display Perform the checking in

Cooling failure, heating failure accordance with the paragraph
(without inside air sensor error)
"Cooling failure/heating failure".
80V2E01018
03-1
Measurement for Performance Check
03
Cautions on Safety ............................................................................................................................................ 03-3
Standard Measurement Values for Performance Check (S/N 9001~9200) ...................................................... 03-4
Standard Measurement Values for Performance Check (S/N 9201~) .............................................................. 03-7
Preparation for Performance Check ............................................................................................................... 03-10
Engine ............................................................................................................................................................. 03-12
Measuring engine speed ........................................................................................................................... 03-12
Clutch Oil Pressure ......................................................................................................................................... 03-16
Measuring clutch oil pressure ................................................................................................................... 03-16
Hydraulic Cylinder ........................................................................................................................................... 03-17
Cylinder natural drift .................................................................................................................................. 03-17
Boom Rising Time ........................................................................................................................................... 03-19
Full Steering Time ........................................................................................................................................... 03-21
Loading/Steering Circuit Relief Valve .............................................................................................................. 03-23
Loading circuit relief valve setting pressures ............................................................................................ 03-23
Steering circuit relief valve setting pressures ............................................................................................ 03-28
Stop Valve ....................................................................................................................................................... 03-33
Stop valve adjustment procedure ............................................................................................................. 03-33
Fan Revolution ................................................................................................................................................ 03-34
Service Brake .................................................................................................................................................. 03-36
Service brake performance check ............................................................................................................ 03-36
Service brake friction plate wear measurement ........................................................................................ 03-37
Cautions on installing brake discs ............................................................................................................. 03-38
Parking Brake ................................................................................................................................................. 03-39
Parking brake performance check ............................................................................................................ 03-39
Parking brake clearance adjustment ......................................................................................................... 03-40
Brake Circuit Oil Pressure ............................................................................................................................... 03-42
Unloader valve setting pressure ............................................................................................................... 03-42
Brake valve oil pressure ............................................................................................................................ 03-45
03-2
Accumulator Circuit Charging Time ................................................................................................................. 03-47

Number of Brake Pedal Applications .............................................................................................................. 03-49
Declutch Engagement ..................................................................................................................................... 03-50
03-3
80ZV-2 Measurement for Performance Check
Cautions on Safety
Cautions on Safety
WARNING CAUTION
Unexpected movement of the machine may cause an Touching the fan or the V belt of the engine or the hot
accident resulting in injury or death. area while the engine is running may cause severe
Therefore, to provide repair service with the engine accidents.
running, be sure to observe the following items: Make sure to stop the engine before opening the
- Park the machine on level ground. engine room side cover.
moving.
- Determine the signals between the service man.
areas.
- Near articulation areas of the machine
- Under the machine
- Around the engine
- In front of or behind the machine
WARNING
Operation under the boom or the bucket may lead to
severe accidents.
Make sure to apply the safety lock of the boom and
the bucket control lever provided in the cab, remove
the starter key, and attach a "DO NOT OPERATE!"
tag to the cab.
CAUTION
Be careful not to be burnt by bursting high pressure
oil.
Release the pressure remaining inside the circuit and
open the cap of the hydraulic tank before removing
the plug from the pressure measurement port so that
the internal pressure of the hydraulic tank is released
and burst of the high pressure oil can be prevented.
WARNING
Entering the articulation area of the machine body
while the engine is running may cause severe acci-
dents.
Make sure to stop the engine, pull out the starter key,
and attach a "DO NOT OPERATE!" tag to the cab
before entering the articulation area.
03-4
Standard Measurement Values for Performance Check (S/N 9001~9200)
Standard Measurement Values for Performance Check

(S/N 9001~9200)
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)
Standard measurement val-

Item
ues for performance check
Remarks
Fuel efficient
System Measurement item Normal
mode
Minimum no-load speed, Low Idle (LI) 800±50
Maximum no-load speed, High Idle (HI) 2,300±50
Maximum speed in torque converter stall mode 2,285±100 2,120±100
Engine
Engine speed
(min-1) (rpm) Maximum speed in multiple control valve relief mode 2,285±100 2,040±100
Maximum speed in torque converter stall plus multiple

1,840 +150
- 100 1,705 +150
- 100
control valve relief mode
Clutch pressure Idling (LI) 1.3±0.2 (13±2) (185±28)

Transmission
Engine speed
MPa (kgf/cm2) (psi) Maximum (HI) 1.5±0.2 (15±2) (213±28)
Clutch time lag Neutral→Forward 1st speed

0.3±0.1 Before wheels move
(sec) (engine speed: 1,500 min-1 (rpm))
03-5
Item Standard measure-

ment values for perfor- Remarks
System Measurement item mance check
Cylinder drift Boom cylinder 3 (1/8) or less

(when boom and
bucket are horizon-
tal and with no load)
(mm/min) (in/min) Bucket cylinder 4 (5/32) or less
Idling (LI) 21±3.0

Boom rising time
-1
(no load) Engine speed 1,500 min (rpm) 10±1.0
(sec)
Maximum (HI) 6.0±0.5
Idling (LI) 5.0±0.5
Full steering time -1
Engine speed 1,500 min (rpm) 2.1±0.3
(sec)
20.6±0.5 (210±5)
Loading line main relief pressure (HI)
Hydraulic pressure
(2,986±71)
Run engine at lowest

23.5±0.5 (240±5)
Loading line overload relief pressure (LI) possible speed
(3,413±71)
while setting
Relief valve
20.6±0.5 (210±5)
setting pressure Steering line main relief pressure (HI)
(2,986±71)
MPa (kgf/cm2) (psi)
24.5 +1.0 +10
0 (250 0 )
Steering line overload relief pressure (LI) +142 possible speed
(3,555 0 ) while setting
3.5 (36)
Pilot line reducing pressure (LI)
(512)
Engine water temp. <80ºC

T/C oil temp. <110ºC 1,050 +75
- 200
Fan maximum Hydraulic oil temp. <90ºC
revolution (HI)
min-1 (rpm) Engine water temp. >95ºC
T/C oil temp. >115ºC 1,500 +75
- 200
Hydraulic oil temp. >95ºC
Fan minimum
revolution (LI) Engine water temp. >60ºC 500 +75
- 200
min-1 (rpm)
03-6

Shift lever Slowly increase the

2nd speed reverse engine speed, and
position Brake pedal fully
Performance of check that the machine
depressed and held
service brake does not move at the
down during test.
Engine speed Maximum (HI) maximum engine
speed.
Shift lever Before brake check, be

3rd speed reverse
position sure to disconnect the
Performance of
↑ cable connector of
parking brake
parking brake solenoid
Engine speed Maximum (HI) valve.
11.8±0.5 (120±5)
Off (Cut-out)
(1,706±71)
Unloader valve
Brake
Brake line setting setting pressure

6.9±1.0 (70±10)
pressure On (Cut-in)
(995±142)
MPa (kgf/cm2) (psi)
Low-pressure alarm switch setting pressure 3.9±0.5 (40±5)

(For brake accumulator circuit) (569±71)
The time from the low-pressure alarm is

Accumulator charge
Engine speed (LI) turned off till the unloading valve cuts off 8
time (sec)
pressure
Run engine 1 minute high idle, then stop the engine. Repeat stepping on the
Number of brake (Turn key switch "ON" with engine off.) brake pedal as follows:
at least 9 times
pedal applications Step on the brake pedal and release, and check the number On: 5 sec.
of times until the low-pressure alarm is tuned on. Off: 5 sec.
Declutch 1/5 slope
Engine: Maximum speed/ Inching pedal: Quick release
engagement 15 (6) or less (approx. 11º), unladen,
(Distance the loader rolls back before moving forward.)
(cm) (in) 1st speed
Note
These are the standard measurement values for the
machines at the time when delivered from the factory.
03-7
Standard Measurement Values for Performance Check (S/N 9201~)
Standard Measurement Values for Performance Check

(S/N 9201~)
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)
Standard measurement val-

Item
ues for performance check
Remarks
Fuel efficient
System Measurement item Normal
mode
Minimum no-load speed, Low Idle (LI) 800±50
Maximum no-load speed, High Idle (HI) 2,300±50 2,100±50
Maximum speed in torque converter stall mode 2,270±100 2,095±100
Engine
Engine speed
(min-1) (rpm) Maximum speed in multiple control valve relief mode 2,275±100 2,275±100
Maximum speed in torque converter stall plus multiple

1,830 +150
- 100 1,690 +150
- 100
Clutch pressure Idling (LI) 1.3±0.2 (13±2) (185±28)

Transmission
Engine speed
MPa (kgf/cm2) (psi) Maximum (HI) 1.5±0.2 (15±2) (213±28)
Clutch time lag Neutral→Forward 1st speed

0.3±0.1 Before wheels move
(sec) (engine speed: 1,500 min-1 (rpm))
03-8

Cylinder drift Boom cylinder 3 (1/8) or less

(when boom and
bucket are horizon-
tal and with no load)
(mm/min) (in/min) Bucket cylinder 4 (5/32) or less
Idling (LI) 21±3.0

Boom rising time
-1
(no load) Engine speed 1,500 min (rpm) 10±1.0
(sec)
Idling (LI) 5.0±0.5
Full steering time -1
Engine speed 1,500 min (rpm) 2.1±0.3
(sec)
20.6±0.5 (210±5)
Loading line main relief pressure (HI)
Hydraulic pressure
(2,986±71)

23.5±0.5 (240±5)
Loading line overload relief pressure (LI) possible speed
(3,413±71)
while setting
Relief valve
20.6±0.5 (210±5)
setting pressure Steering line main relief pressure (HI)
(2,986±71)
MPa (kgf/cm2) (psi)
24.5 +1.0 +10
0 (250 0 )
Steering line overload relief pressure (LI) +142 possible speed
(3,555 0 ) while setting
3.5 (36)
Pilot line reducing pressure (LI)
(512)
Engine water temp. <80ºC

T/C oil temp. <110ºC 1,050 +75
- 200
Fan maximum Hydraulic oil temp. <90ºC
revolution (HI)
min-1 (rpm) Engine water temp. >95ºC
T/C oil temp. >115ºC 1,500 +75
- 200
Hydraulic oil temp. >95ºC
Fan minimum
revolution (LI) Engine water temp. >60ºC 500 +75
- 200
min-1 (rpm)
03-9

Shift lever Slowly increase the

2nd speed reverse engine speed, and
position Brake pedal fully
Performance of check that the machine
depressed and held
service brake does not move at the
down during test.
Engine speed Maximum (HI) maximum engine
speed.
Shift lever Before brake check, be

3rd speed reverse
position sure to disconnect the
Performance of
↑ cable connector of
parking brake
parking brake solenoid
Engine speed Maximum (HI) valve.
11.8±0.5 (120±5)
Off (Cut-out)
(1,706±71)
Unloader valve
Brake
Brake line setting setting pressure

6.9±1.0 (70±10)
pressure On (Cut-in)
(995±142)
MPa (kgf/cm2) (psi)
Low-pressure alarm switch setting pressure 3.9±0.5 (40±5)

(For brake accumulator circuit) (569±71)
The time from the low-pressure alarm is

Accumulator charge
Engine speed (LI) turned off till the unloading valve cuts off 8
time (sec)
pressure
Run engine 1 minute high idle, then stop the engine. Repeat stepping on the
Number of brake (Turn key switch "ON" with engine off.) brake pedal as follows:
at least 9 times
pedal applications Step on the brake pedal and release, and check the number On: 5 sec.
of times until the low-pressure alarm is tuned on. Off: 5 sec.
Declutch 1/5 slope
Engine: Maximum speed/ Inching pedal: Quick release
engagement 15 (6) or less (approx. 11º), unladen,
(Distance the loader rolls back before moving forward.)
(cm) (in) 1st speed
Note
These are the standard measurement values for the
machines at the time when delivered from the factory.
03-10
Preparation for Performance Check

Preparation of measurement units
- To measure pressure, be sure to prepare the hose,
WARNING adapter, and wrench for pressure port plug in addi-
Unexpected movement of the machine may cause an tion to the measurement instruments.
accident resulting in injury or death. Therefore, to
provide repair service with the engine running, be - Check operation of the measurement instruments.
sure to observe the following items: Carefully handle the instruments. If something
- Park the machine on level ground. comes in contact with an instrument or large shock is
- Apply the parking brake. applied to an instrument, the instrument may be
- Block the tires with chocks to prevent the tires from damaged. In addition, periodic inspection of the
moving. instruments is also important. If the zero point of an
- Determine the signals between the service men. instruments is not properly adjusted, the value indi-
- Prohibit any person from walking into dangerous cated by the instrument may be wrong.
areas.
- Near articulation area of the machine Cautions regarding measurement
- Under the machine - Take safety precautions before starting measure-
- Around the engine ment work, and carefully measure and record the
- In front of or behind the machine valves.
- Measure a value three times or more. If the obtained
values greatly differs from each other, an error has
CAUTION been made in measuring the value.
Do not touch the fan or V-belt of the engine or a high Measure the value again.
temperature section if the engine is running. An accident Calculate the average value from the various read-
resulting in injury may occur. ings.
Be sure to stop the engine before you open the side
cover of the engine room. Keep all guards in place. Warm-up
Avoid high temperature components even when the - If the machine is too cold, measured values may be
engine is stopped. 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.
03-11
Procedure for warm-up
Gauge Engine water temperature T/C. T/M oil temperature
110ºC(230ºF)
97ºC(206ºF) 100ºC(212ºF)
100ºC(212ºF) 120ºC(248ºF)
35ºC(95ºF) 103ºC(217ºF)
50ºC(122ºF)
125ºC(257ºF)
Indication
White Red Red

White
Resistance
120~125 75~80
between S and E (Ω)
Resistance
120~125 85~90
between S and V (Ω)
Resistance
170~190 130~150
between E and V (Ω)
1. Torque converter oil temperature

Perform torque converter stall operation by refer-
ring to "Stall speed measurement procedure".
Check the approximate temperature using the tem-
perature 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 con-
tact 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.
03-12
Engine
Engine
Temperature of torque converter oil :
WARNING 50~80ºC (120~180ºF)
Unexpected movement of the machine may cause an Temperature of hydraulic oil :
accident resulting in injury or death. 50~80ºC (120~180ºF)
Therefore, to provide repair service with the engine Temperature of engine coolant :
running, be sure to observe the following items: 50~80ºC (120~180ºF)
- Apply the parking brake. 1. Press the brake pedal.
- Block the tires with chocks to prevent the tires from Set and confirm the transmission shift lever is neu-
moving. tral position.
- Determine the signals between the service men.
- Prohibit any person from walking into dangerous 2. Set and confirm the parking brake to the "ON" posi-
areas. tion.
- Near articulation area of the machine
- Under the machine 3. Lower the bucket onto the ground.
- Around the engine
- In front of or behind the machine 4. Set the boom and bucket control lever to "Neutral
position".
CAUTION 5. Set the shift lever to the forward position.

Do not touch the fan or V-belt of the engine or high-
temperature section if the engine is running. Note
An accident resulting in injury may occur. To avoid "Hibernate mode".
Be sure to stop the engine before you open the side In "Hibernate mode", decrease the engine speed 850
cover of the engine room. min-1 to 725 min-1 under following condition.
Keep all guards in place. When the transmission shift lever is placed in "N" posi-
Avoid high temperature components even when the tion, the engine coolant temperature is higher than
engine is stopped. 60ºC, and the engine speed is held at 950 min-1 or less
Use a photo tachometer when checking engine revo- for 10 seconds.
lution.
6. Record low idle speed.
7. Set and confirm the transmission shift lever is neu-

tral.
Measuring engine speed
8. Set the declutch ON/OFF switch to ON.
Press the brake pedal all the way to the floor.
Measurement instrument
Note
- Tachometer (MODM) 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
Standard measurement value declutch ON/OFF switch to ON, release this mode.
Low idle (min-1): 800±50 9. Gradually increase the engine speed.

Measure the speed (high Idle) when the accelerator
High idle (min-1): 2,400±50 pedal is fully pressed down.
10. Record high idle speed.

03-13
Engine
Stall speed measurement procedure Engine speed measurement procedure in multiple

WARNING
Unexpected movement of the machine for abnormal
IMPORTANT
brake performance may cause an accident resulting When the relief valve is activated, the oil temperature
in injury or death. rises rapidly. Therefore, long relief operation may
Before measuring, make sure that the machine has damage the seals or cause the spool to stick inside
sufficient brake performance. the valve.
This is why relief operation should be limited to 10
seconds.
IMPORTANT To repeat the relief operation, be sure to wait more
In the stall mode, the torque converter oil tempera- than 10 seconds with medium engine speed before
ture rises rapidly. Therefore, long stall operation may next relief operation, and cool the inside of the valve.
damage the seals, and the damaged seal may cause Using this cycle safely warms up cold oil.
oil leakage.
This is why stall test should be limited to 20 seconds. 1. Press the brake pedal.
The torque converter oil temperature should not be Set and confirm the transmission shift lever is neu-
exceeded 120°C (250°F). tral position.
To repeat the stall operation, be sure to wait more
than 10 seconds with medium engine speed before 2. Set and confirm the parking brake to the "ON" posi-
next stall operation so that the torque converter oil is tion.
cooled enough.
3. Lower the boom to the lowest limit. Roll back the
1. Press the brake pedal. bucket fully until the bucket contacts to the stopper.
Set and confirm the transmission shift lever is neu-
tral position. 4. Set the declutch ON/OFF switch to ON.
2. Set and confirm the parking brake to the "ON" posi-
tion. Note
To avoid "fuel saving mode at idle time".
3. Lower the boom to the lowest limit. Roll back the In "fuel saving mode at idle time", not activated promptly
bucket fully until the bucket contacts to the stopper. and engine may not reach the maximum revolution.
4. Set the parking brake to the "OFF" position. 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 6. Place the bucket control lever in roll back position.
then set the transmission shift lever to the forward Measure the engine speed.
3rd speed position.
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
03-14
Engine
Maximum speed in torque converter stall plus multi- 1. Press the brake pedal.
ple control valve relief mode. Set and confirm the transmission shift lever is neu-
tral position.
WARNING 2. Set and confirm the parking brake to the "ON" posi-
Unexpected movement of the machine for abnormal tion.
brake performance may cause an accident resulting
in injury or death. 3. Lower the boom to the lowest limit. Roll back the
Before measuring, make sure that the machine has bucket fully until the bucket contacts to the stopper.
sufficient brake performance.
4. Set the parking brake to the "OFF" position.
IMPORTANT 5. Set the declutch ON/OFF switch to OFF.

In the stall mode, the torque converter oil tempera-
ture rises rapidly. Therefore, long stall operation may 6. Press the brake pedal all the way to the floor, and
damage the seals, and the damaged seal may cause then set the transmission shift lever to the 3rd
oil leakage. speed position.
This is why stall test should be limited to 20 seconds.
The torque converter oil temperature should not be 7. Gradually increase the engine speed.
exceeded 120°C (250°F).
To repeat the stall operation, be sure to wait more 8. Place the bucket control lever in roll back position.
than 10 seconds with medium engine speed before
next stall operation so that the torque converter oil is 9. Measure the engine speed when the accelerator
cooled enough. 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
03-15
Engine
Cause of extremely high or low measurement value

and solution The engine speed is too high in multiple control valve relief mode.
Minimum no-load speed (LI) or maximum no-load speed (HI) low

Adjustment or
Relief valve pressure too low
Possible cause Solution disassembly
Disassembly
Insufficient warm up Warm up Defective pump / pump seals
& repair
Inspection &
Malfunctioning accelerator control link
repair
Clogged fuel filter Clean
Defective fuel pump Repair The engine speed is too low in multiple control valve relief mode.
Defective fuel injection nozzle Repair

Valve clearances incorrect Adjustment
Inspection
Insufficient compression pressure Repair Engine low power
& repair
Extremely high relief pressure of
Adjustment
multiple control valve
The engine speed is too high in torque converter stall mode.
Possible cause Solution The engine speed is too high in torque converter stall plus multiple
Slipping transmission clutch or defect Disassembly control valve relief mode.
inside of transmission & repair
Disassembly Possible cause Solution
Defect inside torque converter
& repair
Slipping transmission clutch or defect inside of Disassembly
transmission or T/C & repair
Relief pressure too low Adjustment
Disassembly
The engine speed is too low in torque converter stall mode. Defective pump / pump seals
& repair
Caused by reduction in engine power The engine speed is too low in torque converter stall plus multiple
control valve relief mode.
Clogged air cleaner element Cleaning
Inspection
Fuel Engine low power
Improper type of fuel & repair
replacement
Extremely high relief pressure of multiple control
Clean or Adjustment
Clogged fuel filter or suction strainer valve or steering valve
replace
Use antifreeze
Frozen fuel / wax build up
mixture
Inspection
Malfunctioning accelerator control link
& repair
Defective fuel pump Repair
Defective fuel injector nozzle Repair
Insufficient compression pressure Repair

03-16
Clutch Oil Pressure
Clutch Oil Pressure
Measuring clutch oil pressure
T/C inlet oil pressure

(PF1/2)
Forward clutch oil 4th speed clutch oil

pressure (PF1/4) pressure (PF1/4)
1st speed clutch oil

pressure (PF1/4)
3rd speed clutch oil
pressure (PF1/4)
Reverse clutch oil

pressure (PF1/4)
2nd speed clutch oil

pressure (PF1/4)
80ZVE32030
- Pressure gauge 2 MPa (20 kgf/cm2) (284 psi)

WARNING with 2~3 m hose
Unexpected movement of the machine may cause an - Clutch oil pressure measurement value :
accident resulting in injury or death. 1.3±0.2 MPa (13±2 kgf/cm2) (185±28 psi)
To prevent such an accident during clutch oil pres- at engine idling speed (LI)
sure measurement, be sure to closely communicate 1.5±0.2 MPa (15±2 kgf/cm2) (213±28 psi)
with the person in the cab by giving signals to each at engine maximum speed (HI)
other. Also use a gauge with a hose long enough to - Torque converter oil temperature :
reach outside from the articulation area. 50~80ºC (120~180ºF)
03-17
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
6. Stop the engine.
Standing under the boom or bucket during service
work is dangerous. An accident resulting in injury or 7. Attach vinyl tape to the cylinder rod at a point
death may be caused. 100~150 mm (4~6 in) away from the cylinder head
To prevent such an accident, be sure to lock the cover.
boom and bucket control levers in the cab, securely
support the boom, and remove the starter key. 8. Measure the accurate distance from the cylinder
In addition, hang a "DO NOT OPERATE!" tag on the head cover to the vinyl tape. This is distance "A"
steering wheel. mm (in). Measure the distance again 5 minutes
later. This is distance "B" mm (in).
Measurement instrument 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
Drift rate depends on the viscosity of the hydraulic oil
and its temperature. In other words, high temperature of
the hydraulic oil reduces the viscosity. Reduction in oil
viscosity increases oil leakage through the seals, and
Measurement procedure increases the drift rate. Cold thick oil reduces the drift
rate.
1. Unload the bucket.
2. Press the brake pedal.

IMPORTANT
Set and confirm the transmission shift lever is neu- At the completion of measurement, if the vinyl tape
tral position. used for measurement is not removed from the cylin-
der rod, the tape may be caught by the rod seal. The
3. Set and confirm the parking brake switch to the tape will cause oil leakage from the rod seal. To pre-
"ON" position. vent oil leakage, be sure to remove the vinyl tape.
4. Keep the boom and bucket horizontal.

03-18
Hydraulic Cylinder
Possible causes of excessive cylinder drift: Possible causes of excessive cylinder drift:
Bucket cylinder Boom cylinder
Boom cylinder
Bucket cylinder
80ZV03002 80V2E03001
Bucket cylinder rod side flange Boom cylinder rod side flange
Possible cause Solution Possible cause Solution

Disassembly & Disassembly &
Damaged cylinder piston seal / barrel Damaged cylinder piston seal / barrel
repair repair
Defective multiple control valve overload relief Disassembly & Oil leakage from multiple control valve boom Disassembly &
valve repair spool repair
Oil leakage from multiple control valve bucket Disassembly &
spool repair - Identifying defective part
Just like the bucket cylinder, no pressure should be
- Identifying defective part applied to the rod side of the boom cylinder when the
Pressure is applied to the bucket cylinder bottom weight of the boom is resting on the boom cylinders.
side to support the bucket. There should be no pres-
sure applied to the cylinder rod side. Carefully loosen the split flange (see the arrow) for
the pipe on the cylinder rod side.
Keep the boom and bucket horizontal, and stop the
engine. Carefully loosen the split flange (see the If the compressed oil spouts from the cylinder, judge
arrow) on the cylinder rod side. If the compressed oil that the piston seal and/or barrel of the boom cylider
spouts from the cylinder, judge that the piston seal is damaged. If the compressed oil spouts from the
and/or cylinder barrel is damaged. If the compressed pipe side, judge that the piston seal of the other cyl-
oil spouts from the hose side, judge that the piston inder is defective.
seal of the other cylinder is defective.
If no oil spouts from the split flange, judge that oil is
If no compressed oil spouts from the cylinder, judge leaking from the multiple control valve spool.
that the cause is the defective multiple control over-
load 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.
03-19
Boom Rising Time
Boom Rising Time

Measurement procedure
WARNING
1. Unload the bucket.
Standing under the boom or bucket during service
work is dangerous. An accident resulting in injury or 2. Press the brake pedal.
death may occur. Set and confirm the transmission shift lever is neu-
Stay out of the area around the raised boom. tral position.
3. Set and confirm the parking brake switch to the

Measurement instrument "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
7. Set the shift lever to the forward position.
boom rising time.
Note
To avoid "Hibernate mode".
In "Hibernate mode", decrease the engine speed 800
Standard measurement value (sec) min-1 to 725 min-1 under following condition.
When the transmission shift lever is placed in "N" posi-
Idling (LI) 21±3.0 tion, the engine coolant temperature is higher than
Engine speed 1,500 min-1 (rpm) 10.0±1.0 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.

tral.
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.

Note
declutch ON/OFF switch to ON, release this mode.
03-20
Boom Rising Time
14. Adjust the engine speed to high idle (HI). Possible causes of slow boom rising time:
15. Measure the time required for the boom from the Possible cause Solution
lowest to the highest limit. Disassembly
Damaged main pump / seals
& repair
Note Disassembly
Damaged steering pump / seals
Even if the boom kick out system is installed, the boom & repair
control lever should be held in the UP position until the Disassembly
Multiple control valve spool sticking
boom rises to the highest limit. & repair
Disassembly
Malfunctioning ELS valve
& repair
Inspection
Malfunctioning ELS switch or harness
& repair
Inspection
Malfunctioning controller or harness
& repair
Inspection
Internal oil leakage of boom cylinder
& repair
Disassembly
Malfunctioning steering valve
& repair
How to determine the cause (damaged main pump or

steering pump):
97ZV03005 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
03-21
Full Steering Time
Full Steering Time

WARNING
1. Adjust the stopper bolts of the front chassis so that
Standing in the articulation area during service work the front chassis stopper contacts to the rear chas-
is dangerous. An accident resulting in injuly or death sis.
may occur.
During this test, prevent any person from walking 2. Unload the bucket.
around the machine or in the articulation area.
Measurement instrument tral position.
- Stop watch 4. Set and confirm the parking brake switch to the
"ON" position.
- Tachometer (MODM)
5. Lower the boom, and roll back the bucket.
(Bucket and boom are not on to ground for steer-
ing)
Warm-up the engine before measuring full
6. Confirm the parking brake switch is in the “ON”
steering time. position and release the brake pedal.
Standard measurement value (sec) Note

Idling (LI) 5±0.5 In "Hibernate mode", decrease the engine speed 800
1,500 min-1 (rpm) 2.1±0.3 min-1 to 725 min-1 under following condition.
Engine speed
Full accelated engine
2.0±0.3 tion, the engine coolant temperature is higher than
speed
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 steer-

ing.

tral.
11. Adjust the engine speed to 1,500 min-1.
12. Measure and record the time required for full steer-
ing.
13. Gradually increase the engine speed.

Accelerator pedal is fully pressed down.
03-22
Full Steering Cycle Time
14. Measure and record time required for full steering. Possible causes for slow steering times:
- From full left to full right or Possible cause Solution

- From full right to full left Disassembly
Turn the steering wheel as fast as possible during Damaged steering pump / seals
& repair
the test. Malfunctioning steering valve flow control Disassembly
plunger or steering spool & repair
IMPORTANT
After measuring, return the stopper bolts. Flow control plunger
(Refer to "Stop valve" in Check & Adjustment.) P
Pc
Steering valve
T
90ZV03005
97ZV03007
Full steering
03-23
Loading/Steering Circuit Relief Valve
Loading circuit relief valve setting Measurement instruments

pressures
Pressure gauge
WARNING 30 MPa (300 kgf/cm2) (5,000 psi)

(for loading line with 3 m (10 ft.) hose and steering line
Unexpected movement of the machine may cause an with 1.5~3 m (4~10 ft.) hose)
Therefore, to provide repair service with the engine 5 MPa (50 kgf/cm2) (1,000 psi)
running, be sure to observe the following items : (for pilot line) with 2~3 m (6~10 ft.) hose
- Apply the parking brake. Note
- Block the tires with chocks to prevent the tires from For safety, route the gauge to an area where it may be
moving. safely read by the person doing the test.
areas.
- Near articulation areas of the machine Gauge port
- Under the machine
- Around the engine
Gauge port location Port size
Main relief
(1), (2), (3)
pressure
(1), (2), (3)
CAUTION Overload relief
G (PF) 1/4 with O-ring
(1), (2), (3)
Be careful, you may get burned if the high pressure pressure
oil spouts out. To prevent such an accident, be sure (4)
to release the residual pressure from the pipe, and Pilot line pressure
(4), (5)
G (PF) 3/8 with O-ring
(Reducing valve) (5)
open the cap of the hydraulic tank before removing G (PF) 1/4 with O-ring
the plug from the pressure measurement port.
CAUTION
Do not touch the fan or V-belt of the engine or a high-
temperature section if the engine is running. An acci-
dent resulting in injury may occur.
Be sure to stop the engine before you open the
access panel of the engine room. Keep all guards in
place.
Avoid high temperature components even when the
engine is stopped.
03-24
Standard measurement value MPa Measuring loading circuit main relief pres-
(kgf/cm2) (psi) sure
Loading line main relief pressure 20.6±0.5 1. Unload the bucket.

(at maximum speed) (210±5) (2,986±71)
Loading line overload relief pressure 23.5±0.5
(at idling speed) (240±5) (3,413±71)
tral position.
3.5
Pilot line
(36) (512) 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 approxi- 7. Set the declutch ON/OFF switch to ON.
mately 30 cm (1 ft.) above the ground. Press the brake pedal all the way to the floor.
Tilt down the bucket until it comes in contact with Note

the ground. Place the bucket control lever in the To avoid "fuel saving mode at idle time".
roll back position, and then lower the boom. In "fuel saving mode at idle time", not activated promptly
Push down on, then open the cap of the hydraulic Press the brake pedal all the way to the floor with the
tank to release the residual pressure. declutch ON/OFF switch to ON, release this mode.
8. Move the bucket control lever to the roll back posi-

tion. Hold the lever at that position.
9. Increase the engine speed to the maximum, and

measure and record the pressure using the pres-
sure 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 pres-

sure, 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.
03-25
Bucket cylinder Main relief valve
Adjusting
screw
Tank port
(1)
(2)
Lock nut
80ZVE43001 85ZVE43004
Multiple control valve
Main relief valve (3)
Overload relief
valve
Overload relief
valve
70ZVE43002
Valve assembly
(5)
(PPI) (Z)
(Z2) (Z1)
(4) (PA)
ACF (ACCF) (ACCR)
(PARKING)
(TA)
(T) (P)
Reducing valve
(for pilot)
85V2E43001
03-26
Measuring loading circuit overload relief Adjusting overload relief pressure

pressure
adjusting screw.
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. IMPORTANT
At the completion of check and adjustment of over-
Bucket cylinder bottom side (gauge port (2) or (3))
load relief valve pressure, be sure to reset the main
relief valve to the original condition.
1. Lower the boom to the lowest limit.
2. Move the bucket control lever to the roll back posi- Overload relief valve
tion.

Lock nut
Note
min-1 to 725 min-1 under following condition.
tion, the engine coolant temperature is higher than
60ºC, and the engine speed is held at 950 min-1 or less Adjusting screw
for 10 seconds.
4. Keep the engine speed at low idle. 70ZV43005
5. Hold the bucket control lever at the roll back posi-

tion 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.
03-27
Measuring pilot circuit relief pressure Reducing valve
WARNING
Lock nut
Trapped pressure in brake circuit could cause serious
injury when the plug is removed.
Fully release all residual accumulator pressure
before servicing.

Adjusting screw
Note 90ZVE43004
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

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.
03-28
Steering circuit relief valve setting Measurement instruments

pressures
Pressure gauge
WARNING 30 MPa (300 kgf/cm2) (5,000 psi)

(for loading line with 3 m (10 ft.) hose and steering line
Unexpected movement of the machine may cause an with 1.5~3 m (4~10 ft.) hose)
Therefore, to provide repair service with the engine 5 MPa (50 kgf/cm2) (1,000 psi)
running, be sure to observe the following items : (for pilot line) with 2~3 m (6~10 ft.) hose
- Apply the parking brake. Note
- Block the tires with chocks to prevent the tires from For safety, route the gauge to an area where it may be
moving. safely read by the person doing the test.
areas.
- Near articulation areas of the machine Gauge port
- Under the machine
- Around the engine
Gauge port location Port size
Main relief
pressure
CAUTION Overload relief
(1), (2) G (PF) 1/4 with O-ring
Be careful, you may get burned if the high pressure pressure

oil spouts out. To prevent such an accident, be sure Reducing
to release the residual pressure from the pipe, and (3) Rc (PT 1/8)
pressure
the plug from the pressure measurement port.
CAUTION
Be sure to stop the engine before you open the
access panel of the engine room. Keep all guards in
place.
Avoid high temperature components even when the
engine is stopped.
03-29
Standard measurement value MPa Measuring steering circuit main relief pres-
(kgf/cm2) (psi) sure
Steering line main relief pressure 20.6±0.5 1. Unload the bucket.

(at maximum speed) (210±5) (2,986±71)
Steering line overload relief pressure 24.5 +1.0
(at idling speed)
0
(250 +100 ) (3,555 +1420 )
tral position.
3.5
Pilot line
(36) (512) 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. Attach the pressure gauge to the gauge port ((1) or
Releasing residual pressure from tank and pipes (2)).
Steer the machine in a straight position. 6. Set the declutch ON/OFF switch to ON.
Keep the bottom surface of the bucket horizontal, Press the brake pedal all the way to the floor.
and stop the engine when the bucket is approxi-
mately 30 cm (1 ft.) above the ground. Note
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 chas-
sis contact each other.
Continue to hold the steering wheel fully turned.
8. Increase the engine speed to high idle, and mea-

sure 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 artic-

ulation stopper or screw the stopper (bolt) in until the
front and rear chassis contact each other.
WARNING
If the machine begins to move with the articulation
stopper applied, it may cause an accident resulting in
injury or death.
After the measurement, be sure to disconnect and
store the articulation stopper.
03-30
Adjusting steering line main pressure Reducing valve
Adjusting screw
Steering cylinder Lock nut
(2)
(A)
Note
(3)
North America equipped (1)
M/c's have quick
connectors at ports
(1) and (2).
70ZV43007 (B) 115ZV43006a
Loosen the lock nut and adjust the pressure by the Steering valve
adjusting screw.
Turn clockwise the adjusting screw to raise the steering Overload relief
valve
line main pressure.
Main relief valve

70ZV43008
Main relief valve
Lock nut
Adjusting
screw
Steering valve
70ZV43009
03-31
Measuring steering circuit overload relief Adjusting overload relief pressure

pressure
Port B Port A
Lock nut
To From
steering valve Orbitrol®
Stopper
(bolt) Spool
Adjusting screw
Installed Bolt Check valve

on front chassis Installed on rear chassis
70ZV43005
95ZV42033
adjusting screw.
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.
WARNING
3. Steer the machine until the front and rear chassis
If the machine begins to move with the articulation
contact each other. Continue to hold the steering
stopper applied, it may cause an accident resulting in
wheel fully turned.
injury or death.
After the measurement, be sure to disconnect and
Note
store the articulation stopper.
Because the stop valve is installed into the steering line,
oil pressure does not reach the set point when the
steering is fully turned. IMPORTANT
When measuring oil pressure, be sure to apply the artic-
ulation stopper or screw the stopper (bolt) in until the At the completion of check and adjustment of over-
front and rear chassis contact each other. load relief valve pressure, be sure to reset the main
relief valve to the original condition.
Note
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.
03-32
Measuring pilot circuit relief pressure Adjusting pilot line pressure

(reducing pressure)
adjusting screw.
Turn clockwise the adjusting screw to raise the pilot line

pressure.
Adjusting screw
Lock nut
IMPORTANT
After the completion of the adjustment of the pilot line
pressure, be sure to tighten the lock nut.
(T)
(A)
(3)
(TS)
(B)
115ZV43007
Gauge port plug width across flat

5 mm
2. Move the bucket control lever to the roll back posi-

tion.
Note
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 posi-

tion and record the pressure.
03-33
Stop Valve
Stop Valve
Stop valve adjustment procedure Reference dimension
Front chassis
Stop valve
Stopper (rear chassis)
(bolt) (L.H, R.H)
Front chassis
Reference dimension Rear chassis

33.9~38.4 mm Reference dimension
(1.33~1.51 in) 9.7~19.3 mm (0.38~0.76 in)
Stopper (bolt) length Clearance between machine body and stopper K85ZVE43003
K85ZVE43002
Articulation angle ( º) 37 36 35
WARNING Clearance between machine body and 9.7 14.5 19.3
stopper (mm) (in) (0.38) (0.57) (0.76)
When the machine turns, the clearance in the articu- 33.9 36.2 38.4
Stopper (bolt) length (mm) (in)
lation area closes. As a result, people may be caught, (1.33) (1.42) (1.51)
leading to a severe accident. To prevent such an
accident, observe the following items strictly when *The target value should be the articulation angle "36º".
adjusting the steering stopper.
- Stop the engine before starting adjustment of the - After adjustment, turn the steering wheel slowly at a
stopper bolt. rate of 5 sec or more per turn, and confirm the clear-
- When confirming the operation after setup, keep ance between the machine body and the stopper.
proper distance from the articulation area of the
machine. - When adjustment is completed, tighten the lock nut
of the stopper (bolt).
The stop valve works when the spool is pushed in 3 mm
(0.118 in). : 90 N-m (9.2 kgf-m) (67 lb-ft)
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 "9.7~19.3 mm
(0.38~0.76 in)" shown in the table below.
03-34
Fan Revolution
Fan Revolution
CAUTION
- Tachometer (Photo tachometer)
Cooling fan Fan motor (1) Flow control valve (2)
cover of the engine room. Keep all guards in place.
Avoid high temperature components even when the Flow control
solenoid (3)
engine is stopped.
MCU
T P TC From
To return
filter Fan motor assy unloader valve
Hydraulic circuit diagram 90V2E42011a

03-35
Fan Revolution
Measuring number of fan maximum revolu-

tions
Flow control valve

Proportional solenoid valve
Pump
Throttle (D)
Command current
P
Throttle section (E)
B C
MB MA
Adjusting screw
Mainspool (dummy)
T
Spring for flow
control valve
K70V2J42006
1. Disconnect the cable connector of flow control sole-

noid.
2. Measure the number of tan revolutions while the

engine at high idle.
3. If the maximum number of revolutions is not cor-

rect, adjust it using the adjusting screw.
Loosen lock nut and turn the adjusting screw clock-
wise to increase the number of fan revolution.
Possible causes by extremely high or low measure-

ment value and solution.
Fan speed is low High revolution is high
Possible cause Solution Possible cause Solution
Defective proportional solenoid valve Replacement Adjust the setting

Inappropriate setting the adjusting screw
screw
Defective fan motor Replacement
Adjust the setting
Inappropriate setting the adjusting screw
screw
03-36
Service Brake
Service Brake
Service brake performance check Method 2
If no test course available as described "Method 1",

Method 1 carry out the following method.
WARNING IMPORTANT
Separate the test course by using rope etc. and keep The following method is easy and simple, however it
persons away from the test course. In addition, post is not an accurate way, because the braking force
persons in several positions near the course to warn and rim-pull may vary on each machine. Confirm
others and avoid an accident while checking the ser- engine & transmission performance via using a stall
vice brake performance. test. See page 03-4.
Reconfirm the brake performance by the method 1 as
soon as possible.
Condition
WARNING
1. Test course Unexpected movement of the machine may cause an
Level, straight, dry and the paved ground. accident resulting in injury or death.
Before starting brake performance check, be sure to
2. Run the machine and depress the brake pedal at observe the following items:
20 km/h (12.5 mph). - Place the machine on level ground.
Measure and record the braking distance. - Check that there is enough clearance for brake
performance check around the machine.
- During performance check, prohibit any person to
walking near the machine.
1. Lower the boom to the lowest limit, and roll back
Braking distance the bucket fully until the bucket contacts to the stop-
8 m (8 3/4 yd) or shorter per.
Possible causes of extremely long braking distance 2. Set the parking brake switch to the "OFF" position.
Possible cause Solution 3. Set the declutch switch to OFF, and then depress
Low brake line pressure Check and repair the brake pedal all the way to the floor.
Friction plate wear Check and repair
Brake valve malfunction Check and repair 4. Set the shift lever to 2nd reverse speed.
Note 5. Gradually increase the engine speed. The machine

The brake performance check methods 1 and 2 are should not move at the maximum engine speed.
based on the law and the regulation in Japan.
When checking the service brake performance, follow Possible cause of machine moving during brake
the law and/or local regulation in your country, state, or performance check.
province.
Low brake line pressure Check and repair
Friction plate wear Check and repair
Brake valve malfunction Check and repair
03-37
Service Brake
Service brake friction plate wear

measurement
Slide caliper
Retainer
Steel plate
Friction plate
80ZVE53002
WARNING
Unexpected movement of machine could cause seri-
Oil inlet port
Internal gear
ous injury or death. To prevent such an accident,
observe the following items before checking the
brake friction plate wear:
- Stop the engine.
- Determine the signals between the persons related
Steel plate Brake retainer to this work for engine starting to prevent an acci-
dent.
80ZVE53003 - Prohibit any person from walking into the danger-
ous area.
IMPORTANT
After inserting calipers, do not rotate the wheels. If
the wheels are rotated, the calipers may be caught
and broken by the reduction gear. In this case, the
reduction gear must be disassembled.
03-38
Service Brake
Measurement procedure Cautions on installing brake discs

Turn the planetary gear so that the oil supply plug is
positioned at the top. Check that the teeth of steel plate A
are as shown in the figure in page 03-37 (only one sec-
B
tion of the plate circumference is as shown in the fig-
ure).
Insert calipers to the inner steel plate to measure the

dimension A. Wheel hub
Note
During measurement, be sure the service brake is Brake piston
applied.
80V2E53003
The wear limit for dimension A is 15.1 mm (0.59 in).
Note that dimension A is 17.4 mm (0.69 in) when the
plate is new and unused. When only the friction plate or the steel plate is to be
replaced, if the brake piston is installed as it is, the
Note brake may drag and the brake disc may seize.
To aid quick measurement on the front axle-raise the
front of the machine so the front tires clear the ground Push back the brake piston by loosening the air bleeder
by about 25 mm (1 in). This allows easy rotation of the nipple before replacing a friction plate or a steel plate.
wheel to align the gear teeth.
- After pushing back the piston, confirm dimension A
from the piston end face to the wheel hub end face.
IMPORTANT
Wheel bearings must be adjusted correctly to get an
accurate measurement for dimension A. Dimension
should be equal at top and bottom.
A: 100.25~101.40 mm (3.95~3.99 in)
Note
Piston stroke B
1.15~3.40 mm (0.045~0.134 in)
- After finishing the installation work, bleed air com-

pletely from the brake line.
03-39
Parking Brake
Parking Brake
Parking brake performance check Method 2
If no test course available as described "Method 1",

Method 1 carry out the following method.
WARNING IMPORTANT
Unexpected movement of the machine may cause an The following method is easy and simple, however it
accident resulting in injury or death. is not an accurate way, because the braking force
Before starting brake performance check, be sure to and rim-pull may vary on each machine.
observe the following items: Confirm engine & transmission performance via stall
- Check that there is enough clearance for brake test. See page 03-4. Reconfirm the brake perfor-
performance check around the machine. mance by the method 1 as soon as possible.
- During performance check, prohibit any person to
WARNING
Unexpected movement of the machine may cause an
Condition Before starting brake performance check, be sure to
observe the following items:
1. Test course - Place the machine on level ground.
1/5 slope (Approx. 11º 19') - Check that there is enough clearance for brake
performance check around the machine.
2. Bucket empty - During performance check, prohibit any person to
3. Parking switch ON
1. Set the parking brake switch to the "ON" position.
2. Disconnect the cable connector of parking brake

Standard measurement value 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 4. Gradually increase the engine speed. The machine
performance check should not move at the maximum speed.

IMPORTANT
Clearance between brake drum and shoe
Clearance adjustment
too large If the machine begins to move with the parking brake
Improperly adjusted spring chamber link Check and adjustment applied, the brake shoes are burnt or misadjusted.
Broken spring chamber spring Check and repair At the completion of parking brake test, be sure to
Parking brake solenoid valve malfunction Check and repair connect the connector of electrical line to the sole-
noid valve again.
Note
The brake performance check methods 1 and 2 are Possible cause Solution
based on the law and the regulation in Japan. Clearance between brake drum and shoe
Clearance adjustment
When checking the service brake performance, follow too large
the law and/or local regulation in your country, state, or Improperly adjusted spring chamber link Check and adjustment
province. Broken spring chamber spring Check and repair
Parking brake solenoid valve malfunction Check and repair
03-40
Parking Brake
Parking brake clearance adjust- Adjustment procedure

ment
Drum rotational direction

for traveling in reverse
B B
Brake lining
Brake shoe
Position of
Inspection hole adjusting Approx. 8º
A screw
2nd propeller shaft
D D
For replacement of shoe assembly refer to Section 54.
A
Adjusting screw rotational
direction for brake shoe
expansion
Rivet Brake shoe
A-A
Adjusting screw
D-D 80ZV53002
A
WARNING Brake lining

Unexpected movement of the machine may cause
Lining thickness A : 6.15 mm (0.24 in)
serious injury or death. Adjusting parking brake clear-
ance requires the parking brake to be released. So,
80ZV53003
to prevent accidental movement, observe the follow-
ing items:
- Park the machine on level ground. 1. To rotate the brake drum during adjustment, lift the
- Block the tires with chocks to prevent the wheels front and rear wheels on one side (or both sides)
from moving. using safety jacks, cribbing, etc.
- Place the bucket to the ground.
- Stop the engine, and then remove the starter key. 2. Turn the inspection hole of the brake drum approxi-
Place "DO NOT OPERATE!" tag on the steering mately 8º counterclockwise from the vertical posi-
wheel. tion as shown in the figure.
- Prohibit any person from walking into the danger- After that, use a screw driver or brake tool to turn
ous area. the adjusting screw to adjust the clearance.
Turn the adjusting screw clockwise (upward) to
If the machine moved during parking brake performance expand the brake shoes until the linings come in
check, the clearance between the brake drum and the contact with the brake drum.
lining is too large. After that, turn the adjusting screw 8 notches coun-
terclockwise (down). The clearance will be adjusted
to 0.23 mm. (0.009 in)
Adjustment range
0.1~0.25 mm (0.004~0.010 in)
3. After the adjustment, check the performance of the

parking brake by referring to "Parking brake perfor-
mance check".
03-41
Parking Brake
Brake lining abrasion check
Shoe Rivet
B Abrasion limit
Lining
Wear limit B : 0.8 mm (0.03 in)
80ZV53004
12 rivets are inserted to fix the lining to the brake shoe.

If the distance from the lining to the rivet head "B" is 0.8
mm (0.03 in) or less at one of the 12 rivet areas, replace
the shoe assembly.
03-42
Brake Circuit Oil Pressure

Unloader valve setting pressure
WARNING
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. (PPI) (Z)
(Z2) (Z1)
moving.
(PA)
- Determine the signals between the service men.
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.
03-43
Method 1 Measurement procedure

Refer to "Brake Main pressure 1" "Brake Main pressure 1. Lower the boom to the lowest limit, and tilt the
2" of MODM "Input/Output Monitor" section. bucket down to the ground.
Then set the parking brake switch to the "ON" posi-
Method 2 tion.
If the pressure gauge is not available as described 2. Stop the engine. Repeatedly depress and release
"Method 2", apply the "Method 1". the brake pedal till you feel light brake to discharge
accumulator pressure.
3. Remove one of the ACF port plug on the valve

Measurement instrument assembly and attach the pressure gauge to the
port.
Hydraulic pressure gauge
20 MPa (200 kgf/cm2) (3,000 psi) 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 pres-
sure).
Gauge port
5. Keep the engine at low idle, and repeatedly
ACF port on valve assembly depress and release the brake pedal to reduce the
Rc (PT) 1/8 accumulator pressure. Measure and record the
pressure when the pointer of the pressure gauge
stops and then starts rising again (cut-in pressure).
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)
03-44
Adjusting unloader valve setting pressure Tightening torque

: ACF port plug: 11.3 N-m (1.15 kgf-m) (8.3 lb-ft)
(S/N 9001~9039) : 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)
24
22
21
Fan motor port
Pump port
Unloader valve
70ZV53001
(S/N 9040~)
21 22
Fan motor port
Pump port
Unloader valve
K115ZV53002
1. Remove the cap nut (24) and loosen the lock nut
(22). (S/N 9040~, nut (24) is not equipped.)
2. Adjust the pressure by the 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" (cut-
in) pressure to the standard setting pressure.
03-45
Brake valve oil pressure Gauge port
Remove air bleeder nipple on the axle housing, and

then install the pressure gauge to the bleeder position.
Size of air bleeder port

le
ng
Force Rc (PT) 3/8

la
da
19
Pe
(In case of the bleeder valve

M10 X 1.0)
15
0
m
m
45
Air bleeder nipple fitting

[59 N-m (6.0 kgf-m) (43 lb-ft)]
80V2E53001
Method 1
Refer to "Brake Pedal Output Oil Pressure" of MODM 85ZVE53001
"Input/Output Monitor" section.
Method 2
If the pressure gauge is not available as described
"Method 2", apply the "Method 1".
Check to be sure the brake valve is fully released.
Press down the brake pedal to check that the oil pres-
sure rises in proportion to the pedal angle.
Release the brake pedal to check that the oil pressure
Hydraulic pressure gauge drops to zero in proportion to the pedal angle. In addi-
10 MPa (105 kgf/cm2) (1,500 psi) tion, visually check for brake oil leakage.
03-46
Brake valve performance
MPa
(kgf/cm2)
(psi)
Output oil pressure (brake port)
4
(40)
(580)
3.34
(34)
(484)
2
(20)
(290)
0 3.9 5 10 15 18.5 19
(deg)
Pedal stroke
80V2E53002
Refer to the curve shown in the above figure.
When the measured value does not match the per-

formance curve, check the following points.

Malfunctioning brake valve Repair or replacement
Brake line oil pressure low
Check and repair
(Pump, reducing valve malfunction)
IMPORTANT
After measuring oil pressure, be sure to tighten the
air bleeder valve. Also be sure to bleed air.
03-47
Accumulator Circuit Charging Time
WARNING
Therefore, to provide repair service with the engine
running, be sure to observe the following items: (PPI) (Z)
- Apply the parking brake. (PA) (Z2) (Z1)
moving. (ACCF) (ACCR)
(PI)
- Determine the signals between the service men. (TA)
- Prohibit any person from walking into dangerous (P)
(T)
areas.
- Near articulation areas of the machine
- Under the machine
- Around the engine
ACF port
CAUTION
Be careful, you may get burned if the high pressure
oil spouts out. To prevent such an accident, be sure
to release the residual pressure from the pipe, and Valve assembly
95V2E03003
the plug and hose from the pressure measurement
port.
- 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
03-48
Standard measurement valve (sec)
Engine speed : Low idle
Unloader valve pressure

3.9 MPa → 11.8 MPa 8
(40 kgf/cm2) (120 kgf/cm2)
(569 psi) (1,706 psi)
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.

Disassembly
Defective unloader valve
& repair
Oil leakage from pipe Check & repair
Disassembly
Defective pilot pump
& repair
03-49
Number of Brake Pedal Applications
Number of Brake Pedal Applications

WARNING
Run engine 1 minute high idle, then stop the engine.
Unexpected movement of the machine may cause an Turn the key to the "ON" position.
at least
accident resulting in injury or death. Step on the brake pedal and release, and check the
9 times
number of times until the low pressure alarm is
Therefore, to provide repair service with the engine turned on 3.9±0.5 MPa (40±5 kgf/cm2) (569±71 psi)
running, be sure to observe the following items:
moving.
- Determine the signals between the service men. 1. Lower the boom to the lowest limit, and tilt down the
- Prohibit any person from walking into dangerous bucket to the ground.
areas.
- Near articulation areas of the machine 2. Set the parking brake switch to the "ON" position.
- Under the machine
- Around the engine 3. Run engine 1 minute high idle, then stop the
- In front of or behind the machine engine.
4. Turn the starter switch to "ON".

CAUTION
5. Depress the right brake pedal all the way to the
Do not touch the fan or V-belt of the engine or a high floor, and hold down the pedal for 5 seconds.
temperature section if the engine is running. An accident Release the pedal, and wait for 5 seconds to
resulting in injury may occur. depress the pedal again. Repeat.
cover of the engine room. Keep all guards in place. 6. Count and record the number of pedal applications
Avoid high temperature components even when the until the low pressure alarm buzzer starts to sound.
engine is stopped.
Possible causes of extremely low measure-

ment value and solution

Insufficient accumulator pressure due to
Check & repair
defective unloader valve
Insufficient accumulator gas (N2) pressure Charging
Insufficient accumulator pressure due to
Check & repair
defective pilot pump
Defective brake valve Check & repair
Defective service brake piston seal Check & repair
Oil leakage from pipe Check & repair

03-50
Declutch Engagement
Declutch Engagement
WARNING
1/5 slope (approx. 11º19'), unloaded bucket, engine
Brake performance check on a slope is dangerous 15 cm (6 in)
maximum speed at 1st speed position, quickly
or less
work. An accident resulting in injury or death may released inching pedal
occur.
Before starting declutch engagement test observe
the following: Cause of extremely high measurement
- Check that the slope is smooth. value and solution
- Check that the brake works well.
- Prohibit any person from walking into the danger-
ous.
Too much delay in resetting declutch Check and replace
- Determine the signs between the service men. switch declutch switch
- Do not enter the area near the moving machine. Refer to "Time lag mea-
Too much time lag in engaging clutch
surement procedure".
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 5. Set the inching cut-off switch to ON.

Measurement rod attached to step 6. Set the parking brake switch to the "OFF" position.
7. Press the inching brake pedal (left pedal) all the

Measurement instrument way to floor.
- Chalk 8. Mark the ground at the pointer position with chalk

- Scale (approx. 1 m) (3 ft.) or tape measure or tape. Increase the engine speed to its maximum,
- Thin rod (approx. 1 m) (3 ft.) used as measurement and set the transmission shift lever to the 1st for-
rod ward speed.
- Vinyl tape
- Assistant / operator 9. Quickly release the inching brake pedal, and mark
- Nylon tie straps (2 or 3) 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.

Warm-up the engine before measuring
declutch engagement
03-51
MEMO
Maintenance Log
Date Machine hours Service performed

Notes

80ZV 2 (EU Trouble)

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

80ZV 2 (EU Trouble)

Uploaded by

Copyright:

Available Formats

93209-00460

May 25, 2009

- Be sure to apply the articulation stopper before starting work.

- Do not start to work in an enclosed area if adequate ventilation is not provided.

- Keep the work area clean. Clean up spills immediately.

- Avoid the use of flammable solvents and cleaners.

- Use safe work platforms to reach higher areas of the machine.

Symbol Item Description

Shows the condition or procedure that will be useful

Shows the weight of a part or unit. The weight

Tightening Shows the tightening torque of a section that should

Shows the type of coating or adhesive and the coat-

Shows the oil or water drain port and the drain

MEASUREMENT FOR PERFORMANCE CHECK ...........03-1

Quick Troubleshooting Table

Hydraulic Group .............................................................................................................................................. 01-16

Brake Group .................................................................................................................................................... 01-28

Electrical Group ............................................................................................................................................... 01-33

Operator Station Group ................................................................................................................................... 01-45

Cautions Regarding Troubleshooting

How to Use Quick Troubleshooting Table

How to use quick troubleshooting table

1. According to the problem explained by the user,

2. Check the machine according to the "Symptoms/

3. Operate the machine, and write the check marks

4. Generally, the possible cause that has many check

Therefore, to provide repair service with the engine

- Park the machine on level ground.

Torque Converter and Transmission Group

1. Machine dose not move in any

Check before starting work.

Setting the declutch ON/OFF switch to OFF allows normal operation.

Torque converter oil becomes milky and cloudy in color.

(If the 70 A fusible link is off, no electrical

Pump produces an abnormal (shrieking) noise.

Pump is extremely heated.

Possible cause Solution

Restricted suction line - pinched, plugged, or internally defec-

Check before starting work.

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

Even when pressing solenoid valve, machine does not move.

Machine may move even when shift lever is in "NEUTRAL".

Resistance of the solenoid valve coil is infinite Ω.

engaged at any other position.

Possible cause Solution

3. Machine moves at the neutral

Check before starting work.

Oil is black and smells scorched.

Possible cause Solution

4. Large shock at starting or chang-

Temperature of the torque converter oil is too high.

Line filter is clogged.

Possible cause Solution

5. Large time lag at starting or

Possible cause Solution

Check before starting work.

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

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

Torque converter oil is discolored or emits nasty smell.

Temperature of the torque converter oil is too high.

Torque converter oil is milky and cloudy in color.

Pump produces an abnormal (shrieking) noise.

Pump is extremely heated.