Kawasaki WHEEL LOADER 92ZV-2 SHOP MANUAL 93221-00080 – PDF DOWNLOAD
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Kawasaki WHEEL LOADER 92ZV-2 SHOP MANUAL 93221-00080 – PDF DOWNLOAD
Language :English
Pages :154
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File Type : PDF
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DESCRIPTION:
Kawasaki WHEEL LOADER 92ZV-2 SHOP MANUAL 93221-00080 – PDF DOWNLOAD
Troubleshooting
Measurement for Performance
Check
Check & Adjustment
Powered by CUMMINS QSM11 ENGINE
Serial No. 92C1-9001 and up
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 Check & Adjustment
- 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 coolant
pipe.
– Be sure to apply the articulation stopper before starting work.
– While supporting the bottom of the chassis using a jack, be sure to support the chassis using the blocks.
– When the boom or bucket is raised or when a unit is lifted by a crane, be sure to place a stand or adequate cribbing
under the unit to prevent unexpected dropping.
– Do not start to work in an enclosed area if adequate ventilation is not provided.
– To remove a heavy unit (20 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.
TABLE OF CONTENTS:
Kawasaki WHEEL LOADER 92ZV-2 SHOP MANUAL 93221-00080 – PDF DOWNLOAD
Troubleshooting
Measurement for Performance
Check
Check & Adjustment
Powered by CUMMINS QSM11 ENGINE
Serial No. 92C1-9001 and up
Foreword 2
Safety Precautions 3
Safety Symbols 4
Symbols 5
CONTENTS 6
MEMO 7
Troubleshooting 8
Cautions Regarding Troubleshooting 10
How to Use Quick Troubleshooting Table 11
Safety Precautions 12
Torque Converter and Transmission Group 13
1 Machine dose not move in any shift lever position 13
2 Machine dose not move at a certain shift lever position (OR:Machine moves only in a certain shift lever position) 14
3 Machine moves at the neutral position (Example: Machine moves forward at the neutral position) 15
4 Large shock at starting or changing speed / direction 16
5 Large time lag at starting or changing speed / direction 17
6 Low power of traction / pushing (Defective torque converter or transmission) 18
7 Torque converter oil is overheating 19
8 Machine moves reverse when starting to climb up on a slope using inching brake 20
9 Automatic speed change is not possible 21
10 Downshift button does not work 22
Hydraulic Group 23
1 Boom and/or bucket do not move 23
2 Boom and/or bucket have low power, or move too slowly 24
3 Excessive cylinder drift 25
4 Boom and/or bucket are spongy (Holding bucket against the ground is not possible-front wheels off the ground) 26
5 Bucket leveler does not work Boom lift kickout and lower kickout does not work 27
6 Steering is not possible or hard to steer 28
7 Machine sways, or has a shock during steering 29
8 ELS (Efficient Loading System) does not work (Excavating and scooping tractive power does not become up during ELS working condition) 30
9 Ride control does not work 31
10 Fan motor rotates abnormally or does not rotate 32
11 Abnormal noise in hydraulic system 33
12 Others 34
Brake Group 35
1 Brake does not work well (In the worst case, the brake does not work at all) 35
2 Brake is dragging when released 36
3 Stepping on the brake pedal sounds the buzzer 37
4 Accumulator pressure does not rise, or too slow in rising 38
5 Parking brake does not work (or: Releasing the parking brake is not possible) 39
Electrical Group 40
1 Instrument panel does not indicate properly 40
2 Fuse for controller is blown 41
Error code (for chassis) 42
Error code (for engine) 45
Operator Station Group 52
Air conditioner 52
Measurement for Performance Check 60
Cautions on Safety 61
Standard Measurement Values for Performance Check 62
Preparation for Performance Check 65
Engine 67
Measuring engine speed 67
Measurement instrument 67
Standard measurement value (Normal mode) 67
Clutch Oil Pressure 71
Measuring clutch oil pressure 71
Hydraulic Cylinder 72
Cylinder natural drift 72
Measurement instrument 72
Standard measurement value (mm/min) (in/min) 72
Measurement procedure 72
Boom Rising Time 73
Measurement instrument 73
Warm-up the engine before measuring boom rising time 73
Standard measurement value (sec) 73
Measurement procedure 73
Full Steering Cycle Time 75
Measurement instrument 75
Warm-up the engine before measuring full steering time 75
Standard measurement value (sec) 75
Measurement procedure 75
Loading/Steering Circuit Relief Valve 77
Loading circuit relief valve setting pressures 77
Measurement instruments 77
Gauge port 77
Standard measurement value MPa (kgf/cm2) (psi) 78
Measuring loading circuit main relief pressure 78
Measuring loading circuit overload relief pressure 80
Measuring pilot circuit relief pressure 81
Steering circuit relief valve setting pressures 82
Measurement instruments 82
Gauge port 82
Standard measurement value MPa (kgf/cm2) (psi) 83
Measuring steering circuit main relief pressure 83
Measuring steering circuit overload relief pressure 85
Measuring pilot circuit relief pressure (reducing pressure) 86
Service Brake 88
Service brake performance check 88
Condition 88
Standard measurement value 88
Parking Brake 89
Parking brake performance check 89
Condition 89
Standard measurement value 89
Brake Circuit Oil Pressure 90
Unloader valve setting pressure 90
Measurement instrument 91
Gauge port 91
Standard measurement value 91
Measurement procedure 91
Brake valve oil pressure 93
Measurement instrument 93
Gauge port 93
Measurement procedure 93
Brake valve performance 94
Accumulator Circuit Charging Time 95
Measurement instrument 95
Gauge installation position 95
Standard measurement valve (sec) 96
Measurement procedure 96
Number of Brake Pedal Applications 97
Standard measurement value 97
Measurement procedure 97
Possible causes of extremely low measurement value and solution 97
Declutch Engagement 98
Measurement instrument 98
Warm-up the engine before measuring declutch engagement 98
Standard measurement value 98
Cause of extremely high measurement value and solution 98
Measurement procedure 98
MEMO 99
Check & Adjustment100
92ZV-2 Check & Adjustment Chassis Group102
Linkage Pin103
Liner103
Adjustment104
Bucket hinge pin section105
How to assemble105
Center Pin106
Adjusting shim106
Installing bearing cover106
Installing bearing outer ring107
92ZV-2 Check & Adjustment Power Group108
Engine109
Measuring engine speed109
Measurement instrument109
Standard measurement value109
Measuring engine oil pressure109
Measurement instrument109
Install position109
Standard measurement value109
Propeller Shaft110
Propeller shaft phase110
Second propeller shaft alignment110
Tightening torque111
Axle112
Axle nut tightening procedure112
Differential gear adjustment procedure113
Preload adjustment113
Bearing installation114
Oil seal installation114
Adjusting tooth contact115
MEMO117
92ZV-2 Check & Adjustment Torque Converter and Transmission Group118
Clutch Oil Pressure119
Measuring clutch oil pressure119
92ZV-2 Check & Adjustment Hydraulic Group120
Loading/Steering Circuit Relief Valve/Ride Control Circuit Reducing Valve (OPT)121
Loading circuit relief valve setting pressures121
Measurement instruments121
Gauge port121
Standard measurement value MPa (kgf/cm2) (psi)122
Measuring loading circuit main relief pressure122
Measuring loading circuit overload relief pressure124
Measuring pilot circuit relief pressure125
Ride control circuit reducing valve setting pressures (OPT)126
Measurement instruments126
Gauge port126
Standard measurement value MPa (kgf/cm2) (psi)127
Measuring ride control circuit reducing pressure127
Steering circuit relief valve setting pressures129
Measurement instruments129
Gauge port129
Standard measurement value MPa (kgf/cm2) (psi)130
Measuring steering circuit main relief pressure130
Measuring steering circuit overload relief pressure132
Measuring pilot circuit relief pressure (reducing pressure)133
Hydraulic Cylinder134
Cylinder natural drift134
Measurement instrument134
Standard measurement value (mm/min) (in/min)134
Measurement procedure134
Stop Valve136
Stop valve adjustment procedure136
MEMO137
92ZV-2 Check & Adjustment Brake Group138
Brake Circuit Oil Pressure139
Unloader valve setting pressure139
Measurement instrument140
Gauge port140
Standard measurement value140
Measurement procedure140
Brake valve oil pressure141
Measurement instrument141
Gauge port141
Measurement procedure141
Brake valve performance142
Service Brake143
Service brake performance check143
Condition143
Standard measurement value143
Service brake friction plate wear measurement144
Measurement procedure145
Cautions on installing brake discs145
Parking Brake146
Parking brake performance check146
Condition146
Standard measurement value146
Maintenance Log147
Notes151
S.M 3/2/2025