KCM WHEEL LOADER 92ZV-2 SHOP MANUAL 93221-00022 – PDF DOWNLOAD

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KCM WHEEL LOADER 92ZV-2 SHOP MANUAL 93221-00022 – PDF DOWNLOAD

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KCM WHEEL LOADER 92ZV-2 SHOP MANUAL 93221-00022 – PDF DOWNLOAD

Language :English
Pages :553
Downloadable : Yes
File Type : PDF

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DESCRIPTION:

KCM WHEEL LOADER 92ZV-2 SHOP MANUAL 93221-00022 – PDF DOWNLOAD

General Information
Standard Measurement Values for
Performance Check
Function & Structure
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 Operator and
  Maintenance Manual.
• To effectively diagnose and repair the machine, it is important to follow the guidelines laid out
  in this Shop Manual.

• 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 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.

TABLE OF CONTENTS:

KCM WHEEL LOADER 92ZV-2 SHOP MANUAL 93221-00022 – PDF DOWNLOAD

General Information
Standard Measurement Values for
Performance Check
Function & Structure
Check & Adjustment
Powered by CUMMINS QSM11 ENGINE
Serial No. 92C1-9001 and up

Foreword 2
Safety Symbols 3
CONTENTS 4
00 General Information 16
How to Use Manual 17
Safety precautions 17
Symbols 18
Outline 19
Layout of main components 19
Inspection and maintenance table 20
Recommended Lubricants 23
Coolant 25
Coolant specification 25
Recommended mixture of antifreeze 25
Lubrication chart 26
Weight of main components 27
Bolt tightening torque 28
Hexagon bolt 28
Flanged hexagon bolt 31
Hose band tightening torque 32
Liquid gasket and screw lock agent 33
Cautions regarding parts removal 33
Cautions regarding reassembly 33
Screw lock agent application procedure 34
How to wind a seal tape 34
Cautions regarding welding repair service 35
03 Measurement for Performance Check 38
Cautions on Safety 39
Standard Measurement Values for Performance Check 40
12 Function & Structure Chassis Group 44
Front Chassis 45
Loading linkage 45
Loading linkage pin 47
Rear Chassis 48
Fuel tank 48
Floor board mount 49
Floor board 49
Viscous mount 49
Center Pin 50
Upper center pin 50
Lower center pin 50
Dust seal 51
13 Check & Adjustment Chassis Group 52
Linkage Pin 53
Liner 53
Adjustment 54
Bucket hinge pin section 55
How to assemble 55
Center Pin 56
Adjusting shim 56
Installing bearing cover 56
Installing bearing outer ring 57
22 Function & Structure Power Group 58
Power Line 59
Engine / Transmission 60
Engine / transmission mount 60
Radiator 61
Radiator mount 63
Torque converter oil cooler 64
Propeller Shaft 65
Second propeller shaft assembly 66
Third propeller shaft assembly 67
Axle Assembly 68
Axle Support 70
Torque Proportional Differential Gear (TPD) 72
Function of TPD 74
Operation of TPD 75
Limited Slip Differential (LSD) (option) 76
LSD structure 76
LSD function 79
LSD operation 79
23 Check & Adjustment Power Group 80
Engine 81
Measuring engine speed 81
Measuring engine oil pressure 81
Propeller Shaft 82
Propeller shaft phase 82
Second propeller shaft alignment 82
Propeller shaft tightening torque 83
Axle 84
Axle nut tightening procedure 84
Differential gear adjustment procedure 85
Preload adjustment 86
Bearing installation 86
Oil seal installation 86
Adjusting tooth contact 87
32 Function & Structure Torque Converter and Transmission Group 90
Torque Converter 91
Torque converter structure 91
Power flow path 91
Torque multiplication 91
Torque Converter (Lock-up) (Option) 92
Lock-up clutch structure 93
Lock-up clutch function (only forward) 93
Automatic shift (with lock-up solenoid) 94
Torque Converter Gear Pump 95
Gear pump specifications 95
Gear pump specifications 96
Transmission 97
Clutch combination 97
Shift lever position 97
Downshift button operation 97
Gear train and number of teeth 98
Clutch specifications 99
Friction plate: mm (in) 99
Clutch Pack100
Forward and 3rd speed clutches100
Reverse and 2nd speed clutches101
1st speed clutch102
4th speed clutch103
Power Flow Path in the Transmission104
Forward104
Forward 1st speed104
Forward 2nd speed104
Forward 3rd speed105
Forward 4th speed105
Reverse106
Reverse 1st speed106
Reverse 2nd, 3rd, and 4th speeds106
Hydraulic System Diagram107
Hydraulic Circuit Diagram108
Oil Flow109
Oil flow in the torque converter line109
From torque converter gear pump to torque converter109
From torque converter to cooling circuit109
From cooler to lubrication circuit109
Oil flow to the clutch109
To forward and reverse clutches109
To speed clutch109
T/C and T/M Oil Circulation110
Control Valve111
System diagram112
Modulation Mechanism113
Clutch control oil pressure curve114
Traveling at forward 1st speed115
Pressure holding115
Changing from forward 1st speed to reverse 1st speed116
Releasing forward clutch and feeding initial oil to reverse clutch116
Trimmer engagement117
Low-pressure holding117
Clutch engagement starting118
Pressure increase118
Clutch Solenoid Valve119
For forward/reverse and speed clutches119
After power-off (clutch disengaged status)119
After power-on (clutch engaged status)120
For trimmer121
After power-off (high clutch pressure status)121
After power-on (just after switching clutch)122
Lock-up clutch solenoid valve (option)123
33 Check & Adjustment Torque Converter and Transmission Group126
Clutch Oil Pressure127
Measuring clutch oil pressure127
Clutch oil pressure standard value127
42 Function & Structure Hydraulic Group128
Flushing Hydraulic Circuit129
Purpose of flushing129
Cautions on Hydraulic Parts Replacement130
Hydraulic Circuit Symbols131
Hydraulic lines131
Pumps & motors131
Cylinders131
Operation methods132
Pressure control valve132
Flow control valve132
Directional control valve133
Check valve133
Miscellaneous hydraulic symbols134
Hydraulic System Operation135
Hydraulic system operation outline135
Loading system135
Steering system135
Efficient loading system136
Fan motor system136
Ride control system (OPT)136
Layout of Hydraulic Units137
Hydraulic Tank138
Hydraulic Tank (S/N 9001~9100)138
Hydraulic tank breather valve (tank cap) (S/N 9001~9100)139
Hydraulic tank (S/N 9101~)140
Hydraulic tank breather valve (tank cap) (S/N 9101~)141
Hydraulic tank specifications142
Hydraulic oil level check143
Hydraulic Pump144
Main pump144
Main pump specifications144
Steering pump145
Steering pump specifications145
Hydraulic pump principle146
Hydraulic pump wear plate147
Hydraulic pump bushing lubrication147
Hydraulic Cylinder148
Boom cylinder148
Bucket cylinder149
Steering cylinder151
Hydraulic cylinder specifications152
Loading System153
Reducing Valve (for Pilot Pressure)154
Pilot valve (S/N 9001~9004)155
Pilot valve function157
Pilot valve operation (modulated position)157
Pre-detent and detent magnet solenoid159
Pilot valve (S/N 9005~9100)160
Pilot valve function162
Pilot valve operation (modulated position)162
Pre-detent and detent magnet solenoid164
Pilot valve (S/N 9101~)165
Pilot valve function167
Pilot valve operation (modulated position)167
Pre-detent and detent magnet solenoid169
Multiple Control Valve (KML35A/2T203)170
Multiple control valve specifications171
Multiple control valve main relief valve172
Main relief valve operation172
Adjusting set pressure173
Multiple control valve overload relief valve (with make-up function)174
Overload relief valve operation174
Make-up valve operation175
Adjusting set pressure175
Multiple control valve make-up valve176
Make-up valve operation176
Multiple control valve bucket spool177
Bucket spool operation177
Multiple control valve boom spool179
Boom spool operation179
Adapter (Orifice)182
Ride Control (OPT)183
Ride control hydraulic circuit183
Ride control function183
Ride control operation184
Preparation mode (ride control switch is OFF)184
Running mode (ride control switch is ON)185
Ride control valve assembly186
Solenoid valve189
Accumulator (for ride control)191
Accumulator function191
Steering System192
Orbitrol®193
Orbitrol® structure193
Valve part193
Rotor part194
Orbitrol® specifications194
Orbitrol® operation195
Neutral195
Turn196
Orbitrol® feed-back mechanism operation197
Steering speed and flow rate control198
Hydraulic pump oil amount and steering force198
Orbit rotor operation principle199
Steering Valve (KVS25-A30/20)200
Steering valve operation202
Neutral position (steering spool in “Neutral”)202
Left turn position203
Steering plunger variable throttle204
Steering valve flow control plunger205
Steering valve main relief valve206
When the pressure is at the preset value or less206
When the pressure exceeds the preset value207
Steering valve overload relief valve208
Overload relief valve operation209
Make-up valve operation209
Steering pilot circuit and its operation210
Flow amplifier notch and pilot orifice211
Stop Valve212
Stop valve function213
Stop valve operation213
Reducing Valve (for Orbitrol®)214
Steering Line Filter215
Efficient Loading System216
Efficient loading system outline216
The operation condition of ELS216
Mounting of the ELS valve217
Mounting of the variable kickout sensor218
Efficient loading system operation219
While the ELS is not operating219
While the ELS is operating219
Fan Motor System220
Mounting of fan motor220
Fan Motor Line221
Hydraulic circuit (fan motor normal rotation)223
Safety valve (with suction function)223
Flow control valve224
Flow control solenoid valve225
Fan motor226
Relief valve229
Reversing Fan Motor Line (OPT)230
Reversing fan motor function230
Fan motor231
Reversing fan control chart233
Hydraulic circuit (Reverse rotation)234
Secondary Steering235
Secondary steering operation236
Secondary steering motor and pump237
43 Check & Adjustment Hydraulic Group238
Loading/Steering Circuit Relief Valve/Ride Control Circuit Reducing Valve (OPT)239
Loading circuit relief valve setting pressures239
Measuring loading circuit main relief pressure241
Measuring loading circuit overload relief pressure242
Measuring pilot circuit relief pressure243
Ride control circuit reducing valve setting pressures (OPT)244
Measuring ride control circuit reducing pressure246
Steering circuit relief valve setting pressures247
Measuring steering circuit main relief pressure249
Measuring steering circuit overload relief pressure250
Measuring pilot circuit relief pressure (reducing pressure)251
Hydraulic Cylinder252
Cylinder natural drift252
Stop Valve254
Stop valve adjustment procedure254
52 Function & Structure Brake Group256
Brake System Outline257
Service brake257
Parking brake257
Adjustment of axle internal pressure257
Brake Units Layout258
Unloader Valve259
Unloader valve operation260
Valve Unit261
Accumulator low pressure sensor262
Accumulator263
In-Line Filter264
Brake Valve265
Brake valve performance chart266
Brake valve outline267
While the valve is not operating267
While the valve is operating268
While the valve is releasing268
Service Brake269
Service brake operation269
Service brake friction plate270
Service brake steel plate270
Service brake piston271
Brake circuit air bleeding procedure272
Bleeding air from brake pipes and axle housing hubs273
Bleeding air from parking brake housing273
Parking Brake274
Parking brake operation275
Operation of parking brake276
Parking brake friction disc277
Friction plate277
Steel plate278
Parking brake solenoid valve279
Solenoid valve operation279
Solenoid valve specifications279
Parking Brake Manual Release280
Brake Circuit Check Valve281
Auto Brake282
Auto brake circuit282
Auto brake operation set value283
Solenoid valve (for Autobrake circuit)284
Solenoid specifications284
Pressure Sensor (for stop lamp and declutch)285
Pressure sensor (for declutch)285
Pressure sensor (for stop lamp)285
53 Check & Adjustment Brake Group288
Brake Circuit Oil Pressure289
Unloader valve setting pressure289
Brake valve oil pressure291
Brake valve performance292
Service Brake293
Service brake performance check293
Service brake friction plate wear measurement294
Cautions on installing brake discs295
Parking Brake296
Parking brake performance check296
62 Function & Structure Electrical Group298
How to Use Electrical Wiring Diagram299
Utilisation des schémas des câblages électriques (FRANÇAIS)300
Verwendung des elektrischen Schaltplans (DEUTSCH)301
Modalità di utilizzo dello schema dei collegamenti elettrici (ITALIANO)302
Cómo utilizar un Diagrama de Alambrado Eléctrico (ESPAÑOL)303
Como Utilizar o Diagrama de Ligações Eléctricas (PORTUGUÊS)304
Electrical Cable Color Codes305
Electrical Circuit Symbols306
Sensor Mount307
Fuse308
Fuse box308
Fusible link310
Engine Start Circuit311
Engine start circuit diagram311
Neutral starter311
Shift lever neutral (N) position311
Shift lever forward/reverse (F/R) position312
Starter switch313
ECM safety features314
Battery relay314
Battery relay operation314
Alternator I terminal wire315
Diode unit315
Neutral relay316
Magnetic switch317
Voltage relay318
Power Generating/Charging Circuit319
Alternator319
ECM (Engine Controller)320
Function of ECM320
Connection diagram320
Monitor lamp test321
Failure diagnosis322
Engine diagnostic switch (option)322
Failure diagnostic chart323
Increment decrement switch (option)324
Quantum fault code information325
Accelerator pedal331
Accelerator pedal installation333
Transmission Control Circuit and Monitor Circuit334
Machine control unit (MCU)334
Connector335
Machine control unit (MCU) connection diagram (S/N 9001~9200)336
Machine control unit (MCU) connection diagram (S/N 9201~)338
Machine control unit (MCU) function340
Forward/reverse (F/R) shifting and speed change340
Automatic shift343
Automatic shift (with lock-up solenoid)343
Machine speed sensor344
Switching from automatic to manual345
Downshift button operation345
Adjustable declutch preset switch346
Back-up alarm347
Parking brake348
Auto brake350
Machine control unit (MCU) failure warning353
Secondary steering function354
Monitoring system355
Items to be monitored and operation condition355
Operation monitor lamps357
Instrument Panel and Switch358
Instrument panel358
Instrument panel rear surface360
Gauge circuit362
Fuel level sensor364
MODM365
MODM function365
Monitor Changeover365
Changing display from one function to next366
Information Monitor368
Information monitor display368
Unit conversion and language selection371
Replacement Monitor372
Replacement time check372
Replacement interval set (timer reset)376
Replacement interval pop-up377
Display language378
Fault Log Monitor378
Fault log history check378
Selection of machine fault log and engine fault log379
Machine fault log navigation380
Engine fault log navigation380
Clear fault log380
Input/Output Monitor384
Input/Output monitor display384
Parameter Setting Monitor388
Parameter setting monitor display388
Specification Setting Monitor397
Specification setting monitor display397
All setting reset400
Default position of specification setting monitor402
Electrical Detent Circuit403
Bucket leveler403
Proximity switch403
Detent solenoid404
Lift kickout & lower kickout405
Location405
Lift kickout406
Lower kickout406
Sensor assy407
Detent solenoid409
Preset height adjustment409
Diode410
Diode check method411
Caution for diode check method411
Continuity check mode411
Diode check mode411
Resistance check mode412
Surge voltage and surge suppression diodes413
72 Function & Structure Operator Station Group414
Cabin415
Glass416
1 Part number 32011-21690417
2 Part number 32011-21700417
3 Part number 32011-21500418
Wiper mount419
Front wiper419
Rear wiper419
Wiper motor420
Operator Seat422
Steering and Transmission Shift Lever423
Tilt case424
Column shaft425
Shift lever425
Air Conditioner426
Air conditioner components426
Air conditioner specifications (system performance)426
Denso air conditioner structure427
Cooling unit427
Heater and accessories429
Air distributor (hood & defroster selection box)429
Air compressor (with magnetic clutch)430
Condenser unit430
Control unit431
Function of cooling mechanism432
Principle of cooling432
Refrigerant433
Refrigerant characteristics434
Cooling circuit435
Electrical circuit436
Control schematic drawing436
Air conditioner functions of components437
Control panel437
Air conditioner unit444
Compressor and magnetic clutch453
Condenser unit456
Receiver dryer458
Sight glass460
Pressure switches460
Pressure relief valve462
Relay A463
Relay B463
Refrigerant hose464
Charge of refrigerant465
Work procedure466
Refrigerant charging tools468
Refrigerant charging procedure471
Troubleshooting using the gauge manifold477
Air conditioner troubleshooting482
73 Check & Adjustment Operator Station Group490
Air Conditioner491
Adjustment of lubricating oil quantity when components of air conditioner are replaced491
When the compressor is replaced492
When the evaporator is replaced493
When the condenser is replaced493
Adjustment of air gap (between hub and rotor) in compressor magnetic clutch494
Compressor V-belt adjustment495
Belt adjustment procedure496
Parts to be replaced periodically497
Air filters497
Receiver dryer497
INDEX498
Maintenance Log503
Notes507
92 Drawing & Diagrams511
Axle Assembly512
Torque Converter and Transmission513
Hydraulic & Brake Circuit514
Brake Circuit515
Electrical Wiring Diagram (1/3) (S/N 9001~9200)516
Electrical Wiring Diagram (2/3) (S/N 9001~9200)517
Electrical Wiring Diagram (3/3) (S/N 9001~9200)518
Electrical Wiring Diagram (1/3) (S/N 9201~)519
Electrical Wiring Diagram (2/3) (S/N 9201~)520
Electrical Wiring Diagram (3/3) (S/N 9201~)521
Electrical Wiring Diagram522
Way of looking at connectors522
Electrical wiring diagram abbreviation chart524
Electrical Connection Diagram (1/2) (S/N 9001~9200)526
Electrical Connection Diagram (2/2) (S/N 9001~9200)527
Electrical Connection Diagram (1/2) (S/N 9201~)528
Electrical Connection Diagram (2/2) (S/N 9201~)529
Electrical Wiring Diagram (CAB)530
Electrical Wiring Diagram (Cabin Air Conditioner)532
Electrical Circuit Diagram (Cabin Air Conditioner)533
Equipment Operation Table (Cabin Air Conditioner)534
Electrical Equipment Layout535
Outline of MODM (Machine Operation Diagnostic Module) Operation544
MODM: Input/Output Monitor – Input/Output Signal Correspondence Table553

S.M 3/2/2025