Within the hour you might be teeing a 30 MPa gauge into the bucket cylinder bottom side, or reading CN codes off the monitor of an 80ZV-2 that quit mid-shift. This set covers serial 80C5-900x and up. That means the Cummins QSC8.3, the MCU/ECM electronics and the full loader hydraulics.
Every hour the loader sits, a pile doesn't get moved and a truck waits at the face. These are the numbers you actually set to: 20.6±0.5 MPa loading main relief, 11.8±0.5 MPa accumulator cut-out, and clutch pressure at idle and full throttle.
Book 93209-00442 holds function, checks and the wiring diagrams by serial range. Book 93209-00451 is teardown and service standards. Book 93209-00460 is troubleshooting by symptom, so a drifting boom takes you straight to its causes.
What's Inside This Manual
| System | Pages | Key Topics |
|---|---|---|
| General Information (Book 93209-00442) | 1-37 | Safety, Symbols, Recommended Lubricants, Coolant Mixture, Bolt Tightening Torque Tables, Liquid Gasket and Screw Lock Agents |
| Measurement for Performance Check | 38-43 | Standard Measurement Values, Clutch Time Lag, Engine Speed and Pressure Checks |
| Chassis Group: Function, Structure, Check & Adjustment | 44-59 | Front and Rear Chassis, Loading Linkage, Center Pin, Fuel Tank |
| Power Group: Function, Structure, Check & Adjustment | 60-91 | Engine and Transmission Mounts, Propeller Shafts, Axles, Differential Gear, T.P.D |
| Torque Converter and Transmission Group | 92-123 | Torque Converter Gear Pump, Power Flow Paths by Speed, Hydraulic Circuit, Clutch Oil Pressure Measurement |
| Hydraulic Group: Function & Structure | 124-229 | Hydraulic Circuit Flushing, Multiple Control Valve, Pilot Reducing Valve, Steering, Fan Motor System, Efficient Loading System |
| Hydraulic Group: Check & Adjustment | 230-245 | Loading Circuit Main and Overload Relief Pressure, Pilot Circuit Relief, Cylinder Natural Drift |
| Brake Group: Function, Structure, Check & Adjustment | 246-285 | Brake Valve, Accumulator Charge Cut-In and Cut-Out, Parking Brake |
| Electrical Group: Function & Structure | 286-399 | MCU and ECM Functions, Fuses and Fusible Link, Monitor and Fault Log, CN/EN Failure Codes, Solenoid Valves |
| Operator Station Group | 400-498 | Cabin, Operator Seat, Denso Air Conditioner with R134a, A/C Troubleshooting |
| Drawings & Diagrams | 499-560 | Hydraulic and Brake Circuit, Electrical Wiring Diagrams by Serial Range, Electrical Equipment Layout, MODM |
| Disassembly & Reassembly: General Information (Book 93209-00451) | 561-587 | Foreword, Contents, General Cautions |
| Disassembly & Reassembly: Chassis Group and Service Standards | 588-623 | Cab, Linkage, Center Pin Removal and Installation |
| Disassembly & Reassembly: Power Group and Service Standards | 624-691 | Engine Removal, Axles, Differential, Propeller Shafts |
| Disassembly & Reassembly: Torque Converter and Transmission | 692-747 | Torque Converter and Transmission Assembly Overhaul, Service Standards |
| Disassembly & Reassembly: Hydraulic Group | 748-823 | Hydraulic Cylinders, Pilot Valve, Orbitrol, Control Valve, Service Standards |
| Disassembly & Reassembly: Brake Group | 824-861 | Brake Components Overhaul and Service Standards |
| Disassembly & Reassembly: Operator Station Group | 862-888 | Cab Components and Service Standards |
| Troubleshooting (Book 93209-00460) | 889-949 | Hydraulic, Steering and Brake Symptoms with Causes Such As Relief Valve Leakage and Cylinder Seal Leakage |
| Measurement for Performance Check (Book 93209-00460) | 950-1006 | Safety Cautions, Measurement Procedures and Record Sheets |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Engine | CUMMINS QSC8.3 | p. 1 |
| Loading line main relief pressure (at maximum speed) | 20.6±0.5 MPa (210±5 kgf/cm2) (2,986±71 psi) | p. 231 |
| Pilot reducing valve set pressure | 3.5 MPa (36 kgf/cm2) (512 psi) | p. 146 |
| Brake accumulator cut-out pressure | 11.8±0.5 MPa (120±5 kgf/cm2) (1,706±71 psi) | p. 276 |
| Brake accumulator cut-in pressure | 6.9±1.0 MPa (70±10 kgf/cm2) (995±142 psi) | p. 276 |
| Clutch oil pressure | 1.3±0.2 MPa (13±2 kgf/cm2) (185±28 psi) at engine idling speed (LI); 1.5±0.2 MPa (15±2 kgf/cm2) (213±28 psi) at engine maximum speed (HI) | p. 123 |
| Torque converter gear pump theoretical displacement | 64.5 cc/rev (3.9 in3/rev) | p. 94 |
| Torque converter gear pump maximum operation speed | 2,400 min-1 (rpm) | p. 94 |
| Clutch time lag, Neutral to Forward 1st (engine 1,500 rpm) | 0.3±0.1 sec | p. 40 |
| Coolant antifreeze in hot climates | 33 % antifreeze mixture | p. 25 |
| Air conditioner refrigerant | R134a | p. 419 |
