Kawasaki 95ZV-2 Wheel Loader Official Workshop Service Repair Manual
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This is the COMPLETE Official Service Repair Manual for the Kawasaki Wheel Loader.
This manual contains deep information about maintaining, assembly, disassembly and servicing your Kawasaki.
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Models And Serials :
Powered by CUMMINS QSX-15 Engine
Serial No. 97C5-9001 and up
CONTENTS :
95ZV-2 General Information .............00-1
How to Use Manual ......................... 00-2
Safety precautions ............................00-2
Symbols ............................................00-3
Outline ............................................. 00-4
Layout of main components .............00-4
Inspection and maintenance table .................... 00-6
Recommended lubricants ..................................00-9
Coolant ...............................................................00-10
Lubrication chart .................................................00-11
Weight of main components ...............................00-12
Bolt tightening torque ..........................................00-13
Hose band tightening torque ..............................00-17
Liquid gasket and screw lock agent ...................00-18
Cautions regarding welding repair service .........00-20
95ZV-2 Measurement for Performance Check ...03-1
Cautions on Safety ................................................03-2
Standard Measurement Values for Performance Check ...03-3
95ZV-2 Function & Structure Chassis Group ....................12-1
Front Chassis .........................................................................12-2
Loading linkage ........................................................................12-2
Loading linkage pin ..................................................................12-4
Rear Chassis ............................................................................12-5
Fuel tank........................... ........................................................12-5
Floor board mount .....................................................................12-6
Center Pin ..................................................................................12-7
Upper center pin .........................................................................12-7
Lower center pin ..........................................................................12-7
Dust seal ......................................................................................12-8
95ZV-2 Check & Adjustment Chassis Group ...........................13-1
Linkage Pin ...................................................................................13-2
Liner ..............................................................................................13-2
Center Pin .................................................................................... 13-5
Adjusting shim .............................................................................. 13-5
Grease nipple installation direction.................................................13-5
Installing bearing outer ring ..........................................................13-5
95ZV-2 Function & Structure Power Group................................22-1
Power Line ....................................................................................22-2
Engine/ Transmission ..................................................................22-4
Engine/ transmission mount ...........................................................22-4
Radiator (S/N 9001~9150) ............................................................ 22-5
Radiator (S/N 9151~) .................................................................... 22-6
Propeller Shaft ............................................................................. 22-8
Second propeller shaft assembly ...................................................22-9
Third propeller shaft assembly ...................................................... 22-10
Axle Assembly ..............................................................................22-11
Axle Support .................................................................................22-12
Torque Proportioning Type Differential Gear (TPD) ...................22-14
Function of T.P.D ..............................................................................22-17
Operation of T.P.D ............................................................................22-18
Limited Slip Differential (LSD) (option) .......................................22-19
LSD structure ...................................................................................22-19
LSD function ....................................................................................22-23
LSD operation ..................................................................................22-23
95ZV-2 Check & Adjustment Power Group ..................................23-1
Engine ............................................................................................ 23-2
Measuring engine speed ................................................................ 23-2
Measuring engine oil pressure ........................................................ 23-2
Propeller Shaft ..............................................................................23-3
Propeller shaft phase .................................................................... 23-3
Second propeller shaft alignment ................................................. 23-3
Propeller shaft Tightening torque ..................................................23-4
Axle ............................................................................................... 23-5
Axle nut tightening procedure ....................................................... 23-5
Differential gear adjustment procedure...........................................23-6
95ZV-2 Function&Structure Torque Converter and Transmission Group..32-1
Torque Converter ............................................................................32-2
Torque converter structure ..............................................................32-2
Power flow path ..............................................................................32-2
Torque multiplication ......................................................................32-2
Torque Converter (Lock-up) (Option) ..............................................32-3
Lock-up clutch structure ......................................................................32-4
Lock-up clutch function (only forward) .............................................. 32-4
Torque Converter Gear Pump ........................................................32-4
Gear pump specifications ...............................................................32-6
Gear pump specifications ...............................................................32-6
Transmission ....................................................................................32-8
Clutch combination .............................................................................32-8
Planetary gear ...................................................................................32-8
Shift lever position ..............................................................................32-8
Downshifl button operation .................................................................32-8
Gear train and number of teeth ..........................................................32-9
Clutch Pack ......................................................................................32-12
Power Flow Path in the Transmission ........................................32-13
Forward 1st speed power flow path ..................................................32-13
Forward 2nd speed power flow path ............................................... 32-14
Forward 3rd speed power flow path ................................................32-14
Forward 4th speed power flow path ..................................................32-15
Reverse 1st speed power flow path................................................. 32-16
Reverse 2nd speed power flow path ................................................32-16
Reverse 3rd speed power flow path ................................................ 32-17
Hydraulic System Diagram ..........................................................32-18
Hydraulic Circuit Diagram ............................................................32-20
Oil Flow ..........................................................................................32-22
Oil flow in the torque converter line .................................................32-22
Oil flow to the clutch ........................................................................32-23
T/C and T/M Oil Circulation ............................................................32-23
Modulation Valve Unit ...................................................................32-25
Interior schematic (simple explanation)............................................32-27
Modulator valve function ................................................................. 32-28
Modulator valve operation ................................................................ 32-30
Control Valve Assembly ....................................................................32-32
Check valve .................................................................................... 32-34
Clutch solenoid valve assembly ..................................................... 32-35
Clutch valve assembly ..................................................................... 32-39
95ZV-2 Check &Adjustment Torque Converter and Transmission Group..33-1
Clutch Oil Pressure and Time Lag .............................................33-1
Measuring clutch oil pressure .......................................................33-2
Measuring clutch time lag ..............................................................33-4
95ZV-2 Function &Structure Hydraulic Group ......................... 42-1
Flushing Hydraulic Circuit ............................................................42-2
Purpose of flushing ..........................................................................42-2
Cautions on Hydraulic Parts Replacement ............................... 42-3
Hydraulic Circuit Symbols ............................................................42-4
Hydraulic lines ..................................................................................42-4
Pumps &motors ................................................................................42-4
Cylinders ..........................................................................................42-4
Operation methods...........................................................................42-5
Pressure control valve .....................................................................42-5
Flow control valve ............................................................................42-5
Directional control valve .................................................................. 42-6
Check valve .....................................................................................42-6
Miscellaneous hydraulic symbols ....................................................42-7
Hydraulic System Operation ........................................................42-8
Hydraulic system operation outline ..................................................42-8
Layout of Hydraulic Units ..............................................................42-10
Hydraulic Tank ...............................................................................42-11
Hydraulic Tank (S/N 9001-9300) ......................................................42-11
Hydraulic Tank (S/N 9301-) ..............................................................42-13
Hydraulic tank specifications ............................................................42-15
Hydraulic oil level check ....................................................................42-16
Hydraulic Pump ..............................................................................42-17
Loading and pilot and brake pump/Steering pump ...........................42-17
Loading and pilot and brake pump/Steering pump specifications .....42-17
Hydraulic pump principle ...................................................................42-18
Hydraulic pump wear plate ................................................................42-19
Hydraulic pump bushing lubrication ...................................................42-19
Hydraulic Cylinder ......................................................................... 42-20
Boom cylinder ...................................................................................42-20
Bucket cylinder ................................................................................ 42-20
Steering cylinder ..............................................................................42-21
Hydraulic cylinder specifications ......................................................42-22
Loading System .............................................................................42-23
Reducing Valve (for Pilot Pressure) ..............................................42-24
Pilot Valve (S/N 9001-9250) ............................................................42-25
Pilot Valve (S/N 9215-9255) ............................................................42-30
Pilot valve (S/N 9256-) ....................................................................42-35
Multiple Control Valve (KML35A/2T003B) ....................................42-40
Multiple control valve specifications ................................................42-41
Multiple control valve main relief valve ............................................42-42
Multiple control valve overload relief valve (with make-up function) .42-44
Multiple control valve make-up valve ................................................42-45
Multiple control valve bucket spool ...................................................42-46
Multiple control valve boom spool..................................................... 42-48
Adapter (Orifice) ..............................................................................42-51
Ride Control (OPT) ..........................................................................42-52
Ride control hydraulic circuit .............................................................42-52
Ride control operation ......................................................................42-53
Ride control valve assembly (Reducing valve circuit) .....................42-55
Ride control valve assembly (Accumulator circuit) ..........................42-58
Accumulator (for ride control) ..........................................................42-61
Steering System .............................................................................42-62
Orbitrol............................................................................................42-63
Orbitrol structure .............................................................................42-63
Orbitrol specifications ......................................................................42-64
Orbitrol operation .............................................................................42-64
Orbitrol feed-back mechanism operation .........................................42-67
Steering speed and flow rate control ...............................................42-68
Hydraulic pump oil amount and steering force ................................42-68
Orbit rotor operation principle ...........................................................42-69
Steering Valve (KVS32-A4.0/20) ....................................................42-70
Steering valve operation ..................................................................42-72
Steering spool variable throttle ........................................................42-74
Steering valve flow control spool ....................................................42-75
Steering valve main relief valve .......................................................42-76
Steering valve overload relief valve .................................................42-78
Steering pilot circuit and its operation ..............................................42-80
Stop Valve ........................................................................................42-82
Stop valve function ...........................................................................42-83
Stop valve operation ..........................................................................42-83
Reducing Valve (for Orbitrol) .........................................................42-84
Steering Line Filter .........................................................................42-85
K-Lever (OPT) .................................................................................42-86
Hydraulic circuit ................................................................................42-86
Hydraulic line diagram ......................................................................42-87
Hydraulic line ....................................................................................42-88
Solenoid valve assembly (1/2) ........................................................42-90
Solenoid valve assembly (2/2) ........................................................42-91
Efficient Loading System ..............................................................42-92
Efficient loading system outline .......................................................42-92
Mounting of the ELS valve ...............................................................42-93
Mounting of the variable kickout sensor ...........................................42-94
Efficient loading system operation ...................................................42-95
Fan Motor System .........................................................................42-96
Mounting of fan motor .....................................................................42-96
Fan Motor Line ...............................................................................42-97
Hydraulic circuit (fan motor normal rotation) .....................................42-99
Proportional relief valve (SIN 9001-9150) .......................................42-101
Proportional relief valve (S/N 9151-) ...............................................42-103
Fan motor ..................................................................................... 42-105
Reversing Fan Motor Line (OPT) ................................................. 42-108
Reversing fan motor function............................................................42-108
Hydraulic circuit (Reverse rotation) .................................................42-112
Secondary Steering ......................................................................42-113
Secondary steering operation .........................................................42-113
Secondary steering motor and pump ..............................................42-115
95ZV-2 Check & Adjustment Hydraulic Group ..............................43-1
Loading/Steering Circuit Relief Valve/Ride Control Circuit Reducing Valve (OPT) .........43-2
Loading circuit relief valvesetting pressures ......................................43-2
Ride control circuit reducing valve setting pressures (OPT) ............. 43-7
Steering circuit relief valve setting pressures ....................................43-9
Hydraulic Cylinder ...........................................................................43-14
Cylinder natural drift ......................................................................... 43-14
Stop Valve ....................................................................................... 43-17
Stop valve adjustment procedure ......................................................43-17
95ZV-2 Function & Structure Brake Group ....................................52-1
Brake System Outline ..................................................................... 52-2
Service brake .................................................................................... 52-2
Parking brake ................................................................................... 52-2
Adjustment of axle internal pressure ................................................ 52-2
Brake Units Layout ............................................................................52-3
Unloader Valve ..................................................................................52-4
Unloader valve operation................................................................... 52-6
Valve Unit ........................................................................................ 52-7
Accumulator ...................................................................................... 52-9
Brake Valve ....................................................................................52-10
Brake valve performance chart ...................................................... 52-11
Brake valve outline ......................................................................... 52-12
Service Brake ..................................................................................52-14
Service brake operation ................................................................. 52-14
Service brake friction plate.............................................................. 52-15
Service brake steel plate .................................................................52-16
Service brake piston ........................................................................52-17
Service brake pedal stroke adjusting mechanism (S/N 9001-9014)..52-18
Brake circuit air bleeding procedure ................................................52-20
Parking Brake .................................................................................52-22
Parking brake operation ...................................................................52-25
Parking brake friction plate ..............................................................52-27
Parking brake steel plate .................................................................52-27
Parking brake solenoid valve..............................................................52-28
Parking Brake Manual Release .....................................................52-29
Brake Circuit Check Valve .............................................................52-31
Brake Circuit Check Valve .................................................................52-31
Auto Brake ...................................................................................... 52-32
Auto brake circuit ........................................................................... 52-32
Auto brake operation set value ...................................................... 52-32
Solenoid valve (for Autobrake circuit) ..............................................52-33
Pressure Sensor (for stop lamp and declutch) ...........................52-34
Pressure sensor (for declutch) .......................................................52-34
Pressure sensor (for stop lamp) ....................................................52-34
95ZV-2 Check &Adjustment Brake Group ......................................53-1
Brake Circuit Oil Pressure ..............................................................53-2
Unloader valve setting pressure .......................................................53-2
Brake valve oil pressure ...................................................................53-4
Service Brake ...................................................................................53-6
Service brake performance check .....................................................53-6
Service brake friction plate wear measurement ..................................53-7
Cautions on installing brake discs ......................................................53-9
Parking Brake .................................................................................53-10
Parking brake performance check .....................................................53-10
95ZV-2 Function & Structure Electrical Group .............................62-1
How to Use Electrical Wiring Diagram ........................................62-2
Utilisation des sch~mas des c~blages ~lectriques (FRAN&AIS) .62-3
Verwendung des elektrischen Schaltplans (DEUTSCH) ..62-4
Modalit~ di utilizzo dello schema dei collegamenti elettrici (ITALIANO)...62-5
C6mo utilizar un Diagrama de Alambrado El~ctrico (ESPANOL)..62-6
Como Utilizar o Diagrama de Ligacoes El~ctricas (PORTUGUS)..62-7
Electrical Cable Color Codes .........................................................62-8
Electrical Circuit Symbols ..............................................................62-9
Sensor Mount ..................................................................................62-10
Fuse .................................................................................................62-11
Fuse box .........................................................................................62-11
Fusible link .....................................................................................62-13
Engine Start Circuit .......................................................................62-14
Engine start circuit diagram ............................................................ 62-14
Neutral starter .................................................................................62-15
Starter switch ................................................................................. 62-16
Battery relay .................................................................................. 62-17
Alternator I terminal wire ...............................................................62-18
Diode unit .......................................................................................62-18
Neutral relay ...................................................................................62-19
Magnetic switch ..............................................................................62-20
Voltage relay ................................................................................. 62-21
Power Generating/Charging Circuit .......................................... 62-22
Alternator ........................................................................................62-22
ECM (Engine Controller) ..............................................................62-23
Function of ECM ............................................................................62-23
Connection diagram ..................................................................... 62-23
Monitor lamp test ..........................................................................62-24
Failure diagnosis ..........................................................................62-25
Quantum fault code information ...................................................62-28
Accelerator pedal ........................................................................ 62-34
Transmission Control Circuit and Monitor Circuit .................62-37
Machine control unit (MCU) .........................................................62-37
Machine control unit (MCU) connection diagram ..........................62-39
Machine control unit (MCU) function ............................................ 62-41
Adjustable declutch preset switch .................................................62-50
Monitoring system ..........................................................................62-60
Operation monitor lamps .................................................................62-62
Instrument Panel and Switch ........................................................ 62-63
Instrument panel ............................................................................62-63
Instrument panel rear surface ........................................................62-64
Gauge circuit ..................................................................................62-65
Fuel gauge circuit ..........................................................................62-67
MODM ........................................................................................... 62-68
MODM function ...............................................................................62-68
Monitor Changeover .......................................................................62-68
Information Monitor .........................................................................62-71
Replacement Monitor ......................................................................62-75
Fault Log Monitor.............................................................................62-88
Input/Output Monitor ........................................................................62-81
Parameter Setting Monitor .............................................................. 62-92
Specification Setting Monitor ...........................................................62-101
Electrical Detent Circuit ............................................................ 62-107
Bucket leveler .............................................................................. 62-107
Detent solenoid .............................................................................62-108
Lift kickout & lower kickout ............................................................62-109
Sensor assy ................................................................................. 62-111
Detent solenoid ............................................................................ 62-113
Preset height adjustment ............................................................ 62-113
Diode .......................................................................................... 62-114
Diode check method ...................................................................62-115
Caution for diode check method ..................................................62-108
Surge voltage and surge suppression diodes ............................ 62-117
95ZV-2 Function & Structure Operator Station Group ................72-1
Cabin ........................................................................................... 72-2
Glass .............................................................................................. 72-3
Wiper mount .................................................................................. 72-6
Wiper motor ................................................................................... 72-7
Operator Seat ..................................................................................72-9
Steering and Transmission Shift Lever .......................................72-10
Tilt case ...........................................................................................72-11
Column shaft ...................................................................................72-12
Shift lever ........................................................................................72-12
Air Conditioner ..............................................................................72-13
Denso air conditioner components .................................................. 72-13
Denso air conditioner structure ........................................................ 72-14
Function of cooling mechanism ...................................................... 72-19
Cooling circuit .............................................................................. 72-22
Electrical circuit ............................................................................. 72-23
Air conditioner functions of components .........................................72-24
Charge of refrigerant ...................................................................... 72-52
Air conditioner troubleshooting .......................................................72-69
95ZV-2 Check &Adjustment Operator Station Group .................... 73-1
Air Conditioner ................................................................................73-2
Adjustment of lubricating oil quantity when components of air conditioner are replaced ................... 73-2
Adjustment of air gap (between hub and rotor) in compressor magnetic clutch ...............................73-5
Compressor V-belt adjustment ...........................................................73-6
Parts to be replaced periodically..........................................................73-7
95ZV-2 Drawing &Diagrams .............................................................92-1
Axle Assembly ................................................................................. 92-2
Torque Converter and Transmission ............................................. 92-3
Hydraulic &Brake Circuit (S/N 9001-9250) ................................... 92-4
Brake Circuit ................... ................................................................92-6
Electrical Wiring Diagram (1/3) (S/N 9001-9048) ........................... 92-7
Electrical Wiring Diagram (2/3) (S/N 9001-9048) ............................ 92-8
Electrical Wiring Diagram (3/3) (S/N 9001-9042) ............................ 92-9
Electrical Wiring Diagram (1/3) (S/N 9049-9250) .......................... 92-10
Electrical Wiring Diagram (2/3) (S/N 9049-9250) ...........................92-11
Electrical Wiring Diagram (3/3) (S/N 9049-9250) .......................... 92-12
Electrical Wiring Diagram (1/3) (S/N 9101-9251) ...........................92-13
Electrical Wiring Diagram (2/3) (S/N 9101-9251) ...........................92-14
Electrical Wiring Diagram (3/3) (S/N 9101-9251) ...........................92-15
Electrical Wiring Diagram .............................................................. 92-16
Way of looking at connectors ....................................................... 92-16
Electrical wiring diagram abbreviation chart ...............................92-18
Electrical Wiring Diagram (CAB) ...................................................92-19
Electrical Connection Diagram (1/2) (S/N 9001-9250) .................92-22
Electrical Connection Diagram (2/2) (S/N 9001-9250) .................92-23
Electrical Connection Diagram (1/2) (S/N 9251-) .........................92-24
Electrical Connection Diagram (2/2) (S/N 9251-) .........................92-25
Electrical Wiring Diagram (Cabin Air Conditioner) ...................... 92-26
Electrical Circuit Diagram (Cabin Air Conditioner) .................... 92-27
Equipment Operation Table (Cabin Air Conditioner) .................92-28
Electrical Equipment Layout ....................................................... 92-29
Electrical Equipment Layout (K-Lever) .........................................92-46
Outline of MODM (Machine Operation Diagnostic Module) Operation ..92-41
MODM:Input/Output Monitor-Input/Output Signal Correspondence Table.92-50
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