Kawasaki 95ZV-2 Wheel Loader Official Workshop Service Repair Manual

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. 

This PDF file is Bookmarked and SEARCHABLE to make what you need easy to find. 

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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