Kawasaki 92ZV-2 WHEEL LOADER SHOP MANUAL 93221-00061 – PDF DOWNLOAD

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Kawasaki 92ZV-2 WHEEL LOADER SHOP MANUAL 93221-00061 – PDF DOWNLOAD

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Kawasaki 92ZV-2 WHEEL LOADER SHOP MANUAL 93221-00061 – PDF DOWNLOAD

Language :English
Pages :322
Downloadable : Yes
File Type : PDF

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DESCRIPTION:

Kawasaki 92ZV-2 WHEEL LOADER SHOP MANUAL 93221-00061 – PDF DOWNLOAD

Disassembly & Reassembly
Service Standard
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.

TABLE OF CONTENTS:

Kawasaki 92ZV-2 WHEEL LOADER SHOP MANUAL 93221-00061 – PDF DOWNLOAD

Disassembly & Reassembly
Service Standard
Powered by CUMMINS QSM11 ENGINE
Serial No. 92C1-9001 and up

Foreword 2
Safety precautions 3
Safety Symbols 4
CONTENTS 6
00 General Information 12
Symbols 13
Weight of Main Components 14
Bolt Tightening Torque 15
Hose Band Tightening Torque 19
Liquid Gasket and Screw Lock Agent 20
Cautions regarding parts removal 20
Cautions regarding reassembly 20
Screw lock agent application procedure 21
How to wind a seal tape 21
Cautions Regarding Welding Repair Service 22
Cautions Regarding Handling of Bearing 24
Bearing installation cautions 24
Interference fits for a bearing 24
Bearing operation test after installation 25
Bearing removal cautions 25
Applying and Storing Articulation Stopper 26
Applying articulation stopper 26
Storing articulation stopper 27
14 Disassembly & Reassembly Chassis Group 28
Deck 29
Deck removing and installing 29
Deck removing 29
Deck installing 30
Fuel Tank 31
Fuel tank removing and installing 31
Fuel tank removing 31
Fuel tank installing 31
Fuel tank installation cautions 31
Hydraulic Tank 32
Hydraulic tank removing and installing 32
Hydraulic tank removing 32
Hydraulic tank installing 33
Hydraulic tank installation cautions 33
Engine Room 34
Engine room removing and installing 34
Engine room removing 34
Engine room installing 36
Engine room installation cautions 36
Cab 37
Cab removing and installing 37
Cab removing 37
Cab installing 38
Floor Board 39
Floor board removing and installing 39
Floor board removing 39
Floor board installing 41
Floor board installation cautions 41
Boom 42
Boom removing and installing 42
Boom removing 42
Boom installing 44
Boom installation cautions 44
Center Pin 45
Upper center pin 45
Center pin shim adjustment 45
Lower center pin 46
Center pin removing and installing 47
Center pin removing 47
Center pin installing 50
Center pin installation cautions 50
Partition Plate 51
Partition plate removing and installing 51
Partition plate removing 51
Partition plate installing 52
Lower Cover 53
Lower cover removing and installing 53
Lower cover removing 53
Lower cover installing 53
15 Service Standard Chassis Group 54
Linkage 55
Linkage Pin Standard Clearance Values 56
Liner clearance adjustment 56
Center Pin 57
Center pin shim adjustment 57
Bearing cover installing 57
Lower center pin bearing outer ring installing 58
Attachment Leveler 59
Attachment leveler 60
Attachment leveler adjustable angle 60
24 Disassembly & Reassembly Power Group 62
Power Line 63
Power line tightening torque 63
Radiator 64
Radiator tightening torque 64
Radiator removing and installing 65
Radiator removing 65
Radiator installing 67
Radiator core removing and installing 68
Radiator core removing 68
Radiator core installing 69
Fan 70
Fan removing and installing 70
Fan removing 70
Fan installing 70
Fan installation cautions 71
Engine 72
Engine removing and installing 72
Engine removing 72
Engine installing 74
Engine installation cautions 74
Propeller Shaft 75
Propeller shaft removing and installing 75
Second propeller shaft removing 75
Third propeller shaft removing 76
Propeller shaft installing 76
Propeller shaft installation cautions 76
Air Cleaner 77
Air cleaner removing and installing 77
Air cleaner removing 77
Air cleaner installing 78
Air cleaner installation cautions 78
Muffler 79
Muffler removing and installing 79
Muffler removing 79
Muffler installing 79
Muffler installation cautions 79
Front Axle Assembly 80
Front axle assembly tightening torque 80
Axle nut tightening procedure 81
Floating seal installing 81
Front axle assembly removing and installing 82
Front axle assembly removing 82
Front axle assembly installing 84
Front axle assembly installation cautions 84
Service brake air bleeding procedure 84
Front axle disassembling and assembling 85
Front axle disassembling 85
Front axle assembling 88
Front axle assembly cautions 88
Floating seal installing 88
Internal gear hub installing 90
Axle nut tightening 91
Brake adjustment 91
Internal Gear Hub 93
Internal gear hub disassembling and assembling 93
Internal gear hub disassembling 93
Internal gear hub assembling 94
Internal gear hub assembly cautions 95
Spider Assembly 96
Spider assembly disassembling and assembling 96
Spider assembly disassembling 96
Spider assembly assembling 96
Spider assy assembly cautions 97
Special Tool 98
Special tool for axle 98
Rear Axle Assembly102
Rear axle assembly tightening torque102
Axle nut tightening procedure103
Floating seal installing103
Rear axle assembly removing and installing104
Rear axle assembly removing104
Rear axle assembly installing106
Rear axle disassembling and assembling106
Axle Support107
Axle support tightening torque107
Axle support disassembling and assembling108
Axle support disassembling108
Axle support assembling108
Axle support assembly cautions109
Bushing installing109
Differential Assembly110
Differential assembly removing and installing110
Differential assembly removing110
Differential assembly installing112
Differential assembly installation cautions112
Front differential tightening torque113
Rear differential tightening torque114
Differential assembly disassembling115
Differential assembly assembling119
25 Service Standard Power Group126
Propeller Shaft Service Standard127
Axle and Differential Service Standard128
Axle group128
Differential129
34 Disassembly & Reassembly T/C and T/M130
Torque Converter and Transmission Assembly131
Torque converter and transmission assembly tightening torque131
Torque converter and transmission assembly removing and installing132
Torque converter and transmission assembly removing132
Torque converter and transmission assembly installing137
Transmission assembly installation cautions138
Torque Converter Assembly140
Torque converter assembly tightening torque140
Torque converter assembly disassembling and assembling141
Torque converter assembly disassembling141
Torque converter assembly assembling146
Lock-up torque converter disassembling and assembling147
Lock-up torque converter disassembling147
Lock-up torque converter assy assembling148
Lock-up torque converter assy assembly cautions148
Transmission Assembly149
Transmission assembly tightening torque149
Transmission assembly disassembling and assembling150
Transmission assembly disassembling150
Transmission assembly assembling153
Cautions regarding reassembly153
Transmission Forward/Reverse Clutch Pack156
Forward/reverse clutch pack disassembling and assembling156
Forward/reverse clutch pack disassembling156
Forward/reverse clutch pack assembling158
Forward/reverse clutch pack assembly cautions158
Transmission 1st/3rd Speed Clutch Pack159
Transmission 1st/3rd speed clutch pack disassembling and assembling159
Transmission 1st/3rd speed clutch pack disassembling159
Transmission 1st/3rd speed clutch pack assembling160
Transmission 1st/3rd speed clutch pack assembly cautions160
Transmission 2nd Speed Clutch Pack161
Transmission 2nd speed clutch pack disassembling and assembling161
Transmission 2nd speed clutch pack disassembling161
Transmission 2nd speed clutch pack assembling162
Transmission 2nd speed clutch pack assembly cautions162
Transmission 4th Speed Clutch Pack163
Transmission 4th speed clutch pack disassembling and assembling163
Transmission 4th speed clutch pack disassembling163
Transmission 4th speed clutch pack assembling164
Transmission 4th speed clutch pack assembly cautions164
Control Valve Assembly166
Control valve tightening torque166
Control valve removing and installing167
Control valve removing167
Control valve installation cautions168
Control valve disassembling and assembling169
Control valve disassembling169
Control valve assembling171
Control valve assembly cautions171
35 Service Standard T/C and T/M172
Transmission Assembly173
Control Valve175
Torque Converter Gear Pump176
Gear pump specifications176
Clutch Plate Thickness/Piston Stroke177
Clutch plate178
Piston stroke178
Clutch Oil Pressure179
Clutch oil pressure standard value179
44 Disassembly & Reassembly Hydraulic Group180
Hydraulic Parts Removal and Installation Warning181
Hydraulic Parts Disassembly and Assembly Cautions182
Hydraulic parts disassembly cautions182
Hydraulic parts assembly cautions182
Hydraulic Pump Assembly183
Hydraulic pump assembly removing and installing183
Hydraulic pump assembly removing183
Hydraulic pump assembly installing183
Hydraulic pump installation cautions183
Hydraulic pump assembly disassembling and assembling184
Hydraulic pump assembly cross section and tightening torque185
Oil seal replacement procedure187
Loading and pilot and brake pump disassembling188
Loading and pilot and brake pump assembling191
Loading and pilot and brake pump assembly cautions191
Steering pump disassembling193
Steering pump assembling196
Steering pump assembly cautions196
Hydraulic Cylinder198
Boom cylinder removing and installing198
Boom cylinder removing198
Boom cylinder installing199
Boom cylinder installation cautions199
Bucket cylinder removing and installing200
Bucket cylinder removing200
Bucket cylinder installing201
Bucket cylinder installation cautions202
Steering cylinder removing and installing203
Steering cylinder removing203
Steering cylinder installing204
Steering cylinder installation cautions204
Hydraulic cylinder disassembling and assembling205
Hydraulic cylinder cross section and tightening torque205
Hydraulic cylinder disassembling207
Hydraulic cylinder assembling209
Hydraulic cylinder assembly cautions210
Pilot Valve211
Pilot valve removing and installing211
Pilot valve removing211
Pilot valve installing213
Pilot valve installation cautions213
Pilot valve disassembling and assembling (S/N 9001~9017)214
Pilot valve cross section and tightening torque214
Pilot valve disassembling215
Pilot valve assembling222
Pilot valve assembly cautions222
Pilot valve disassembling and assembling (S/N 9018~)224
Pilot valve cross section and tightening torque224
Pilot valve disassembling225
Pilot valve assembling231
Pilot valve assembly cautions231
Multiple Control Valve232
Multiple control valve removing and installing232
Multiple control valve removing232
Multiple control valve installing233
Multiple control valve installation cautions233
Multiple control valve cross section and tightening torque234
Multiple control valve disassembling235
Multiple control valve assembling237
Multiple control valve assembly cautions237
Orbitrol®238
Orbitrol® removing and installing238
Orbitrol® removing238
Orbitrol® installing239
Orbitrol® installation cautions239
Orbitrol® cross section and tightening torque240
Orbitrol® disassembling241
Orbitrol® assembling244
Steering Valve248
Steering valve removing and installing248
Steering valve removing248
Steering valve installing249
Steering valve installation cautions249
Steering valve cross section and tightening torque250
Steering valve disassembling251
Steering valve assembling252
Stop Valve253
Stop valve removing and installing253
Stop valve removing253
Stop valve installing253
Stop valve installation cautions254
Stop valve disassembling and assembling255
Stop valve cross section and tightening torque255
Stop valve disassembling256
Stop valve assembling256
Fan Motor257
Fan motor removing and installing257
Fan motor removing257
Fan motor installing258
45 Service Standard Hydraulic Group260
Hydraulic Cylinder261
Pilot Valve263
Steering Valve265
54 Disassembly & Reassembly Brake Group266
Unloader Valve267
Unloader valve removing and installing267
Unloader valve removing267
Unloader valve installing268
Unloader valve installation cautions268
Unloader valve cross section and tightening torque269
Unloader valve disassembling271
Unloader valve assembling271
Manifold Valve Assembly272
Valve assembly removing and installing272
Valve assembly removing272
Valve assembly installing273
Valve assembly disassembling and assembling273
Valve assembly cross section and tightening torque274
Accumulator275
Accumulator removing and installing275
Accumulator removing275
Accumulator installing276
Accumulator installation cautions276
Accumulator disassembling and assembling277
Accumulator disassembling277
Accumulator assembling278
Nitrogen gas charging279
Nitrogen gas charging procedure279
Brake Valve281
Brake valve removing and installing281
Brake valve removing281
Brake valve installing282
Brake valve installation cautions282
Brake valve cross section and tightening torque (main valve)283
Brake valve disassembling284
Brake valve assembling287
Brake valve assembly cautions287
Service Brake288
Service brake disassembling and assembling288
Service brake installation cautions288
Parking Brake289
Parking brake removing and installing289
Parking brake cross section and tightening torque289
Parking brake disassembling and assembling290
Parking brake disassembling290
Parking brake assembling291
Parking brake assembly assembling cautions291
55 Service Standard Brake Group292
Brake Valve293
Service Brake294
Parking Brake295
74 Disassembly & Reassembly Operator Station Group296
Air Conditioner297
Air conditioner removing and installing297
Air conditioner removing297
Air conditioner installing298
Air conditioner disassembling and assembling299
Air conditioner tightening torque299
Air conditioner disassembling302
Air conditioner assembling306
75 Service Standard Operator Station Group308
Air Conditioner309
Periodical Inspection/Servicing309
Tightening Torque309
Tightening torque for hose and pipes309
Tightening torque for screws and bolts in special control regions309
INDEX310
Maintenance Log315
Notes319

S.M 3/2/2025