Kawasaki Wheel Loader 60ZV2 Workshop Manual + Parts Catalog Manual

Description

Kawasaki Wheel Loader 60ZV2 Workshop Manual + Parts Catalog Manual 

File Details:

Kawasaki Wheel Loader 60ZV2 Workshop Manual + Parts Catalog Manual 

Language : English
Pages : 500+
Size : 34.1 MB
Downloadable : Yes
Format : PDF

KAWASAKI WHEEL LOADER 60ZV2 WORKSHOP MANUAL + PARTS CATALOG MANUAL:

Image Preview:

Table of Contents:

Kawasaki Wheel Loader 60ZV2 Workshop Manual + Parts Catalog Manual 

60ZV-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 ……………………………………………………………………………………………….. 00-5
Recommended lubricants …………………………………………………………………………………………………………… 00-8
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
60ZV-2 Measurement for Performance Check ……………………………………………………………………………………….. 03-1
Cautions on Safety ………………………………………………………………………………………………………………………….. 03-2
Standard Measurement Values for Performance Check ……………………………………………………………………….. 03-3
60ZV-2 Function & Structure Chassis Group ………………………………………………………………………………………….. 12-1
Front Chassis …………………………………………………………………………………………………………………………………. 12-2
Loading linkage …………………………………………………………………………………………………………………………. 12-2
Loading linkage pin ……………………………………………………………………………………………………………………. 12-3
Rear Chassis …………………………………………………………………………………………………………………………………. 12-4
Fuel tank ………………………………………………………………………………………………………………………………….. 12-4
Floor board mount ……………………………………………………………………………………………………………………… 12-5
Center Pin ……………………………………………………………………………………………………………………………………… 12-6
Upper center pin ……………………………………………………………………………………………………………………….. 12-6
Lower center pin ……………………………………………………………………………………………………………………….. 12-6
Dust seal ………………………………………………………………………………………………………………………………….. 12-7
60ZV-2 Check & Adjustment Chassis Group ………………………………………………………………………………………….. 13-1
Linkage Pin ……………………………………………………………………………………………………………………………………. 13-2
Liner ………………………………………………………………………………………………………………………………………… 13-2
Center Pin ……………………………………………………………………………………………………………………………………… 13-4
Adjusting shim …………………………………………………………………………………………………………………………… 13-4
Installing bearing cover ………………………………………………………………………………………………………………. 13-4
60ZV-2 Function & Structure Power Group ……………………………………………………………………………………………. 22-1
Power Line …………………………………………………………………………………………………………………………………….. 22-2
Engine / Transmission ……………………………………………………………………………………………………………………… 22-3
Engine / transmission mount ……………………………………………………………………………………………………….. 22-3
Radiator …………………………………………………………………………………………………………………………………………. 22-4
Propeller Shaft ……………………………………………………………………………………………………………………………….. 22-6
Second propeller shaft assembly …………………………………………………………………………………………………. 22-7
Third propeller shaft assembly …………………………………………………………………………………………………….. 22-8
Axle Assembly ………………………………………………………………………………………………………………………………… 22-9
Axle Support …………………………………………………………………………………………………………………………………. 22-10
Differential Gear ……………………………………………………………………………………………………………………………. 22-12
Function of T.P.D ……………………………………………………………………………………………………………………… 22-13
Operation of T.P.D ……………………………………………………………………………………………………………………. 22-14
60ZV-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
Tightening torque ………………………………………………………………………………………………………………………. 23-4
Axle ………………………………………………………………………………………………………………………………………………. 23-5
Axle …………………………………………………………………………………………………………………………………………. 23-5
Differential gear …………………………………………………………………………………………………………………………. 23-6
60ZV-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 Gear Pump …………………………………………………………………………………………………………… 32-3
Gear pump specifications …………………………………………………………………………………………………………… 32-3
Transmission ………………………………………………………………………………………………………………………………….. 32-4
Gear arrangement ……………………………………………………………………………………………………………………… 32-4
Clutch specifications ………………………………………………………………………………………………………………….. 32-5
Valve location ……………………………………………………………………………………………………………………………. 32-6
Clutch Pack ……………………………………………………………………………………………………………………………………. 32-7
Forward and 2nd speed clutch …………………………………………………………………………………………………….. 32-7
Reverse and 1st speed clutch ……………………………………………………………………………………………………… 32-8
3rd speed clutch ………………………………………………………………………………………………………………………… 32-9
Power Flow Path in the Transmission ………………………………………………………………………………………………. 32-10
Hydraulic System Diagram …………………………………………………………………………………………………………….. 32-12
Hydraulic Circuit Diagram ………………………………………………………………………………………………………………. 32-13
Oil Flow ……………………………………………………………………………………………………………………………………….. 32-14
Oil flow in the torque converter line …………………………………………………………………………………………….. 32-14
Oil flow to the clutch …………………………………………………………………………………………………………………. 32-14
T/C and T/M Oil Circulation …………………………………………………………………………………………………………….. 32-15
Control Valve ………………………………………………………………………………………………………………………………… 32-16
System diagram ………………………………………………………………………………………………………………………. 32-18
Modulation Mechanism ………………………………………………………………………………………………………………….. 32-19
Clutch control oil pressure curve ………………………………………………………………………………………………… 32-19
Accumulator …………………………………………………………………………………………………………………………………. 32-23
Accumulator for 1st speed clutch ……………………………………………………………………………………………….. 32-23
Clutch Solenoid Valve ……………………………………………………………………………………………………………………. 32-25
For forward/reverse and speed clutches ……………………………………………………………………………………… 32-25
60ZV-2 Check & Adjustment Torque Converter and Transmission Group ………………………………………………….. 33-1
Clutch Oil Pressure …………………………………………………………………………………………………………………………. 33-2
60ZV-2 Function & Structure Hydraulic Group ………………………………………………………………………………………… 42-1
Flushing Hydraulic Lines ………………………………………………………………………………………………………………….. 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
Layout of Hydraulic Units …………………………………………………………………………………………………………………. 42-8
Hydraulic Tank ………………………………………………………………………………………………………………………………… 42-9
Hydraulic tank breather valve (tank cap) ……………………………………………………………………………………… 42-10
Hydraulic tank specifications ……………………………………………………………………………………………………….42-11
Hydraulic oil level check ……………………………………………………………………………………………………………..42-11
Hydraulic Pump …………………………………………………………………………………………………………………………….. 42-12
Hydraulic pump specifications …………………………………………………………………………………………………… 42-12
Hydraulic pump principle …………………………………………………………………………………………………………… 42-13
Hydraulic pump wear plate ……………………………………………………………………………………………………….. 42-14
Hydraulic pump bushing lubrication ……………………………………………………………………………………………. 42-14
Hydraulic Cylinder …………………………………………………………………………………………………………………………. 42-15
Boom cylinder …………………………………………………………………………………………………………………………. 42-15
Bucket cylinder ………………………………………………………………………………………………………………………… 42-15
Steering cylinder ……………………………………………………………………………………………………………………… 42-16
Hydraulic cylinder specifications ………………………………………………………………………………………………… 42-17
Return Filter …………………………………………………………………………………………………………………………………. 42-18
Loading System ……………………………………………………………………………………………………………………………. 42-19
Relief Valve Assembly ……………………………………………………………………………………………………………………. 42-20
Relief valve operation ………………………………………………………………………………………………………………. 42-21
Check valve operation ……………………………………………………………………………………………………………… 42-21
Accumulator …………………………………………………………………………………………………………………………………. 42-22
Accumulator specifications ……………………………………………………………………………………………………….. 42-22
Pilot Valve (TH40MS) …………………………………………………………………………………………………………………….. 42-23
Pilot valve specifications …………………………………………………………………………………………………………… 42-24
Pilot valve performance chart ……………………………………………………………………………………………………. 42-24
Pilot valve operation …………………………………………………………………………………………………………………. 42-26
Multiple Control Valve (KVS-120H-2) ……………………………………………………………………………………………….. 42-28
Multiple control valve specifications ……………………………………………………………………………………………. 42-29
Multiple control valve main relief valve ……………………………………………………………………………………….. 42-30
Multiple control valve overload relief valve ………………………………………………………………………………….. 42-32
Multiple control valve make-up valve ………………………………………………………………………………………….. 42-33
Multiple control valve bucket spool …………………………………………………………………………………………….. 42-34
Multiple control valve boom spool ………………………………………………………………………………………………. 42-36
Elbow Adapter ………………………………………………………………………………………………………………………………. 42-39
Pilot Valve Filter ……………………………………………………………………………………………………………………………. 42-40
Steering System ……………………………………………………………………………………………………………………………. 42-41
Priority Valve ………………………………………………………………………………………………………………………………… 42-43
Priority valve specifications ……………………………………………………………………………………………………….. 42-43
Priority valve operation …………………………………………………………………………………………………………….. 42-44
Orbitrol® ………………………………………………………………………………………………………………………………………. 42-47
Orbitrol® construction ……………………………………………………………………………………………………………….. 42-47
Orbitrol® specification ………………………………………………………………………………………………………………. 42-48
Orbitrol® operation …………………………………………………………………………………………………………………… 42-49
Orbitrol® feed-back mechanism operation …………………………………………………………………………………… 42-51
Steering speed and flow rate control ………………………………………………………………………………………….. 42-52
Hydraulic pump oil amount and steering force ……………………………………………………………………………… 42-52
Orbit rotor operation principle ……………………………………………………………………………………………………. 42-53
Auxiliary valves ……………………………………………………………………………………………………………………….. 42-54
Emergency check valve ……………………………………………………………………………………………………………. 42-56
Inlet check valve ……………………………………………………………………………………………………………………… 42-56
Cushion Valve ………………………………………………………………………………………………………………………………. 42-57
Cushion valve specifications ……………………………………………………………………………………………………… 42-58
Cushion valve operation …………………………………………………………………………………………………………… 42-58
60ZV-2 Check & Adjustment Hydraulic Group ………………………………………………………………………………………… 43-1
Loading/Steering Circuit Relief Valve …………………………………………………………………………………………………. 43-2
Loading circuit relief valve setting pressures …………………………………………………………………………………. 43-2
Steering circuit relief valve setting pressures …………………………………………………………………………………. 43-7
Hydraulic Cylinder …………………………………………………………………………………………………………………………..43-11
Cylinder natural drift …………………………………………………………………………………………………………………..43-11
60ZV-2 Function & Structure Brake Group …………………………………………………………………………………………….. 52-1
Brake Circuit ………………………………………………………………………………………………………………………………….. 52-2
Brake Units Layout ………………………………………………………………………………………………………………………….. 52-3
Hydraulic Servo Master Cylinder ………………………………………………………………………………………………………. 52-4
Hydraulic servo master cylinder specifications ………………………………………………………………………………. 52-5
Performance diagram ………………………………………………………………………………………………………………… 52-5
Hydraulic servo master cylinder operation …………………………………………………………………………………….. 52-6
Pressure Difference Switch ………………………………………………………………………………………………………………. 52-8
Service Brake …………………………………………………………………………………………………………………………………. 52-9
Service brake operation ……………………………………………………………………………………………………………… 52-9
Service brake friction plate ………………………………………………………………………………………………………… 52-10
Service brake steel plate …………………………………………………………………………………………………………… 52-10
Brake circuit air bleeding procedure …………………………………………………………………………………………….52-11
Parking Brake ……………………………………………………………………………………………………………………………….. 52-12
Brake Control ……………………………………………………………………………………………………………………………….. 52-13
Service brake linkage ……………………………………………………………………………………………………………….. 52-13
Parking brake linkage ………………………………………………………………………………………………………………. 52-14
Brake Oil Reservoir ……………………………………………………………………………………………………………………….. 52-15
Brake oil reservoir specifications ……………………………………………………………………………………………….. 52-15
60ZV-2 Check & Adjustment Brake Group …………………………………………………………………………………………….. 53-1
Hydraulic Servo Master ……………………………………………………………………………………………………………………. 53-2
Hydraulic servo master performance inspection …………………………………………………………………………….. 53-2
Service Brake …………………………………………………………………………………………………………………………………. 53-4
Service brake performance check ……………………………………………………………………………………………….. 53-4
Service brake friction plate wear measurement ……………………………………………………………………………… 53-5
Parking Brake …………………………………………………………………………………………………………………………………. 53-6
Parking brake performance check ……………………………………………………………………………………………….. 53-6
Parking brake clearance adjustment …………………………………………………………………………………………….. 53-7
Brake Control …………………………………………………………………………………………………………………………………. 53-9
Adjusting brake pedal and switch ………………………………………………………………………………………………… 53-9
Parking brake linkage adjustment ………………………………………………………………………………………………..53-11
60ZV-2 Function & Structure Electrical Group ………………………………………………………………………………………… 62-1
How to Use Electrical Wiring Diagram ……………………………………………………………………………………………….. 62-2
Electrical Cable Color Codes ……………………………………………………………………………………………………………. 62-3
Electrical Circuit Symbols …………………………………………………………………………………………………………………. 62-4
Sensor Mount …………………………………………………………………………………………………………………………………. 62-5
Fuse ……………………………………………………………………………………………………………………………………………… 62-6
Fuse box ………………………………………………………………………………………………………………………………….. 62-6
Fusible link ……………………………………………………………………………………………………………………………….. 62-8
Engine Start Circuit …………………………………………………………………………………………………………………………. 62-9
Engine start circuit diagram ………………………………………………………………………………………………………… 62-9
Neutral starter …………………………………………………………………………………………………………………………. 62-10
Starter switch ……………………………………………………………………………………………………………………………62-11
Battery relay ……………………………………………………………………………………………………………………………. 62-12
Alternator I terminal wire …………………………………………………………………………………………………………… 62-12
Diode unit ……………………………………………………………………………………………………………………………….. 62-12
Neutral relay ……………………………………………………………………………………………………………………………. 62-13
Magnet switch …………………………………………………………………………………………………………………………. 62-14
Voltage relay …………………………………………………………………………………………………………………………… 62-15
Power Generating/Charging Circuit …………………………………………………………………………………………………. 62-16
Alternator ……………………………………………………………………………………………………………………………….. 62-16
ECM (Engine Controller) ………………………………………………………………………………………………………………… 62-17
Function of ECM ……………………………………………………………………………………………………………………… 62-17
Connection diagram …………………………………………………………………………………………………………………. 62-17
Monitor lamp test …………………………………………………………………………………………………………………….. 62-18
Failure diagnosis ……………………………………………………………………………………………………………………… 62-19
Quantum fault code information …………………………………………………………………………………………………. 62-22
Accelerator pedal …………………………………………………………………………………………………………………….. 62-29
Transmission Control Circuit and Monitor Circuit ……………………………………………………………………………….. 62-31
Machine control unit (MCU) ………………………………………………………………………………………………………. 62-31
Machine control unit (MCU) connection diagram ………………………………………………………………………….. 62-33
Machine control unit (MCU) function …………………………………………………………………………………………… 62-34
Monitoring system ……………………………………………………………………………………………………………………. 62-45
Instrument Panel and Switch ………………………………………………………………………………………………………….. 62-47
Instrument panel ……………………………………………………………………………………………………………………… 62-47
Instrument panel rear surface ……………………………………………………………………………………………………. 62-48
Gauge circuit …………………………………………………………………………………………………………………………… 62-49
Fuel level sensor ……………………………………………………………………………………………………………………… 62-51
Electrical Detent Circuit ………………………………………………………………………………………………………………….. 62-52
Bucket leveler …………………………………………………………………………………………………………………………. 62-52
Boom kick-out …………………………………………………………………………………………………………………………. 62-52
Detent solenoid ……………………………………………………………………………………………………………………….. 62-53
Diode …………………………………………………………………………………………………………………………………………… 62-54
Diode check method ………………………………………………………………………………………………………………… 62-55
Caution for diode check method ………………………………………………………………………………………………… 62-55
Surge voltage and surge suppression diodes ………………………………………………………………………………. 62-57
Diagnostic System ………………………………………………………………………………………………………………………… 62-58
Diagnostic system flow …………………………………………………………………………………………………………….. 62-58
Diagnostic failure history memory data ……………………………………………………………………………………….. 62-59
Diagnostic failure history indication and deletion ………………………………………………………………………….. 62-63
Diagnostic switch …………………………………………………………………………………………………………………….. 62-65
60ZV-2 Check & Adjustment Electrical Group ………………………………………………………………………………………… 63-1
Cautions Regarding Electric Circuit Check …………………………………………………………………………………………. 63-2
Disconnecting or reinstalling connector ………………………………………………………………………………………… 63-2
How to attach the probes of the circuit tester …………………………………………………………………………………. 63-4
Electrical Transmission Control System Troubleshooting Flowchart ………………………………………………………. 63-5
Standard troubleshooting flowchart ………………………………………………………………………………………………. 63-5
MCU Abnormal Operation Judgment …………………………………………………………………………………………………. 63-6
MCU check ………………………………………………………………………………………………………………………………. 63-6
MCU LED indicator ……………………………………………………………………………………………………………………. 63-8
Electrical Circuit Check ………………………………………………………………………………………………………………….. 63-10
Shift lever input electrical circuit check ……………………………………………………………………………………….. 63-10
Declutch input electrical circuit check …………………………………………………………………………………………. 63-12
Downshift button input electrical circuit check ……………………………………………………………………………… 63-14
Machine speed sensor input electrical circuit check ……………………………………………………………………… 63-15
Clutch solenoid valve output electrical circuit check ……………………………………………………………………… 63-16
Neutral relay electrical circuit check ……………………………………………………………………………………………. 63-19
Checking parking brake circuit …………………………………………………………………………………………………… 63-21
Gauge circuit electrical circuit check …………………………………………………………………………………………… 63-22
Bucket leveler electrical circuit check …………………………………………………………………………………………. 63-25
60ZV-2 Drawing & Diagrams ……………………………………………………………………………………………………………….. 92-1
Axle Assembly ………………………………………………………………………………………………………………………………… 92-2
Torque Converter and Transmission ………………………………………………………………………………………………….. 92-3
Loading/Steering Hydraulic Line ……………………………………………………………………………………………………….. 92-4
Brake Circuit …………………………………………………………………………………………………………………………………… 92-5
Electrical Wiring Diagram (1/2) …………………………………………………………………………………………………………. 92-6
Electrical Wiring Diagram (2/2) …………………………………………………………………………………………………………. 92-7
Electrical Wiring Diagram …………………………………………………………………………………………………………………. 92-8
Electrical wiring diagram abbreviation chart ………………………………………………………………………………….. 92-8
Electrical Connection Diagram ………………………………………………………………………………………………………….. 92-9
Electrical Wiring Diagram (CAB) ……………………………………………………………………………………………………… 92-10
Electrical Equipment Layout ……………………………………………………………………………………………………………. 92-12

Description:

Kawasaki Wheel Loader 60ZV2 Workshop Manual + Parts Catalog Manual 

• 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. General Information Functions and structure 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 methods. 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.

Please Note:

• This is the SAME exact manual used by your dealers to fix your vehicle.
• The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
• Any queries / doubts regarding your purchase, please feel free to contact [email protected]