Kawasaki Wheel Loader 65ZIV-2 Shop Manual AAA-S65C3V01-012 – PDF DOWNLOAD

AAA-S65C3V01-012

(93207-00081)

Troubleshooting
MeasurementforPerformanceCheck

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.

Safety Precautions

The most important point in providing repair service is safety. To ensure safety, observe the general cautions
described below.
・This manual is intended for properly trained and equipped service technicians.
・Any work on the machine must be performed by the trained personnel only.
・Carefully read this manual to thoroughly understand the operation method before you operate or repair the
machine.
・Be sure to wear appropriate clothes and protectors, such as safety boots, hard hat and goggles.
・Place the machine on a level and solid ground, and place chocks against the wheels to prevent movement.
・Remove the cable from the battery before starting the service work, and attach a “DO NOT OPERATE!” tag to the
steering wheel.
・Be sure to release the internal pressure before you remove a pipe, such as the hydraulic oil, air, or engine coolant
pipe.
・Be sure to apply the articulation stopper before starting work.
・While supporting the bottom of the chassis using a jack, be sure to support the chassis using the blocks.
・When the boom or bucket is raised or when a unit is lifted by a crane, be sure to place a stand or adequate
cribbing under the unit to prevent unexpected dropping.
・Do not start to work in an enclosed area if adequate ventilation is not provided.
・To remove a heavy unit (20kg (40 lbs) or more), be sure to use a crane or other lifting tool.
・Just after stopping operation, be careful not to directly touch a hot component. You may get burned.
・Contact tire manufacturer’s local dealer for tire servicing and changing.
・Always store the tools in good condition, and use them properly.
・Keep the work area clean. Clean up spills immediately.
・Avoid the use of flammable solvents and cleaners.
・When working outdoors keep work areas, ladders, steps, decks and work platforms clear of snow, ice, and mud.
・Use safe work platforms to reach higher areas of the machine.

AAA-S65C3V01-012

(93207-00081)

Troubleshooting
MeasurementforPerformanceCheck

Cautions Regarding Troubleshooting ・01-3
How to Use Quick Troubleshooting Table ・01-4
Safety Precautions・01-5
Quick Troubleshooting Table
Torque Converter and Transmission Group
1 Machine does not move in any shift lever position ・01-6
2 Machine does not move at a certain shift lever position・01-7
(or: Machine moves only in a certain shift lever position)
3 Machine moves at the neutral position 01-8
(Example: Machine moves forward at the neutral position)
4 Large shock at starting or changing speeds / direction01-9
5 Large time lag at starting or changing speed / direction・01-10
6 Low power・01-11
(Defective torque converter or transmission)
7 Torque converter oil is overheating・01-12
8 Machine moves reverse when starting to
climb up on a slope using inching brake・01-13
9 Automatic speed change is not possible 01-14
10 PUS(QUAD) switch does not work01-15
Hydraulic Group
1 Boom and/or bucket do not move・01-16
2 Boom and/or bucket have low power, or move too slowly 01-18
3 Excessive cylinder drift・01-21
4 Boom and/or bucket are spongy 01-24
(Holding bucket against the ground is not possible)
5 Bucket positioner (kick-out) does not work ・01-25
6 Steering is not possible or hard to steer・01-26
7 Machine sways, or a shock during steering 01-27
8 Abnormal noise in hydraulic system 01-28
9 Others 01-29
01-1
Brake Group
1 Brake does not work well
(In the worst case, the brake does not work at all) ・01-31
2 Brake is dragging when released ・01-32
3 Brake oil level lowers too much01-33
4 Stepping on the brake pedal sounds the buzzer 01-34
5 Air pressure does not rise, or too slow in rising ・01-35
(Pressure indicated on the pressure gauge is too small)
6 Parking brake does not work ・01-36
(or: Releasing the brake is not possible)
Electrical Group
1 Engine hard to start or will not start 01-37
2 Engine will not stop even if the starter switch is turned
to “OFF” (or: Starting the engine is not possible) ・01-38
3 Instrument panel does not indicate properly ・01-39
4 Breaker of the transmission controller is turned off・01-40