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Kawasaki Wheel Loader 90Z6 Service manual + Parts manual + Wiring diagrams + Troubleshooting manual – PDF DOWNLOAD
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Kawasaki Wheel Loader 90Z6 Service manual + Parts manual + Wiring diagrams + Troubleshooting manual
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Description
Kawasaki Wheel Loader 90Z6 Service manual + Parts manual + Wiring diagrams + Troubleshooting manual
File Details:
Kawasaki Wheel Loader 90Z6 Service manual + Parts manual + Wiring diagrams + Troubleshooting manual
Language : English
Pages : 800+
Size : 257 MB
Downloadable : Yes
Format : PDF
KAWASAKI WHEEL LOADER 90Z6 SERVICE MANUAL + PARTS MANUAL + WIRING DIAGRAMS + TROUBLESHOOTING MANUAL – PDF DOWNLOAD:
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Table of Contents:
Kawasaki Wheel Loader 90Z6 Service manual + Parts manual + Wiring diagrams + Troubleshooting manual
SECTION 1 GENERAL............................................................................ 5 1 Precautions for Disassembling and Assembling........................................... 7 Precautions for Disassembling and Assembling......................................... 7 Precautions for Using Floating Seal.............................................. 8 Precautions for Using Nylon Sling................................................ 9 2 Tightening............................................................................. 13 Tightening Bolts and Nuts............................................................ 13 Specified Tightening Torque Chart................................................ 13 Tightening Order................................................................. 14 Precautions for Split Flange..................................................... 15 Nut and Bolt Locking............................................................. 15 Piping Joint......................................................................... 16 Union Joint...................................................................... 16 Pipe Joint....................................................................... 17 O-Ring Seal Joint................................................................ 17 Quick Coupling................................................................... 18 Screw-In Connection.............................................................. 19 Seal Tape Application........................................................... 19 Low-Pressure-Hose Clamp Tightening............................................... 19 Connecting Hose.................................................................. 20 3 Painting............................................................................... 21 Painting............................................................................. 21 4 Bleeding Air .......................................................................... 27 Bleeding Air from Hydraulic Oil Tank................................................. 27 Bleeding Air from Hydraulic System................................................... 28 Bleed Air from the Fuel System....................................................... 29 Bleeding Air from Radiator........................................................... 30 Bleeding Air from Brake (Axle)....................................................... 31 5 Pressure Release Procedure............................................................. 33 Front Attachment Hydraulic Circuit Pressure Release Procedure........................ 33 Ride Control Accumulator Pressure Release Procedure.................................. 34 Parking Brake Accumulator Pressure Release Procedure................................. 35 6 Preparation............................................................................ 37 Preparation before Inspection and Maintenance........................................ 37 Articulation Lock................................................................ 38 Machine Position for Inspection and Maintenance (lift arm raise)................. 39 SECTION 2 MAINTENANCE STANDARD............................................................... 41 1 Body................................................................................... 43 Center Hinge......................................................................... 43 Pilot Valve (Two Lever Type )............................................................ 45 2 Front Attachment....................................................................... 47 Pin and Bushing...................................................................... 47 Standard Dimensions for Lift Arm and Bucket.......................................... 49 Bucket Stopper Clearance............................................................. 50 Bucket Dump Stopper.............................................................. 50 Bucket Rollback (Tilt) Stopper .................................................. 50 SECTION 3 BODY TOC........................................................................... 51 1 Cab.................................................................................... 53 Removal and Installation of Cab...................................................... 53 2 Counterweight.......................................................................... 69 Removal and Installation of Counterweight............................................ 69 3 Center Hinge........................................................................... 71 Removal and Installation of Center Hinge............................................. 71 Removal and Installation of the Hydraulic Hoses of Front Chassis Side................ 79 4 Engine................................................................................. 87 Removal and Installation of Engine................................................... 87 Removal and Installation of Exterior Parts...........................................105 Removal of Side Cover............................................................106 Installation of Side Cover.......................................................108 Removal of Engine Roof ..........................................................110 Installation of Engine Roof......................................................112 Removal and Installation of Deck and Step/Covers.................................114 Removal and Installation of Air Cleaner..............................................117 5 Radiator Assembly......................................................................121 Replacement of Radiator, Oil Cooler, Air Cooler, and Torque Converter Cooler.........121 6 Hydraulic Oil Tank.....................................................................139 Removal and Installation of Hydraulic Oil Tank.......................................139 7 Fuel Tank..............................................................................147 Removal and Installation of Fuel Tank................................................147 8 Pump Device............................................................................153 Removal and Installation of Pump Device..............................................153 Disassembly and Assembly of Pump Device..............................................159 Removal of Pilot Pump and Regulator..............................................160 Installation of Pilot Pump and Regulator.........................................161 Disassembly of Main Pump.............................................................163 Assembly of Main Pump................................................................166 Disassembly and Assembly of Regulator................................................171 Removal and Installation of Accessory Pump...........................................179 Disassembly and Assembly of Accessory Pump...........................................180 9 Control Valve..........................................................................181 Removal and Installation of Control Valve............................................181 Disassembly of Control Valve.........................................................187 Assembly of Control Valve............................................................191 10 Pilot Valve...........................................................................195 Removal and Installation of Pilot Valve (Two Lever Type ) ..........................195 Disassembly of Pilot Valve (Two Lever Type)..........................................201 Assembly of Pilot Valve (Two Lever Type).............................................208 Removal and Installation of Pilot Valve (Multi-Function Joystick Type)...............215 Disassembly and Assembly of Pilot Valve (Multi-Function Joystick Type)...............221 11 Charging Block........................................................................227 Removal and Installation of Charging Block...........................................227 Disassembly and Assembly of Charging Block...........................................235 12 Cooling Fan System....................................................................243 Removal and Installation of Fan Motor................................................243 Structure of Fan Motor...............................................................249 Removal and Installation of Fan Pump.................................................251 Disassembly of Fan Pump..............................................................255 Assembly of Fan Pump.................................................................258 Structure of Fan Pump................................................................261 Removal and Installation of Fan Control Valve (Option)...............................263 Structure of Fan Control Valve (Option)..............................................265 Removal and Installation of Reversing Fan Motor (Option).............................267 13 Exhaust Muffler.......................................................................275 Removal and Installation of Muffler..................................................275 14 Ride Control Device...................................................................283 Removal and Installation of Ride Control Valve and Accumulator (Option)..............283 Disassembly of Ride Control Valve (Option)...........................................289 Assembly of Ride Control Valve (Option)..............................................292 15 Battery Disconnect Switch ............................................................297 Removal and Installation of Battery Disconnect Switch (Option).......................297 SECTION 4 TRAVEL SYSTEM......................................................................299 1 Tire...................................................................................301 Removal and Installation of Front Tire...............................................301 Removal and Installation of Rear Tire................................................303 2 Drive Unit.............................................................................309 Removal and Installation of Drive Unit...............................................309 Structure of Drive Unit..............................................................321 Disassembly and Assembly of Drive Unit...............................................329 Draining Oil and Removing Charging Pump..........................................329 Removing Control Valve...........................................................331 Removing Speed Sensor............................................................332 Installing Charging Pump.........................................................333 Installing Control Valve.........................................................335 Installing Speed Sensor..........................................................336 3 Axle...................................................................................337 Removal and Installation of Front Axle...............................................337 Removal and Installation of Rear Axle................................................347 Disassembly of Axle..................................................................360 Front Axle Assembly..............................................................355 Rear Axle Assembly...............................................................355 Axle Assembly....................................................................356 Planetary Carrier Assembly ......................................................357 Removal of Axle Support (Rear Axle)..................................................358 Disassembly of Axle..................................................................360 Removal of Housings..............................................................360 Disassembly of Housings..........................................................361 Disassembly of Planetary Carrier Assembly........................................363 Removal of Brake.................................................................364 Removal of Differential Case Assembly............................................365 Disassembly of Differential Case Assembly........................................366 Removal of Bearing Cage Assembly.................................................367 Assembly of Axle.....................................................................368 Assembly of Differential Case ...................................................372 Assembly of Bearing Cage Assembly................................................372 Installation of Bearing Cage Assembly............................................377 Installation of Differential Case................................................373 Adjustment of Ring Gear Backlash and Adjustment of Ring Gear Teeth Engagement....374 Installation of Bearing Cage Assembly............................................377 Adjustment of Brake Disc Clearance ..............................................378 Installation of Brake ...........................................................380 Assembly of Housings ............................................................382 Preload Adjustment of Axle Shaft Bearing (Shim Adjustment) ......................384 Assembly and Installation of Planetary Carrier Assembly..........................386 Installation of Housing..........................................................388 Installation of Axle Support (Rear Axle).........................................390 Disassembly of Differential..........................................................393 Torque Proportional Differential (TPD)...........................................400 Limited Slip Differential (LSD)..................................................401 Disassembly of Bearing Cage Assembly.............................................395 Disassembly of Differential Case Assembly (TPD)..................................397 Disassembly of Differential Case Assembly (LSD)..................................398 Assembly of Differential.............................................................400 Torque Proportional Differential (TPD)...........................................400 Limited Slip Differential (LSD)..................................................401 Assembly of Differential Case Assembly (TPD).....................................402 Assembly of Differential Case (LSD)..............................................404 Assembly of Bearing Cage ........................................................406 4 Propeller Shaft........................................................................409 Removal and Installation of Propeller Shaft..........................................409 Removal of Bottom Covers (Option)................................................409 Removal of Second Propeller Shaft................................................410 Removal of Third Propeller Shaft ................................................413 Installation of Third Propeller Shaft............................................414 Installation of Second Propeller Shaft...........................................415 Installation of Bottom Covers (Option)...........................................418 5 Brake Valve............................................................................419 Removal and Installation of Brake Valve..............................................419 Disassembly of Brake Valve Assembly (Option).........................................423 Assembly of Brake Valve Assembly (Option)............................................426 Structure of Brake Valve ............................................................429 Disassembly of Brake Valve ..........................................................430 Assembly of Brake Valve .............................................................431 Brake Valve Maintenance Standard.....................................................432 6 Steering Pilot Valve...................................................................433 Removal and Installation of Steering Pilot Valve.....................................433 Disassembly of Steering Pilot Valve..................................................437 Assembly of Steering Pilot Valve.....................................................440 7 Steering Valve.........................................................................445 Removal and Installation of Steering Valve ..........................................445 Disassembly and Assembly of Steering Valve...........................................449 8 Steering Cylinder......................................................................453 Removal and Installation of Steering Cylinder .......................................453 Disassembly of Steering Cylinder.....................................................457 Assembly of Steering Cylinder........................................................460 Removal and Installation of Steering Accumulator.....................................463 9 Secondary Steering Device..............................................................465 Removal and Installation of Secondary Steering Pump (Option).........................465 10 Stop Valve............................................................................469 Removal and Installation of Stop Valve...............................................469 Adjustment of Stop Valve Installation Position.......................................471 Disassembly of Stop Valve............................................................473 Assembly of Stop Valve...............................................................474 11 Axle Oil Cooler.......................................................................475 Removal and Installation of Axle Oil Cooler (Option).................................475 Structure of Oil Cooler Assembly (Option)............................................487 Structure of Oil Cooler Pump Unit (Option)...........................................488 Structure of Check Valve Assembly (Option)...........................................490 SECTION 5 FRONT ATTACHMENT TOC...............................................................493 1 Front Attachment.......................................................................495 Removal and Installation of Front Attachment.........................................495 Installation Position (Lift Arm).................................................500 Installation Position (Bucket Cylinder)..........................................501 Removal and Installation of Lever (Bell Crank))......................................507 Installation Position (Lever (Bell Crank)).......................................512 Installation Position (Bucket Link)..............................................513 Installation Position (Bucket Cylinder)..........................................514 Removal and Installation of Bucket...................................................521 Installation Position (Lift Arm).................................................523 Direction of Install (Bucket Link)...............................................524 2 Cylinder...............................................................................527 Removal and Installation of Lift Arm Cylinder .......................................527 Installation Position (Lift Arm Cylinder)........................................529 Removal and Installation of Bucket Cylinder......................................533 Installation Position (Bucket Cylinder)......................................537 Disassembly of Lift Arm Cylinder.................................................543 Assembly of Lift Arm Cylinder....................................................548 Disassembly of Bucket Cylinder...................................................555 Assembly of Bucket Cylinder......................................................560 INDEX........................................................................................567
Description:
Kawasaki Wheel Loader 90Z6 Service manual + Parts manual + Wiring diagrams + Troubleshooting manual
The service manual covers the following files:
90Z6+DR+EX-Cover.pdf
90Z6+DR+TR.pdf
90Z6+DR+TR-Cover.pdf
90Z6+FS+EX.pdf
90Z6+FS+EX-Cover.pdf
90Z6+FS+TR.pdf
90Z6+FS+TR-Cover.pdf
90Z6+FS+TR-Diagrams.pdf
90Z6+PC+????-Cover.pdf
90Z6+PC+????-Cover.pdf
90Z6+PC+??-Cover.pdf
90Z6+T+EX-Cover.pdf
90Z6+T+TR.pdf
90Z6+T+TR-Cover.pdf
90Z6+Trbl(EXP)(93213-00771).pdf
93313-00550.pdf
93313-00580_1.pdf
93313-00580_2.pdf
93313-00581-1.pdf
93313-00581-2.pdf
93313-00581???.pdf
93313-00600(TURKEY)..pdf
93313-00610.pdf
15M002+90Z6+OM+Revision.pdf
90Z6_OMM(TR)(93113-00762).pdf
90Z6_TT(93213-00801)TR (1).pdf
90Z6_TT(93213-00801)TR.pdf
90Z6+(F&S)-Diagrams(00761).pdf
90Z6+DR+EX.pdf
- Our shop manuals consist of the Technical Manual, the Workshop Manual and the Engine Manual.
Information included in the Technical Manual: Technical information needed for machine pre-delivery and delivery, operation and activation of all devices and systems, operational performance tests, and troubleshooting procedures. Each page has a number, located on the center lower part of the page, and each number contains the following information: Example: Technical Manual: T 1-3-5 T Technical Manual 1 Section Number 3 Group Number 5 Consecutive Page Number for Each Group - Information included in the Workshop Manual: Technical information needed for maintenance and repair of the machine, tools and devices needed for maintenance and repair, maintenance standards, and removal / installation and assembly / disassembly procedures. Information included in the Engine Manual: Technical information needed for machine pre-delivery and delivery and maintenance and repair of the machine, operation and activation of all devices and systems, troubleshooting and assembly / disassembly procedures
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]
