Kawasaki WHEEL LOADER 90ZV-2 SHOP MANUAL 93213-00461 – PDF DOWNLOAD

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Kawasaki WHEEL LOADER 90ZV-2 SHOP MANUAL 93213-00461 – PDF DOWNLOAD

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Kawasaki WHEEL LOADER 90ZV-2 SHOP MANUAL 93213-00461 – PDF DOWNLOAD

Language :English
Pages :553
Downloadable : Yes
File Type : PDF

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DESCRIPTION:

Kawasaki WHEEL LOADER 90ZV-2 SHOP MANUAL 93213-00461 – PDF DOWNLOAD

General Information
Standard Measurement Values for
Performance Check
Function & Structure
Check & Adjustment
Powered by CUMMINS QSM11 Engine
Serial No. 90C5-9001 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 WHEEL LOADER 90ZV-2 SHOP MANUAL 93213-00461 – PDF DOWNLOAD

General Information
Standard Measurement Values for
Performance Check
Function & Structure
Check & Adjustment
Powered by CUMMINS QSM11 Engine
Serial No. 90C5-9001 and up

Foreword 2
Safety Symbols 3
CONTENTS 4
00 General Information 16
How to Use Manual 17
Safety precautions 17
Symbols 18
Outline 19
Layout of main components 19
Inspection and maintenance table 20
Recommended Lubricants 23
Coolant 24
Coolant specification 24
Recommended mixture of antifreeze 24
Lubrication chart 25
Weight of main components 26
Bolt tightening torque 27
Hexagon bolt 27
Flanged hexagon bolt 30
Hose band tightening torque 31
Liquid gasket and screw lock agent 32
Cautions regarding parts removal 32
Cautions regarding reassembly 32
Screw lock agent application procedure 33
How to wind a seal tape 33
Cautions regarding welding repair service 34
03 Measurement for Performance Check 36
Cautions on Safety 37
Standard Measurement Values for Performance Check 38
12 Function & Structure Chassis Group 42
Front Chassis 43
Loading linkage 43
Loading linkage pin 45
Rear Chassis 46
Floor board mount 46
Floor board 46
Viscous mount 46
Fuel tank (S/N 9001~9450) 47
Fuel tank (S/N 9451~) 48
Center Pin 49
Upper center pin 49
Lower center pin 49
Dust seal 50
13 Check & Adjustment Chassis Group 52
Linkage Pin 53
Liner 53
Adjustment 54
Bucket hinge pin section 55
How to assemble 55
Center Pin 56
Adjusting shim 56
Installing bearing cover 56
Installing bearing outer ring 57
22 Function & Structure Power Group 58
Power Line 59
Engine / Transmission 60
Engine / transmission mount 60
Radiator (S/N 9001~9200) 61
Radiator mount 62
Radiator (S/N 9201~) 63
Radiator mount 64
Propeller Shaft 65
Second propeller shaft assembly 66
Front differential – Transmission 66
Third propeller shaft assembly 67
Transmission – Rear differential 67
Axle Assembly 68
Axle Support 69
Differential Gear 71
Torque proportioning type 71
Function of TPD 73
Operation of TPD 74
Limited Slip Differential (option) 75
LSD structure 75
LSD function 78
LSD operation 78
23 Check & Adjustment Power Group 80
Engine 81
Measuring engine speed 81
Measurement instrument 81
Standard measurement value 81
Measuring engine oil pressure 81
Measurement instrument 81
Install position 81
Standard measurement value 81
Propeller Shaft 82
Propeller shaft phase 82
Second propeller shaft alignment 82
Tightening torque 83
Axle 84
Axle nut tightening procedure 84
Differential gear adjustment procedure 85
Preload adjustment 86
Bearing installation 86
Oil seal installation 86
Adjusting tooth contact 87
32 Function & Structure T/C and T/M Group 90
Torque Converter 91
Torque converter structure 91
Power flow path 91
Torque multiplication 91
Torque Converter Gear Pump 92
Gear pump specifications 92
Transmission 93
Clutch combination 93
Shift lever position 93
Downshift button operation 93
Gear train and number of teeth 94
Clutch specifications 95
Clutch Pack 96
Forward and 3rd speed clutches 96
Reverse and 2nd speed clutches 97
1st speed clutch 98
4th speed clutch 99
Power Flow Path in the Transmission100
Forward100
Reverse102
Hydraulic System Diagram103
Hydraulic Circuit Diagram104
Oil Flow105
Oil flow in the torque converter line105
Oil flow to the clutch105
T/C and T/M Oil Circulation106
Control Valve108
System diagram109
Modulation Mechanism110
Clutch control oil pressure curve111
Traveling at forward 1st speed112
Changing from forward 1st speed to reverse 1st speed113
Trimmer engagement114
Clutch engagement starting115
Clutch Solenoid Valve116
For forward/reverse and speed clutches116
For trimmer118
33 Check & Adjustment T/C and T/M Group120
Clutch Oil Pressure121
Measuring clutch oil pressure121
42 Function & Structure Hydraulic Group122
Flushing Hydraulic Circuit123
Purpose of flushing123
Cautions on Hydraulic Parts Replacement124
Hydraulic Circuit Symbols125
Hydraulic lines125
Pumps & motors125
Cylinders125
Operation methods126
Pressure control valve126
Flow control valve126
Directional control valve127
Check valve127
Miscellaneous hydraulic symbols128
Hydraulic System Operation129
Hydraulic system operation outline129
Loading system129
Steering system129
Efficient loading system130
Fan motor system130
Ride control system (OPT)130
Layout of Hydraulic Units131
Hydraulic Tank132
Hydraulic tank breather valve (tank cap)133
Hydraulic tank specifications134
Hydraulic oil level check135
Hydraulic Pump137
Hydraulic pump specifications137
Hydraulic pump principle138
Hydraulic pump wear plate139
Hydraulic pump bushing lubrication139
Hydraulic Cylinder140
Boom cylinder140
Bucket cylinder141
Steering cylinder142
Hydraulic cylinder specifications143
Loading System144
Reducing Valve (for Pilot Pressure)145
Pilot valve (S/N 9001~9352)146
Pilot valve function149
Pilot valve operation (modulated position)149
Pre-detent and detent magnet solenoid151
Pilot valve (S/N 9353~)152
Pilot valve function154
Pilot valve operation (modulated position)154
Pre-detent and detent magnet solenoid156
Multiple Control Valve (KML35A/2T202)157
Multiple control valve specifications158
Multiple control valve main relief valve159
Main relief valve operation159
Adjusting set pressure160
Multiple control valve overload relief valve (with make-up function)161
Overload relief valve operation161
Make-up valve operation162
Adjusting set pressure162
Multiple control valve make-up valve162
Make-up valve operation162
Multiple control valve bucket spool163
Bucket spool operation163
Multiple control valve boom spool165
Boom spool operation165
Adapter (Orifice)168
Ride Control (OPT)169
Ride control hydraulic circuit169
Ride control function169
Ride control operation170
Preparation mode (ride control switch is OFF)170
Running mode (ride control switch is ON)171
Ride control valve assembly172
Solenoid valve175
Accumulator (for ride control)177
Accumulator function177
Steering System178
Orbitrol®179
Orbitrol® structure179
Valve part179
Rotor part180
Orbitrol® specifications180
Orbitrol® operation181
Neutral181
Turn182
Orbitrol® feed-back mechanism operation183
Steering speed and flow rate control184
Hydraulic pump oil amount and steering force184
Orbit rotor operation principle185
Steering Valve (KVS25-A30/20)186
Steering valve operation188
Neutral position (steering spool in “Neutral”)188
Left turn position189
Steering plunger variable throttle190
Steering valve flow control plunger191
Steering valve main relief valve192
When the pressure is at the preset value or less192
When the pressure exceeds the preset value193
Steering valve overload relief valve194
Overload relief valve operation195
Make-up valve operation195
Steering pilot circuit and its operation196
Flow amplifier notch and pilot orifice197
Stop Valve198
Stop valve function199
Stop valve operation199
Reducing Valve (for Orbitrol®)200
Steering Line Filter201
K-Lever (OPT)202
Hydraulic circuit202
Hydraulic line diagram203
Hydraulic line204
Solenoid valve assembly (1/2)205
Solenoid valve assembly (2/2)206
Adjustment method206
Efficient Loading System207
Efficient loading system outline207
The operation condition of ELS207
Mounting of the ELS valve208
Mounting of the variable kickout sensor209
Efficient loading system operation210
While the ELS is not operating210
While the ELS is operating210
Fan Motor System211
Mounting of fan motor211
Fan Motor Line212
Hydraulic circuit (fan motor normal rotation)214
Safety valve (with suction function)214
Flow control valve215
Flow control solenoid valve216
Fan motor217
Reversing Fan Motor Line (OPT)220
Reversing fan motor function220
Fan motor221
Reversing fan control chart223
Hydraulic circuit (Reverse rotation)224
Secondary Steering225
Secondary steering operation226
Secondary steering motor and pump227
43 Check & Adjustment Hydraulic Group228
Loading/Steering Circuit Relief Valve/Ride Control Circuit Reducing Valve (OPT)229
Loading circuit relief valve setting pressures229
Measuring loading circuit main relief pressure231
Adjusting main relief pressure231
Measuring loading circuit overload relief pressure232
Adjusting overload relief pressure232
Measuring pilot circuit relief pressure233
Adjusting pilot line pressure233
Ride control circuit reducing valve setting pressures (OPT)234
Measuring ride control circuit reducing pressure236
Adjusting reducing valve pressure236
Steering circuit relief valve setting pressures237
Measuring steering circuit main relief pressure239
Adjusting steering line main pressure239
Measuring steering circuit overload relief pressure240
Adjusting overload relief pressure240
Measuring pilot circuit relief pressure (reducing pressure)241
Adjusting pilot line pressure241
Hydraulic Cylinder242
Cylinder natural drift242
Stop Valve244
Stop valve adjustment procedure244
52 Function & Structure Brake Group246
Brake System Outline247
Service brake247
Parking brake247
Adjustment of axle internal pressure247
Brake Units Layout248
Unloader Valve249
Unloader valve operation251
Valve Unit252
Accumulator low pressure sensor253
Accumulator254
In-Line Filter255
Brake Valve256
Brake valve performance chart257
Brake valve outline258
Service Brake260
Service brake operation260
Service brake friction plate261
Service brake steel plate261
Service brake piston262
Brake circuit air bleeding procedure263
Bleeding air from brake pipes and axle housing hubs264
Parking Brake265
Parking brake operation266
Parking brake solenoid valve267
Solenoid valve operation267
Solenoid valve specifications267
Parking Brake Manual Release268
Parking Brake Spring Chamber270
Secondary Brake271
Secondary brake structure272
Secondary brake operation272
Dry type disc brake auto adjuster mechanism273
Manual release of secondary brake274
Solenoid valve for brake275
Structure275
Operation275
Solenoid specifications275
Secondary brake line air bleeding procedure276
Air bleeding position276
Air bleeding procedure276
Brake Circuit Check Valve277
Pressure Sensor (for stop lamp and declutch)278
Pressure sensor (for Declutch)278
Pressure sensor (for stop lamp)278
53 Check & Adjustment Brake Group282
Brake Circuit Oil Pressure283
Unloader valve setting pressure283
Unloader valve setting pressure measurement284
Brake valve oil pressure285
Brake valve oil pressure measurement285
Brake valve performance286
Service Brake287
Service brake performance check287
Service brake friction plate wear measurement288
Cautions on installing brake discs289
Parking Brake290
Parking brake performance check290
Parking brake clearance adjustment291
Adjustment procedure292
Brake lining abrasion check292
62 Function & Structure Electrical Group294
How to Use Electrical Wiring Diagram295
Utilisation des schémas des câblages électriques (FRANÇAIS)296
Verwendung des elektrischen Schaltplans (DEUTSCH)297
Modalità di utilizzo dello schema dei collegamenti elettrici (ITALIANO)298
Cómo utilizar un Diagrama de Alambrado Eléctrico (ESPAÑOL)299
Como Utilizar o Diagrama de Ligações Eléctricas (PORTUGUÊS)300
Electrical Cable Color Codes301
Electrical Circuit Symbols302
Sensor Mount303
Fuse304
Fuse box304
Fusible link306
Engine Start Circuit307
Engine start circuit diagram307
Neutral starter307
Shift lever neutral (N) position307
Shift lever forward/reverse (F/R) position308
Starter switch309
ECM safety features310
Battery relay310
Battery relay operation310
Alternator I terminal wire311
Diode unit311
Neutral relay312
Magnetic switch313
Voltage relay314
Power Generating/Charging Circuit315
Alternator315
ECM (Engine Controller)316
Function of ECM316
Connection diagram316
Monitor lamp test317
Failure diagnosis318
Engine diagnostic switch (option)318
Failure diagnostic chart319
Increment decrement switch (option)320
Quantum fault code information321
Accelerator pedal327
Accelerator pedal installation328
Transmission Control Circuit and Monitor Circuit330
Machine control unit (MCU)330
Machine control unit (MCU) connection diagram332
Machine control unit (MCU) function334
Forward/reverse (F/R) shifting and speed change334
Automatic shift336
Machine speed sensor337
Switching from automatic to manual338
Downshift button operation338
Adjustable declutch preset switch339
Back-up alarm340
Parking brake341
Machine control unit (MCU) failure warning343
Secondary steering function (OPT)344
Monitoring system346
Items to be monitored and operation condition346
Operation monitor lamps347
Instrument Panel and Switch348
Instrument panel348
Instrument panel rear surface349
Gauge circuit350
Fuel level sensor352
MODM354
MODM function354
Monitor Changeover354
Information Monitor357
Information monitor display357
Unit conversion and language selection360
Replacement Monitor361
Replacement time check361
Replacement interval set (timer reset)365
Replacement interval pop-up366
Display language367
Fault Log Monitor367
Fault log history check367
Selection of machine fault log and engine fault log368
Machine fault log navigation369
Engine fault log navigation369
Clear fault log369
Clear active fault log (error pop up)370
Input/Output Monitor374
Input/Output monitor display374
Parameter Setting Monitor378
Parameter setting monitor display378
Specification Setting Monitor387
Specification setting monitor display387
All setting reset390
Electrical Detent Circuit393
Bucket leveler393
Proximity switch393
Detent solenoid394
Lift kickout & lower kickout395
Location395
Lift kickout395
Lower kickout396
Sensor assy397
Detent solenoid399
Preset height adjustment399
Diode400
Diode check method401
Caution for diode check method401
Continuity check mode401
Diode check mode401
Resistance check mode402
Surge voltage and surge suppression diodes403
72 Function & Structure Operator Station Group404
Cabin405
Glass406
Wiper mount409
Front wiper409
Rear wiper409
Wiper motor410
Operator Seat412
Steering and Transmission Shift Lever413
Tilt case414
Column shaft415
Shift lever415
Air Conditioner416
Denso air conditioner components416
Air conditioner specifications (system performance)416
Denso air conditioner structure417
Cooling unit417
Heater and accessories419
Air distributor (hood & defroster selection box)419
Air compressor (with magnetic clutch)420
Condenser unit420
Control unit421
Function of cooling mechanism422
Principle of cooling422
Refrigerant423
Refrigerant characteristics424
Cooling circuit425
Electrical circuit426
Control schematic drawing426
Air conditioner functions of components427
Control panel427
Air conditioner unit434
Compressor and magnetic clutch443
Condenser unit446
Receiver dryer448
Sight glass450
Pressure switches450
Pressure relief valve452
Relay A453
Relay B453
Refrigerant hose454
Charge of refrigerant455
Work procedure456
Refrigerant charging tools458
Refrigerant charging procedure461
Troubleshooting using the gauge manifold467
Air conditioner troubleshooting472
Fault diagnosis procedure472
73 Check & Adjustment Operator Station Group480
Air Conditioner481
Adjustment of lubricating oil quantity when components of air conditioner are replaced481
Adjustment of air gap (between hub and rotor) in compressor magnetic clutch484
Compressor V-belt adjustment485
Parts to be replaced periodically487
Air filters487
Receiver dryer487
INDEX488
Maintenance Log493
Notes497
Axle Assembly502
Torque Converter and Transmission503
Hydraulic & Brake Circuit504
Electrical Wiring Diagram (S/N 9001~9070)506
(1/3) 506
(2/3)507
(3/3)508
Electrical Wiring Diagram (S/N 9071~9200)509
(1/3)509
(2/3)510
(3/3)511
Electrical Wiring Diagram (S/N 9201~9350)512
(1/3)512
(2/3)513
(3/3)514
Electrical Wiring Diagram (S/N 9351~)515
(1/3)515
(2/3)516
(3/3)517
Electrical Wiring Diagram518
Way of looking at connectors518
Electrical wiring diagram abbreviation chart520
Electrical Wiring Diagram (CAB)521
Electrical Connection Diagram (S/N 9001~9200)524
(1/2)524
(2/2)525
Electrical Connection Diagram (S/N 9201~9350)526
(1/2)526
(2/2)527
Electrical Connection Diagram (S/N 9351~)528
(1/2)528
(2/2)529
Cabin Air Conditioner530
Electrical Wiring Diagram530
Electrical Circuit Diagram531
Equipment Operation Table532
Electrical Equipment Layout533
Front chassis533
Rear chassis535
Floor board539
Control box540
Electrical Equipment Layout (K-Lever)543
Outline of MODM (Machine Operation Diagnostic Module) Operation544
Main Menu545
Information Monitor546
Replacement Monitor547
Fault Log Monitor548
Input/Output Monitor549
Parameter Setting Monitor550
Specification Setting Monitor551
MODM: Input/Output Monitor – Input/Output Signal Correspondence Table553

S.M 3/2/2025