Kawasaki Wheel Loader 95Z7 Service manual + Parts manual + Wiring diagrams + Troubleshooting manual – PDF DOWNLOAD
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Kawasaki Wheel Loader 95Z7 Service manual + Parts manual + Wiring diagrams + Troubleshooting manual
Description
Kawasaki Wheel Loader 95Z7 Service manual + Parts manual + Wiring diagrams + Troubleshooting manual
File Details:
Kawasaki Wheel Loader 95Z7 Service manual + Parts manual + Wiring diagrams + Troubleshooting manual
Language : English
Pages : 8000+
Size : 368 MB
Downloadable : Yes
Format : PDF
KAWASAKI WHEEL LOADER 95Z7 SERVICE MANUAL + PARTS MANUAL + WIRING DIAGRAMS + TROUBLESHOOTING MANUAL – PDF DOWNLOAD:
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Table of Contents:
Kawasaki Wheel Loader 95Z7 Service manual + Parts manual + Wiring diagrams + Troubleshooting manual
FOREWORD.................................................................................... 3 INDEX....................................................................................... 4 CONTENTS.................................................................................... 6 MACHINE NUMBERS............................................................................. 12 Aftertreatment Device................................................................... 13 SAFETY...................................................................................... 14 Recognize Safety Information............................................................ 14 Understand Signal Words................................................................. 14 Follow Safety Instructions.............................................................. 15 Prepare for Emergencies................................................................. 16 Wear Protective Clothing................................................................ 16 Protect Against Noise................................................................... 17 Inspect Machine......................................................................... 17 General Precautions for Cab............................................................. 18 Use Handrails and Steps................................................................. 19 Never Ride Attachment................................................................... 19 Adjust Operator’s Seat.................................................................. 19 Ensure Safety Before Rising from or Leaving Operator’s Seat............................. 20 Fasten Your Seat Belt................................................................... 20 Move and Operate Machine Safely......................................................... 21 Handle Starting Aids Safely............................................................. 21 Operate Only from Operator’s Seat....................................................... 22 Jump Starting........................................................................... 22 Investigate Job Site Beforehand......................................................... 23 Equipment of Head Guard, ROPS, FOPS..................................................... 24 Provide Signals for Jobs Involving Multiple Machines.................................... 24 Keep Riders Off Machine................................................................. 25 Drive Safely............................................................................ 25 Drive Machine Safely (Work Site)........................................................ 26 Drive Safely with Bucket Loaded......................................................... 27 Drive on Snow Safely.................................................................... 27 Travel on Public Roads Safely........................................................... 28 Avoid Injury from Rollaway Accidents.................................................... 28 Avoid Accidents from Backing Up and Turning............................................. 29 Avoid Positioning Bucket or Attachment Over Anyone...................................... 30 Avoid Tipping........................................................................... 30 Never Undercut a High Bank.............................................................. 31 Dig with Caution........................................................................ 31 Perform Truck Loading Safely............................................................ 31 Avoid Power Lines....................................................................... 32 Precautions for Operation............................................................... 32 Precautions for Lightning............................................................... 32 Object Handling......................................................................... 33 Protect Against Flying Debris........................................................... 33 Park Machine Safely..................................................................... 34 Store Attachments Safely................................................................ 34 Transport Safely........................................................................ 35 Handle Fluids Safely−Avoid Fires........................................................ 36 Practice Safe Maintenance............................................................... 37 Warn Others of Service Work............................................................. 38 Support Machine Properly................................................................ 38 Stay Clear of Moving Parts.............................................................. 39 Support Maintenance Properly............................................................ 39 Prevent Parts from Flying............................................................... 40 Prevent Burns........................................................................... 40 Replace Rubber Hoses Periodically....................................................... 41 Avoid High-Pressure Fluids.............................................................. 41 Prevent Fires........................................................................... 42 Evacuating in Case of Fire.............................................................. 43 Beware of Exhaust Fumes................................................................. 44 Precautions for Welding and Grinding.................................................... 44 Avoid Heating Near Pressurized Fluid Lines.............................................. 44 Avoid Applying Heat to Lines Containing Flammable Fluids................................ 45 Precautions for Handling Accumulator and Gas Damper..................................... 45 Precautions for Diesel Exhaust Fluid (DEF).............................................. 45 Remove Paint Before Welding or Heating.................................................. 46 Beware of Asbestos and Silicon Dust and Other Contamination............................. 46 Prevent Battery Explosions.............................................................. 47 Service Air Conditioning System Safely.................................................. 47 Handle Chemical Products Safely......................................................... 48 Dispose of Waste Properly............................................................... 48 Notes for Aftertreatment Device......................................................... 49 Precautions for Communication Terminal.................................................. 49 Articulation Stopper (Lock Bar)......................................................... 51 Joystick Steering System ON/OFF (Option)................................................ 52 SAFETY LABELS............................................................................... 53 1-1 COMPONENTS NAME......................................................................... 66 Components Name......................................................................... 66 1-3 OPERATOR'S STATION...................................................................... 68 Aftertreatment Device................................................................... 68 Automatic Regeneration.................................................................. 70 Repeated Inhibiting of Aftertreatment Device Cleaning............................... 71 Cab Features............................................................................ 72 Front Console........................................................................... 73 Joystick Steering (Option).............................................................. 74 Right Console Fingertip Control Type.................................................... 76 Right Console Multi-Function Joystick Type.............................................. 76 1-12 Monitor Panel.......................................................................... 77 Parking Brake Indicator (Red)........................................................... 78 Brake Oil Low Pressure Indicator (Red).................................................. 78 Hydraulic Oil Level Indicator (Red)..................................................... 78 Low Steering Oil Pressure Indicator (Option) (Red)...................................... 79 Transmission Warning Indicator (Red).................................................... 79 Communication Error Indicator (Yellow).................................................. 79 Discharge Warning Indicator (Red)....................................................... 79 Engine Warning Indicator (Red).......................................................... 80 Overheat Indicator (Red)................................................................ 80 Engine Oil Low Pressure Indicator (Red)................................................. 80 Air Filter Restriction Indicator (Red).................................................. 81 Preheat Indicator (Yellow).............................................................. 81 Coolant Temperature Gauge............................................................... 82 Fuel Gauge.............................................................................. 82 Turn Signal Indicator (Green)........................................................... 83 High Beam Indicator (Blue).............................................................. 83 Work Light Indicator (Yellow)........................................................... 83 Clearance Light Indicator (Green)....................................................... 84 Control Lever Lock Indicator (Red)...................................................... 84 1-20 Multi Function Monitor................................................................. 85 Default Setting......................................................................... 86 Basic Screen............................................................................ 87 How to Use Screens...................................................................... 88 Alarm Occurrence Screen................................................................. 93 Remedy.............................................................................. 95 DEF/SCR System Alarm.................................................................... 98 DEF/AdBlue Level Alarm.............................................................. 98 Urea SCR System Malfunction......................................................... 99 1-35 Aftertreatment Device Regeneration.....................................................100 Aftertreatment Device Regeneration Status Display.......................................100 Automatic regeneration (Auto-regeneration)..............................................101 Manual Regeneration.....................................................................102 1-38 Main Menu..............................................................................103 Ride Control Drive Speed Setting (Option)...............................................104 Dual Lift Arm Auto-Leveler..............................................................105 Brightness Adjustment...................................................................107 Mail (Option)...........................................................................109 1-46 Setting Menu...........................................................................111 Date and Time...........................................................................112 Time Adjustment.....................................................................112 Date Adjustment ....................................................................114 Display Mode Setting................................................................116 Auto Idling Stop........................................................................118 Acting Time Setting.................................................................119 Rear View Camera Monitor................................................................120 Aftertreatment Device Regeneration Inhibited............................................122 Transmission Setting....................................................................124 Shift Change Delay Mode Setting ....................................................124 Lockup Setting .....................................................................126 Traction Control Setting ...........................................................128 Parallel/Tandem Switching Height Setting................................................130 Warm Up Operation.......................................................................132 Display Item Selection..................................................................134 Main Menu Display Order Change..........................................................136 1-73 Information Menu.......................................................................138 Operation Condition.....................................................................139 Fuel Consumption....................................................................139 Maintenance.............................................................................141 Maintenance Notice..................................................................141 Time Remains and Maintenance Interval...............................................143 Troubleshooting.........................................................................145 Monitoring..............................................................................147 1-85 Front Console Switches, Pedals, Steering Wheel, and Joystick Steering (Option).........150 Hazard Switch...........................................................................151 Work Light Switch.......................................................................152 Parking Brake Switch....................................................................153 Neutral Lever Lock (for the Forward/Reverse Lever)......................................154 Key Switch..............................................................................155 Steering Wheel..........................................................................155 Horn Switch.............................................................................179 Joystick Steering (Option)..............................................................156 Joystick Steering Lever.............................................................156 Forward/Reverse Switch..............................................................156 Joystick Steering System Switch.....................................................156 Turn Signal Lever.......................................................................157 Turn Signal Switch (Option).............................................................157 Light Switch............................................................................158 High-Low Beam Switch....................................................................159 Accelerator Pedal.......................................................................160 Brake Pedal.............................................................................160 Service Brake.......................................................................160 Declutch Brake......................................................................160 Forward/Reverse Lever and Shift Switch..................................................161 Forward/Reverse Lever...............................................................161 Shift Switch........................................................................161 Tilt, Telescopic Lever/Steering Column Tilt Pedal.......................................162 Wiper Switch............................................................................162 Wiper Operation.....................................................................162 Front/Rear Wiper Switch.............................................................163 1-102 Right Console / Switches Fingertip Control Type.......................................167 Loading Control Levers..................................................................165 Right Console / Switches Multi-Function Joystick Type...................................167 Loading Multi-Function Joystick Lever (Option)..........................................168 Auxiliary Control Lever (Option)........................................................169 Forward/Reverse Selector Switch.........................................................170 Loading Control Lever Lock Switch.......................................................171 Declutch Position Switch................................................................171 Travel Mode Selector Switch.............................................................172 Power Mode Selector Switch..............................................................173 Fan Reverse Rotation Switch.............................................................174 AUTO ...............................................................................177 Manual Operation ...................................................................175 Hydraulic Coupler Switch (Option).......................................................175 Secondary Steering Operation Check Switch (Option)......................................176 Aftertreatment Device Regeneration Switch...............................................176 Ride Control Switch (Option)............................................................177 AUTO................................................................................177 OFF.................................................................................177 Hold Switch.............................................................................178 Right Console Slide Lever...............................................................179 Horn Switch.............................................................................179 Quick Power Switch......................................................................180 DSS (Down Shift Switch).................................................................181 1-116 OPERATOR'S STATION....................................................................181 Cigar Lighter (24 V DC Electrical Outlet)...............................................182 Ash Tray................................................................................182 Auto Air Conditioner....................................................................183 Feature ............................................................................183 Components Name.....................................................................184 Controller Part Name and Function...................................................185 Tips for Optimal Air Conditioner Usage..................................................190 Adjusting Operator's Seat (Air Suspension Type Seat)....................................191 Rear Tray...............................................................................192 Electric Power Output (Option)..........................................................192 Fuse Box................................................................................193 Hot/Cool Box............................................................................195 Tray and Drink Holder...................................................................195 1-131 ROPS Cab..............................................................................196 Front Interior Light....................................................................198 Rear Interior Light.....................................................................198 Sun Visor...............................................................................199 Emergency Exit Hammer...................................................................199 Coat/Hat Hook...........................................................................199 Upper Switch Panel (Option).............................................................200 Rotary Light Switch (Option)............................................................200 Outside Rear View Mirror................................................................201 Inside Rear View Mirror.................................................................201 Cab Door................................................................................201 Door Lock Knob..........................................................................202 Door Open/Close Lever...................................................................202 Window Open/Close Levers................................................................202 1-138 OPERATOR'S STATION....................................................................203 Battery Disconnect Switch...............................................................203 Articulation Stopper (Lock Bar).........................................................205 Towing Pin..............................................................................206 Inspection/Maintenance Side Access Cover................................................207 Rear Grille.............................................................................208 Steps...................................................................................209 Tool Box................................................................................209 Vandal-Resistant Devices................................................................210 2 BREAK-IN..................................................................................212 Break-in Period for New Machine.........................................................212 Work Mode for Break-in..................................................................212 3 OPERATING THE ENGINE......................................................................214 Inspect Machine Daily Before Starting...................................................214 Check Before Starting...................................................................216 Starting Engine.........................................................................219 Starting in Cold Weather................................................................221 Check After Starting....................................................................222 Using Booster Batteries.................................................................223 Warm Up.................................................................................225 Cold Weather Warm Up....................................................................226 Stopping Engine.........................................................................228 4 MOVING THE MACHINE........................................................................230 Driving the Machine.....................................................................230 Starting to Move........................................................................231 Parking Brake Switch....................................................................236 Drive Speed Change......................................................................237 Changing Forward/Reverse Drive Direction................................................237 Steering Wheel..........................................................................238 Joystick Steering (Option)..............................................................239 Secondary Steering (Option).............................................................240 Emergency Stop and Restart of Operation.................................................240 Precautions for Traveling...............................................................241 Operating in Water or on Soft Ground....................................................242 Precautions for Driving on Slopes.......................................................243 Precautions to be Taken if Machine Failure Occurs.......................................244 Stop....................................................................................245 Parking.................................................................................247 Emergency Stopping......................................................................248 Auto Brake..............................................................................249 5 OPERATING THE MACHINE.....................................................................250 Loading Control Levers..................................................................250 Control Lever Lock......................................................................253 Declutch Position Switch................................................................254 Adjustment of Bucket Auto Leveler.......................................................255 Adjustment of Dual Lift Arm Auto Leveler................................................259 Auto Idling Stop........................................................................260 Aftertreatment Device Manual Regeneration...............................................262 Before Operation........................................................................265 Precautions for Operation...............................................................265 Ensure Safety When Operating on Road Shoulders..........................................265 Avoid Overloading.......................................................................266 Avoid Rapid Steering Changes and/or Sudden Braking......................................266 Avoid Operation with Loads on Only One Side.............................................266 Excavation..............................................................................267 Grading.................................................................................269 Loading.................................................................................270 Dozing..................................................................................273 Stock Piling............................................................................273 Removing Snow...........................................................................274 Lifting Wheel Loader....................................................................274 Precautions for After Operation.........................................................275 6 TRANSPORTING..............................................................................278 Transporting by Road....................................................................278 Selecting a Trailer.....................................................................278 Loading / Unloading on Trailer..........................................................279 Fastening Machine for Transporting......................................................281 Transporting Wheel Loader (Urgent Situation)............................................282 Towing Method...........................................................................286 Lifting Machine.........................................................................287 7 MAINTENANCE...............................................................................288 Correct Maintenance and Inspection Procedures...........................................288 Check the Hour Meter Regularly..........................................................290 Layout..................................................................................291 Preparations for Inspection and Maintenance.............................................293 Articulation Lock.......................................................................295 Inspection/Maintenance Side Access Cover................................................296 Rear Grille.............................................................................297 Inspection and Maintenance Table........................................................298 Kind of Oils............................................................................302 Recommended Grease..................................................................302 Recommended Engine Oil .............................................................302 Recommended Transmission Oil .......................................................303 Recommended Axle Oil ...............................................................303 Recommended Hydraulic Oil ..........................................................304 A. Greasing.................................................................................305 B. Engine...................................................................................311 Check Engine Oil Level ................................................................311 Change Engine Oil ......................................................................312 Replace Engine Oil Filter...............................................................314 Check Oil Separator Hose................................................................315 Change Oil Separator Element............................................................315 C. Power Train..............................................................................316 Check Transmission Oil Level............................................................316 Change Transmission Oil ................................................................317 Change Transmission Oil Filter .........................................................317 Clean Torque Converter Air Breather ....................................................320 Check Axle Oil Level ..................................................................321 Change Axle Oil .......................................................................323 Replace Axle Oil Cooler Line Filter (Option) ...........................................325 Clean Axle Oil Cooler Fins (Option) ....................................................325 D. Hydraulic System.........................................................................326 Inspection and Maintenance of Hydraulic Equipment ......................................326 Check Hydraulic Oil Level ..............................................................327 Change Hydraulic Oil ...................................................................328 Clean Suction Filter ...................................................................330 Clean Pilot Oil Filter .................................................................331 Replace Hydraulic Oil Return Filter.....................................................334 Replace Air Breather Element............................................................335 Check Pilot Circuit Accumulator Function, Gas Leakage, Looseness, and Damage............336 Check Ride Control Accumulator Function, Gas Leakage, Looseness, and Damage (Option)....337 Check Gas Pressure in Ride Control Accumulator (Option).................................337 Check Gas Pressure in Steering Accumulator..............................................337 Check Hoses and Lines...................................................................338 E. Fuel System..............................................................................343 Check Fuel Level........................................................................343 Recommended Fuel....................................................................343 About Biodiesel Fuel................................................................343 Refueling ..........................................................................344 Drain Water and Sediment from Fuel Tank.................................................345 Drain Fuel Filter.......................................................................346 Draining Procedures (Pre-Filter)....................................................347 Bleed Air from the Fuel System......................................................348 Replace Fuel Main Filter Element........................................................350 Replace Fuel Pre-Filter Element.........................................................352 Clean Fuel Pump Strainer................................................................353 Check Fuel Hoses........................................................................354 Check Water Separator (Option)..........................................................355 F. Air Cleaner..............................................................................357 Replace Air Cleaner Element.............................................................357 G. Cooling System...........................................................................358 Coolant.................................................................................358 Check Coolant Level.....................................................................359 Check Fan Drive Belt ...................................................................360 Adjusting Fan Belt..................................................................360 Replacing Fan Belt..................................................................361 Change Coolant..........................................................................362 Clean Radiator/Oil Cooler Cores and Other Cooling System................................365 H. Electrical System........................................................................366 Batteries...............................................................................366 Electrolyte Level Check.............................................................368 Check Electrolyte Specific Gravity..................................................369 Replace Batteries...................................................................370 Check Monitor Functions and All Other Instrument Operation..............................370 Check Work Lights.......................................................................371 Check Horn and Backup Alarm.............................................................372 Check Electrical Harnesses and Fuses....................................................373 Replace Fuse........................................................................373 Fuse Box A .........................................................................374 Fuse Box B .........................................................................374 I. Brake System.............................................................................375 Check Right and Left Brake Interlocking Performance.....................................375 Check Parking Brake Force ..............................................................376 Check Parking Brake Gear Oil Level .....................................................377 Change Parking Brake Gear Oil ..........................................................378 Check Accumulator Function, Gas Leakage, Looseness, and Damage..........................379 Check Gas Pressure in Accumulator.......................................................380 Check Brake Disks (Service and Parking).................................................380 J. Tire.....................................................................................381 Check and Replace Tire (Tire Pressure)..................................................381 Check Tire for Damage...................................................................382 Check Wheel Bolt Torque.................................................................382 Replace Tire........................................................................382 Tire Rotation.......................................................................384 How to Check Wear Amount (Tread Design Groove Depth)................................384 Removal and Installation of Tire ...................................................385 Tire Wheel..........................................................................385 K. Air Conditioner..........................................................................386 Clean/Replace Air Conditioner Circulation/Fresh Air Filters.............................386 Clean Fresh Air Filter..............................................................386 Clean Circulation Air Filter........................................................388 Check Air Conditioner...................................................................389 Check Air Conditioner Piping............................................................389 Check Air Conditioner Condenser.........................................................390 Check Air Conditioner Compressor Belt...................................................390 Compressor Belt Tension Adjustment Procedure........................................390 Check Refrigerant.......................................................................391 Replace Air Conditioner Receiver Dryer..................................................391 Check Compressor and Pulley.............................................................391 L. Aftertreatment Device....................................................................392 Check and Clean Aftertreatment Device...................................................392 M. Urea SCR System..........................................................................393 Specified DEF/AdBlue....................................................................393 Check DEF Level.........................................................................394 Refill DEF..........................................................................394 DEF Exchange Procedure..............................................................396 Replace DEF Supply Module Main Filter...................................................397 Check Dosing Module.....................................................................398 N. Miscellaneous............................................................................399 Check Bucket Teeth and Cutting Edge.....................................................399 Check and Replace Seat Belt and Lower Tether............................................400 Check ROPS cab, Resin Cab Roof, and Roof ...............................................400 Check Windshield Washer Fluid Level ....................................................400 Check Play Amount in Steering Wheel Movement............................................401 Check Play Amount in Joystick Steering Movement (Option)................................402 Check Accelerator Pedal Operation, and Exhaust Gas Color and Noise......................403 Check Rearview Mirror and Inside Rearview Mirror .......................................404 Check Steps and Handrails for Damage and Looseness .....................................404 Clean Engine Compartment and Hood ......................................................405 Check Sound Absorbing Mat Around Engine.................................................405 Check and Adjust Valve Clearance .......................................................405 Check Engine Compression Pressure ......................................................405 Check and Clean Starter and Alternator .................................................406 Check Fuel Injector.....................................................................406 Check Turbocharger .....................................................................406 Check and Adjust Engine Controller (ECM) ...............................................406 Check and Clean EGR Valve ..............................................................406 Check and Clean EGR Cooler..............................................................406 Check Urea SCR System ..................................................................406 Retighten Front Axle and Rear Axle Support Mounting Bolts...............................407 Check Tightening Torque of Nuts and Bolts...............................................408 Tightening Torque Chart.............................................................408 9 MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS........................................420 Maintenance Under Special Environmental Conditions......................................420 Precautions for Maintenance During Cold Weather Season..................................421 10 STORAGE..................................................................................424 Storing the Machine.....................................................................424 11 TROUBLESHOOTING..........................................................................428 Troubleshooting.........................................................................428 12 SPECIFICATIONS...........................................................................434 Specifications..........................................................................434 INDEX.......................................................................................436
Description:
Kawasaki Wheel Loader 95Z7 Service manual + Parts manual + Wiring diagrams + Troubleshooting manual
The service manual covers the following files:
93315-00570_se.pdf
93315-00571-1.pdf
93315-00571-2.pdf
93315-00580.pdf
93315-00580_SE.pdf
93315-00581_.pdf
93315-00641.pdf
93315-00641_SE (1).pdf
93315-00641_SE.pdf
93315-00650(TIRKEY).pdf
-E-95Z7B+US.pdf
??95Z7B+?????+93315-00560.pdf
6WG1(95_115Z7+US)DR-Cover(KCM).pdf
6WG1(95_115Z7+US)FS+93215-00620.pdf
6WG1(95_115Z7+US)FS-Cover(KCM).pdf
6WG1(95Z7+US)DR+93215-00630.pdf
95Z7,+115Z7+PC+????-Cover.pdf
95Z7_US-00667.pdf
95Z7+DR+TR(US).pdf
95Z7+DR+TR-Cover.pdf
95Z7+T+TR(US).pdf
95Z7+T+TR-Cover.pdf
95Z7B(US-D&R).pdf
95Z7B(US-F&S)-TD.pdf
95Z7B_FS_US+(00720).pdf
95Z7B_TS_US(00730).pdf
95Z7B+US+(93115-00700).pdf
93315-00442(PDF+1-3).pdf
93315-00442(PDF+3-3) (1).pdf
93315-00442(PDF+3-3).pdf
93315-00461_JPN_EU_USA_OCEANIA_turkey (1).pdf
93315-00461_JPN_EU_USA_OCEANIA_turkey.pdf
93315-00463.pdf
93315-00471_ALL.pdf
93315-00560.pdf
93315-00570.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]
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