Kawasaki Wheel Loader 95ZIV-3 Operation Maintenance Shop Parts Manual – PDF DOWNLOAD

Description

Kawasaki Wheel Loader 95ZIV-3 Operation Maintenance Shop Parts Manual – PDF DOWNLOAD

FILE DETAILS:

Kawasaki Wheel Loader 95ZIV-3 Operation Maintenance Shop Parts Manual – PDF DOWNLOAD

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

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Kawasaki Wheel Loader 95ZIV-3 Operation Maintenance Shop Parts Manual – PDF DOWNLOAD

95ZIV-3 Shop Manual General Information Functions & Structure 93215-00101 
95ZIV-3 Shop Manual Troubleshooting Measurement for Performance Check 93215-00112 
95ZIV-3 Shop Manual Disassembly & Reassembly Service Standard 93215-00121 
95ZIV-3 Supplement Shop Manual General Information Functions & Structure
95ZIV-3 Operation & Maintenance Manual 93115-00092 (EXP)(EU) 2000
95ZIV-3 Operation & Maintenance Manual AAA-M97C3E02-00Y
95ZIV-3 Dozer Parts Manual AAAP09814-0 (93315-00100) EN
95ZIV-3 Quick Fork For Marble Parts Manual AAAP09844-1 EN 

FORWORD

• Kawasaki pursues a policy of continuing improvement in design and performance of this machine. The right is therefore reserved to vary specifications without prior notice or obligation.
• This machine gives you, our customer, the maximum in performance and durability, state of the art technology and safety. Should you have any question regarding this machine or manual, please contact the Kawasaki loader dealer in your area during regular business hours. A satisfied customer is our goal.
• This manual is compiled for persons who understand English. If an operator or maintenance person does not understand English, please translate what said in this manual into his mother language.

TABLE OF CONTENTS:

Kawasaki Wheel Loader 95ZIV-3 Operation Maintenance Shop Parts Manual – PDF DOWNLOAD

List of Files:
95ZIV-3 Shop Manual General Information Functions & Structure 93215-00101 
95ZIV-3 Shop Manual Troubleshooting Measurement for Performance Check 93215-00112 
95ZIV-3 Shop Manual Disassembly & Reassembly Service Standard 93215-00121 
95ZIV-3 Supplement Shop Manual General Information Functions & Structure
95ZIV-3 Operation & Maintenance Manual 93115-00092 (EXP)(EU) 2000
95ZIV-3 Operation & Maintenance Manual AAA-M97C3E02-00Y
95ZIV-3 Dozer Parts Manual AAAP09814-0 (93315-00100) EN
95ZIV-3 Quick Fork For Marble Parts Manual AAAP09844-1 EN 

FOREWORD 157
Safety Precautions 158
Safety Symbols 159
Symbols 160
OUTLINE 162
Layout of Main Components 163
Recommended Lubricants 164
Lubrication Chart 165
Weight of Main Components 166
Hexagon Bolt Tightening Torque 167
Hose Band Tightening Torque 169
Flanged Hexagon Bolt Tightening Torque 170
Liquid Gasket and Screw Lock Agent 171
Cautions regarding parts removal 171
Cautions regarding reassembly 171
Cautions Regarding Welding Repair Service 172
CHASSIS GROUP 174
Front Chassis 175
Loading system 175
Linkage 176
Rear Chassis 177
Fuel tank 177
Center Pin 178
Clearance Adjustment for Pin Section 179
Adjustment 179
Bucket Hinge Pin Section 180
How to assemble 180
Center Pin 181
Adjusting Shim(#5) 181
Installing bearing cover 181
Installing bearing outer ring(#3) 181
POWER GROUP 182
Outline of Power Line 183
Engine Mount 184
Radiator Mount 185
Propeller Shaft 186
Function 186
Construction 187
Adjusting yoke direction (phase) at reinstallation 187
Adjusting yoke directions (second propeller shaft) 187
Front Axle Assembly 188
Construction 188
Rear Axle Support 190
Construction 190
Differential Gear 192
Construction 192
Function 193
Difference in gear shapes 193
Contact between pinion and side gear 193
Fuel Control 197
TORQUE CONVERTER AND TRANSMISSION GROUP 198
Torque Converter and Transmission 199
Torque Converter 200
Operation of Torque Converter 200
Transmission 201
Outline of Transmission Operation 201
Gear Train and Number of Teeth 202
Clutch Pack 203
Gear Pump 204
Power Flow Path in the Transmission 205
Forward 1st speed 205
Forward 2nd speed 206
Forward 3rd speed 206
Forward 4th speed 206
Reverse 1st speed 207
Reverse 2nd speed 207
Reverse 3rd speed 207
Hydraulic System Diagram 208
Hydraulic Circuit Diagram 209
Torque Converter/Transmission Oil Flow 210
Oil flow in the torque converter line 210
Oil flow to the clutch 210
Modulator Valve Unit 211
Construction 211
Interior schematic (not exact representation) 212
Construction and Operation 214
Clutch Solenoid Valve 213
Construction and Operation 214
When not energized (Clutch disengaged) 214
When energized (Clutch engaged) 214
Modulation Mechanism 215
Function of modulator valve 1 215
Function of modulator valve 2 215
Function of pressure difference sensor 216
Clutch oil pressure control at the time of engine starting 216
Measuring Clutch Oil Pressure 218
HYDRAULIC GROUP 219
Loading/Steering Hydraulic Line 220
Loading/Steering Hydraulic System Diagram 221
Flushing Hydraulic Lines 222
Purpose of flushing 222
Flushing hydraulic line 222
Layout of Hydraulic Units 226
Hydraulic Tank 227
Hydraulic tank cap (with air breather) 228
Functions 228
Specifications of hydraulic tank 229
Hydraulic Oil Level Check 230
Hydraulic Pump 231
Double Pump 231
Features 232
Action of Floating Wear Plate 232
Hydraulic Cylinder 233
Boom cylinder 233
Bucket cylinder 233
Steering cylinder 233
Cylinder specifications 234
Loading System 235
Operation 235
Pilot Valve 236
Structure 236
Function 237
Operation (Modulated position) 237
Operation (Full pressure position) 238
Detent magnet solenoid 239
Pilot Control Line Filter 240
Construction 240
Function 240
Pilot Relief Valve Unit 241
Construction 241
Relief valve 242
Function 242
Operation 242
Check valve 242
Construction 242
Multiple Control Valve (KML) 243
Main relief valve 244
Function 244
Operation 244
Bucket plunger 245
Boom plunger 247
Overload relief valve (with make-up function) 250
Operation 250
Make-up valve 251
Adapter (with orifice) 252
Construction 252
Location 252
Function 252
Steering System 253
Operation 253
Steering Valve (Pilot) 254
Construction 254
Operation 255
Neutral 255
Turn 256
Operation of feed-back mechanism 257
Steering speed and flow rate control 258
Operating principle of the rotor 259
Main Steering Valve 260
Function 261
Operation 262
Variable throttle of steering plunger 264
Operation of flow control plunger 264
Main relief valve 265
Overload relief valve (with make-up function) 266
Construction 266
Operation 266
Operation as overload relief valve 267
Pilot circuit and its operation 268
Oil flow 268
Operation of the pilot groove (flow amplifier notch) 269
Emergency Steering 270
Function 270
Operation condition 270
Oil flow 270
In normal operation 270
When the emergency steering system works 270
Hydraulic Line Diagram 271
Stop Valve 272
Construction 272
Operation 272
Accumulator 273
Function 273
BRAKE GROUP 274
Brake Circuit 275
Outline of brake system 276
Layout of Brake Units 277
Unloader Valve 279
Function 280
Brake Valve 281
Brake Valve (Main Valve) 281
Construction 282
Function 282
Brake Valve (Pilot Valve) 283
Auto-adjuster Valve 285
Construction 285
Operation 286
Service Brake 287
Construction 287
Friction plate 288
Steel plate 288
Checking Wear of Service Brake Friction Plate 289
Purging Air from Park Brake / Auto Brake Circuits 290
Bleeding park brake circuit 290
Bleeding auto brake circuit 291
Brake Line Air Bleeding 292
Air bleeding positions and its order 292
Parking Brake 294
Brake drum construction 294
Construction 295
Adjusting Parking Brake Clearance 296
Adjusting clearance 296
Checking brake lining for abrasion loss 296
Parking Brake (for front) 297
Solenoid Valve (for front parking brake) 298
Solenoid Valve (for rear parking brake) 299
Manual operation 300
Solenoid Valve (for auto brake) 301
Installation position 301
Operation 301
Oil Cylinder 302
Operation 302
Accumulator 303
Reducing Valve 304
Operation 304
Low Pressure Switch 305
Structure 305
Construction 305
ELECTRICAL GROUP 306
How to Use Electrical Wiring Diagram 308
Cable Color Codes 309
Cable color code 309
Electrical Wiring Diagram 310
Layout of Electrical Equipment 314
Front chassis 314
Floor board and cab 315
Rear chassis(1/2) 316
Rear chassis(2/2) 317
Electrical Connection Diagram 318
Layout of Electrical Equipment Inside Cab Control Box 320
Layout of Electrical Equipment Around Battery Relay 321
Fusible Link/Fuse 322
Fuse inside the control box 322
Fusible link 323
Problems caused by fused fusible link 323
Engine Start Circuit 324
Neutral starting device 324
Shift lever neutral (N) position 324
Shift lever forward/reverse 「F 」「R 」position 324
Starter switch 326
Function 326
Battery relay 327
Function 327
Operation 327
Diode unit 327
Neutral relay 328
Magnet switch 329
Voltage relay 329
Alternator/Charge Circuit 330
Alternator 330
Engine Stop Circuit 331
Transmission Control Circuit and Monitor Circuit 332
Controller 332
T/M Controller connection diagram 333
Forward/reverse(F/R)shifting and speed change 334
Operation of solenoid valve 335
Automatic shift 335
Switching from automatic to manual 336
Operation of QUAD switch 336
Shift lever 336
Clutch solenoid valve (Common to L H R 1 2 3 ) 337
QUAD switch 337
Sensor for machine speed and E/G revolution 337
Modulation at clutch switching 338
Modulator valve (1) [MV1 ] 339
Operation 339
Modulator valve (2) [MV2 ] 340
Transmission cut – off (Inching) 341
Inching pressure switch 341
Operation pressure 341
Contact 341
Return pressure 341
Back-up alarm 342
Back-up relay 342
Parking brake 344
In parking mode 344
In running mode 344
Operation of parking brake 344
Parking brake solenoid valve 345
Auto-brake 346
When shifting between forward and reverse occurs above 12km/hr 348
When machine speed is excessive 348
Auto brake solenoid valve 348
Warning for transmission controller failure 349
Emergency movement 350
Monitor Circuit 351
Monitor 351
Monitor controller 352
Instrument Panel 356
Rear surface of instrument panel 358
Gauge circuit 359
Temperature sensor (For engine water temperature and torque converter oil temperature) Resistance between gauge terminals (Ω) Between S and E 110 Between S and V 110 Between E and V 150 50 °C (122 °F) 120 °C (248 °F) Terminal 80 〔176 °F 〕 359
Tachometer circuit 360
Fuel gauge circuit 360
Fuel level sensor 360
Electric Detent Circuit 361
Bucket positioner 361
Boom kick-out unit 361
Float 361
Pilot valve 362
Emergency Steering Circuit 363
Electrical Wiring Diagram 363
Electrical Connection Diagram 363
Cautions Regarding Electric Circuit Check 364
Flow Chart for Troubleshooting of Electrical Transmission Control System 366
Judgment of Transmission Controller Abnormal Operation 367
On/Off Statuses of Transmission Controller LED Indicator 368
In running status 368
In parking status 369
Function of Diagnostic system for Electrical Transmission Controller 372
Failure Code (T/M controller) 373
Diagnostic (Transmission Controller) 375
Function of Diagnostic System for Monitor Controller 377
Warning Lamps Checked by Diagnostic Circuit 378
Failure record memory 379
Failure History Indication 380
Electrical Wiring Connection 381
Electrical Wiring Connection 381
Checking Shift Lever Input Circuit 382
Transmission controller LED indicator 382
Disconnection check 382
Shortcircuit check 382
Checking Inching (declutch) Input Circuit 384
Transmission controller LED indicator 384
Checking QUAD Switch Input Circuit 386
If the “S” indicator does not light: Checking QUAD switch 386
Checking Machine Speed Sensor Input Circuit 387
Checking Clutch Solenoid Valve Output Circuit 388
Checking Modulator Valve (1), (2) Input Circuit 390
Checking Neutral Relay Circuit 392
Checking Parking Brake Circuit 394
Checking Auto Brake Circuit 395
Checking Fuel Valve Circuit 396
Checking Gauge Circuit 398
Checking Fuel Level Gauge Circuit 400
Speedometer circuit 401
OPERATOR STATION GROUP 402
ROPS Cabin 403
Outline drawing 403
Connection diagram 404
Electrical wiring diagram 405
Rear (option) 407
Wiper motor 406
Floor Board 408
Operator seat 409
Layout of meters, lamps and switches 410
Monitor symbols and actuation conditions 411
Error warning lamps (which are lit in red) 411
Operation indicator lamps 412
Control box 413
Viscous mount 414
Floor board mounting area 414
Steering and Transmission Shift Lever 415
Structure 415
Steering shaft assembly 416
Column bushing 416
Handle tilt adjustment lever assembly 417
Transmission shift lever assembly 418
Transmission shift lever 419
Air Conditioner 420
Air conditioner mount 420
Specifications 421
Air conditioner line routing 421
Structure 422
Air conditioner unit 422
Air damper unit 423
Air duct unit 424
Compressor (with magnetic clutch) 424
Condenser unit 425
Control unit 425
Control panel 425
Cooling mechanism 426
Principle of cooling 426
Refrigerant 426
Refrigerant characteristics 427
Cooling circuit 428
Electrical circuit diagram 429
Electrical wiring diagram 430
Functions of components 431
Control unit 431
Control panel 431
Control amplifier 433
Troubleshooting the control unit 433
Air conditioner unit 434
Air mixing damper damper A point A selection 434
Evaporator 435
Troubleshooting the evaporator 435
Expansion valve (box type) 436
Operation of expansion valve (box type) 437
Troubleshooting the expansion valve 437
Heater radiator 438
Troubleshooting the heater radiator 438
Water valve 438
Troubleshooting the water valve 438
Actuator for air mixing 439
Specifications 439
Troubleshooting the actuator for air mixing 439
Duct for vent selection 440
Actuator for vent selection 441
Specifications 441
Troubleshooting the actuator for vent selec-tion 441
Blower motor assembly 442
Specifications 442
Troubleshooting the blower motor 442
Blower resistor 442
Troubleshooting the blower resistor 442
Thermistor 443
Troubleshooting the thermistor 443
Air filter and air damper box 444
Air damper box 444
Actuator for inside/outside air selection 445
Specifications 445
Troubleshooting the actuator for inside/out-side air selection 445
Air filter 446
Specifications 446
Troubleshooting the air filter 446
Compressor and magnetic clutch 447
Compressor 447
Specifications 447
Magnetic clutch 447
Specifications 448
Troubleshooting the compressor and mag-netic clutch 448
Condenser unit 449
Condenser 449
Condenser fan motor Refrigerant inlet 449
Specifications 449
Resistor 449
Specifications 449
Troubleshooting the condenser unit 449
Receiver dryer 450
Receiver tank 450
Desiccant 450
Strainers 450
Specifications 450
Troubleshooting the receiver tank 450
Access tube 451
Pressure switches 451
Troubleshooting the pressure switch 452
Sight glass 453
Relays 453
Relay A 454
Relay B 454
Troubleshooting the relay 454
Refrigerant hose 455
Charge of refrigerant 456
Evacuation and Charging Procedures 457
Work chart 457
Refrigerant charging tools 458
Refrigerant charging procedure 460
Troubleshooting using the gauge manifold 465
Adjustment of lubricating oil quantity 468
when components of air conditioner are replaced 468
When the compressor is replaced 469
When the evaporator is replaced 470
When the condenser is replaced 470
When the receiver dryer is replaced 470
Adjustment of water valve and air mixing dampers 471
Adjustment of water valve 471
Adjustment of air mixing damper B 471
Adjustment of air gap (between hub and rotor) in compressor magnet clutch 472
Adjustment of V belt in compressor 473
Parts to be replaced periodically 474
FOREWORD 477
Safety Precautions 478
Safety Symbols 479
Symbols 480
TROUBLESHOOTING 482
Cautions Regarding Troubleshooting 484
How to Use Quick Troubleshooting Table 485
Safety Precautions 486
Torque Converter and Transmission Group 487
Machine does not move in any shift lever position 487
Machine does not move at a certain shift lever position (OR : Machine moves only in a certain shift lever position) 488
Machine moves at the neutral position (Example: Machine moves forward at the neutral position) 489
Large shock at starting or changing speeds /direction 490
Large time lag at starting or changing speed /direction 491
Low power (Defective torque converter or transmission) 492
Torque converter oil is overheating 493
Machine moves reverse when starting to climb up on a slope using inching brake 494
Automatic speed change is not possible 495
QUAD (PUS) switch does not work 496
Hydraulic Group 497
Boom and/or bucket do not move 497
Boom and/or bucket have low power, or move too slowly 498
Excessive cylinder drift 499
Boom and/or bucket are spongy (Holding bucket against the ground is not possible) 500
Bucket positioner (kick-out) does not work 501
Steering is not possible or hard to steer 502
Machine sways, or has a shock during steering 503
Abnormal noise in hydraulic system 504
Others 505
Brake Group 506
Brake does not work well (In the worst case, the brake does not work at all) 506
Brake is dragging when released 507
Stepping on the brake pedal sounds the buzzer 508
Accumulator pressure does not rise, or too slow in rising 509
Parking brake does not work (or:Releasing the brake is not possible) 510
Auto brake does not work 511
Electrical Group 512
Engine hard to start or will not start 512
Engine will not stop even if the starter switch is turned to “OFF” (or:Starting the engine is not possible ) 513
Instrument panel does not indicate properly 514
Breaker of the transmission controller is turned off 515
MEASUREMENT FOR PERFORMANCE CHECK 516
Standard Measurement Values for Performance Check 517
Preparation for Performance Check 519
Measuring Engine Speed 521
Measuring Clutch Oil Pressure and Time Lag 525
Measuring Cylinder Drift 527
Measuring Boom Cycle Time 529
Measuring Full Steering Cycle Time 530
Adjusting Steering Stopper 531
Measuring Steering Wheel/Lever Operating Force 532
Measuring Relief Valve Setting Pressures 533
Checking Brake Performance 537
Measuring Brake Line Setting Pressure 539
Measuring Accumulator Charging Time 541
Measuring Number of Brake Pedal Applications 542
Measuring Declutch Engagement 543
Measuring Radiator Cooling Capability 544
FOREWORD 549
Safety Precautions 550
Safety Symbols 551
Symbols 552
Hexagon Bolt Tightening Torque 553
Flanged Hexagon Bolt Tightening Torque 555
Hose Band Tightening Torque 556
Liquid Gasket and Screw Lock Agent 557
Cautions Regarding Welding Repair Service 558
Weight of Main Components 560
Applying and Storing Articulation Stopper 561
CHASSIS GROUP　14 563
Deck 564
Fuel Tank 565
Hydraulic Tank 566
Engine Room 567
ROPS 570
Cab 571
Floor Board 574
Boom 576
Center Pin 579
CHASSIS GROUP 15 584
Linkage 585
Linkage Pin Standard Clearance Values 586
Center Pin 587
Bucket 588
Bucket Positioner and Boom Kick-Out (Optional) 589
POWER GROUP 24 592
Power Line 593
Radiator 594
Engine 597
Propeller Shaft 599
Air Cleaner 600
Muffler 602
Fan 603
Engine Oil Pan 605
Axle Assembly 607
Differential Assembly 636
POWER GROUP 25 649
Propeller Shaft Service Standard 650
Axle Service Standard 651
Differential Service Standard 652
TORQUE CONVERTER & TRANSMISSION GROUP 34 653
Power Line 654
Transmission Assembly 655
Clutch Assembly 681
Low and 3rd Clutch Spider 697
1st, 2nd Clutch Spider 699
Reverse Clutch Spider 701
1st Clutch Assembly 703
High Clutch Assembly 707
Modulator Valve Assembly 712
TORQUE CONVERTER & TRANSMISSION GROUP 35 715
Transmission Assembly 716
Gear Pump 718
Gear Train and Number of Teeth 719
Clutch Oil Pressure 720
HYDRAULIC GROUP 44 721
Hydraulic Pump 722
Steering Pilot Valve 725
Steering Valve 736
Stop Valve 744
Multiple Control Valve 748
Boom Cylinder 755
Bucket Cylinder 758
Steering Cylinder 762
Hydraulic Cylinder Tightening Torque 765
Pilot Valve 771
Pilot Relief Valve Unit 779
HYDRAULIC GROUP 45 781
Steering Valve 782
Hydraulic Cylinder 783
Pilot Valve 784
BRAKE GROUP 54 785
Brake Valve Assembly 786
Accumulator 790
Unloader Valve 800
Auto-Adjuster Valve 804
Removing and Reinstalling Service Brake 808
Oil Cylinder Oil 809
Parking Brake 814
BRAKE GROUP 55 823
Service Brake 824
Parking Brake 825
ELECTRICAL GROUP 64 826
Wiper Motor 827
Controller 829
Fuse 831
OPERATOR STATION GROUP 74 832
Air Conditioner 833
Air conditioner mount 833
Removing and installing of air conditioner 834
Condenser mount 836
Condenser unit 836
Removing and installing of conditioner 837
Compressor mount 838
Removing and installing of compressor 839
OPERATOR STATION GROUP 75 840
Air Conditioner 841

S.M 9/2/2025