Kawasaki WHEEL LOADER 95ZV-2 SHOP MANUAL 93215-00481 – PDF

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Kawasaki WHEEL LOADER 95ZV-2 SHOP MANUAL 93215-00481 – PDF DOWNLOAD

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Kawasaki WHEEL LOADER 95ZV-2 SHOP MANUAL 93215-00481 – PDF DOWNLOAD

Language :English
Pages :580
Downloadable : Yes
File Type : PDF

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DESCRIPTION:

Kawasaki WHEEL LOADER 95ZV-2 SHOP MANUAL 93215-00481 – PDF DOWNLOAD

General Information
Standard Measurement Values for
Performance Check
Function & Structure
Check & Adjustment
Powered by CUMMINS QSX-15 Engine
Serial No. 97C5-9001 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.

Safety Symbols

An accident may occur if you disregard safety rules. In this manual, several expressions are used according to levels of danger for inspection and repair work as shown below. Read the work procedures and cautions described in this manual, and take preventive measures against possible problems before starting service work

TABLE OF CONTENTS:

Kawasaki WHEEL LOADER 95ZV-2 SHOP MANUAL 93215-00481 – PDF DOWNLOAD

General Information
Standard Measurement Values for
Performance Check
Function & Structure
Check & Adjustment
Powered by CUMMINS QSX-15 Engine
Serial No. 97C5-9001 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 21
Recommended lubricants 24
Coolant 25
Coolant specification 25
Recommended mixture of antifreeze 25
Lubrication chart 26
Weight of main components 27
Bolt tightening torque 28
Hexagon bolt 28
Flanged hexagon bolt 31
Hose band tightening torque 32
Liquid gasket and screw lock agent 33
Cautions regarding parts removal 33
Cautions regarding reassembly 33
Screw lock agent application procedure 34
How to wind a seal tape 34
Cautions regarding welding repair service 35
03 Measurement for Performance Check 38
Cautions on Safety 39
Standard Measurement Values for Performance Check 40
12 Function & Structure Chassis Group 44
Front Chassis 45
Loading linkage 45
Loading linkage pin 47
Rear Chassis 48
Fuel tank 48
Floor board mount 49
Floor board 49
Viscous mount 49
Center Pin 50
Upper center pin 50
Lower center pin 50
Dust seal 51
13 Check & Adjustment Chassis Group 52
Linkage Pin 53
Liner 53
Bucket hinge pin section 54
How to assemble 54
Adjustment 55
Center Pin 56
Adjusting shim 56
Grease nipple installation direction 56
Installing bearing outer ring 56
22 Function & Structure Power Group 58
Power Line 59
Engine / Transmission 61
Engine / transmission mount 61
Radiator (S/N 9001~9150) 62
Radiator (S/N 9151~) 63
Propeller Shaft 65
Second propeller shaft assembly 66
Third propeller shaft assembly 67
Axle Assembly 68
Axle Support 69
Torque Proportioning Type Differential Gear (TPD) 71
Function of TPD 74
Operation of TPD 75
Limited Slip Differential (LSD) (option) 76
LSD structure 76
LSD function 80
LSD operation 80
23 Check & Adjustment Power Group 82
Engine 83
Measuring engine speed 83
Measuring engine oil pressure 83
Propeller Shaft 84
Propeller shaft phase 84
Second propeller shaft alignment 84
Propeller shaft tightening torque 85
Axle 86
Axle nut tightening procedure 86
Differential gear adjustment procedure 87
Preload adjustment 88
Bearing installation 89
Oil seal installation 89
Adjusting tooth contact 90
32 Function & Structure T/C and T/M Group 92
Torque Converter 93
Torque converter structure 93
Power flow path 93
Torque multiplication 93
Torque Converter (Lock-up) (Option) 94
Lock-up clutch structure 95
Lock-up clutch function (only forward) 95
Automatic shift (with lock-up solenoid) 96
Torque Converter Gear Pump 97
Gear pump specifications 97
Gear pump specifications 98
Transmission 99
Clutch combination 99
Planetary gear 99
Shift lever position 99
Downshift button operation 99
Gear train and number of teeth100
Clutch specifications100
Friction plate101
Steel plate102
Clutch Pack103
Power Flow Path in the Transmission104
Forward 1st speed power flow path104
Forward 2nd speed power flow path105
Forward 3rd speed power flow path105
Forward 4th speed power flow path106
Reverse 1st speed power flow path107
Reverse 2nd speed power flow path107
Reverse 3rd speed power flow path108
Hydraulic System Diagram109
Hydraulic Circuit Diagram111
Oil Flow113
Oil flow in the torque converter line113
Oil flow to the clutch113
T/C and T/M Oil Circulation114
Modulator Valve Unit116
Interior schematic (simple explanation)118
Modulator valve function119
Modulator valve 1119
Modulator valve 2 (D Solenoid valve)120
Pressure sensor120
Clutch oil pressure control at the time of engine starting120
Modulator valve operation121
Control Valve Assembly123
Check valve125
Clutch solenoid valve assembly126
For high/reverse and speed clutches128
Clutch valve assembly130
33 Check & Adjustment T/C and T/M Group132
Clutch Oil Pressure and Time Lag133
Measuring clutch oil pressure133
Clutch oil pressure measurement procedure134
Possible causes for low clutch pressure134
Measuring clutch time lag135
Time lag measurement procedure135
Possible causes for clutch time lag135
42 Function & Structure Hydraulic Group136
Flushing Hydraulic Circuit137
Purpose of flushing137
Cautions on Hydraulic Parts Replacement138
Hydraulic Circuit Symbols139
Hydraulic System Operation143
Hydraulic system operation outline143
Loading system143
Steering system143
Efficient loading system144
Fan motor system144
Ride control system (OPT)144
Layout of Hydraulic Units145
Hydraulic Tank146
Hydraulic Tank (S/N 9001~9300)146
Hydraulic tank breather valve (tank cap) (S/N 9001~9300)147
Hydraulic Tank (S/N 9301~)148
Hydraulic tank breather valve (tank cap)(S/N 9301~)149
Hydraulic tank specifications150
Hydraulic oil level check151
Hydraulic Pump152
Loading and pilot and brake pump/Steering pump152
Loading and pilot and brake pump/Steering pump specifications152
Hydraulic pump principle153
Hydraulic pump wear plate154
Hydraulic pump bushing lubrication154
Hydraulic Cylinder155
Boom cylinder155
Bucket cylinder155
Steering cylinder156
Hydraulic cylinder specifications157
Loading System158
Reducing Valve (for Pilot Pressure)159
Pilot valve (S/N 9001~9250)160
Pilot valve function162
Pilot valve operation (modulated position)162
Pre-detent and detent magnet solenoid164
Pilot valve (S/N 9251~9255)165
Pilot valve function167
Pilot valve operation (modulated position)167
Pre-detent and detent magnet solenoid169
Pilot valve (S/N 9256~)170
Pilot valve function172
Pilot valve operation (modulated position)172
Pre-detent and detent magnet solenoid174
Multiple Control Valve (KML35A/2T003B)175
Multiple control valve specifications176
Multiple control valve main relief valve177
Main relief valve operation177
Adjusting set pressure178
Multiple control valve overload relief valve (with make-up function)179
Overload relief valve operation179
Make-up valve operation180
Multiple control valve make-up valve180
Make-up valve operation180
Multiple control valve bucket spool181
Bucket spool operation181
Multiple control valve boom spool183
Boom spool operation183
Adapter (Orifice)186
Ride Control (OPT)187
Ride control hydraulic circuit187
Ride control function187
Ride control operation188
Ride control valve assembly (Reducing valve circuit)190
Reducing valve191
Check valve191
Solenoid valve192
Ride control valve assembly (Accumulator circuit)193
Shuttle valve194
Solenoid valve194
Check valve195
Accumulator (for ride control)196
Accumulator function196
Steering System197
Orbitrol®198
Orbitrol® structure198
Valve part198
Rotor part199
Orbitrol® specifications199
Orbitrol® operation200
Neutral200
Turn201
Orbitrol® feed-back mechanism operation202
Steering speed and flow rate control203
Hydraulic pump oil amount and steering force203
Orbit rotor operation principle204
Steering Valve (KVS32-A40/20)205
Steering valve operation207
Steering spool variable throttle209
Steering valve flow control spool210
Steering valve main relief valve211
Steering valve overload relief valve213
Overload relief valve operation214
Make-up valve operation214
Steering pilot circuit and its operation215
Flow amplifier notch and pilot orifice216
Stop Valve217
Stop valve function218
Stop valve operation218
Reducing Valve (for Orbitrol®)219
Steering Line Filter220
K-Lever (OPT)221
Hydraulic circuit221
Hydraulic line diagram222
Hydraulic line223
Solenoid valve mount224
Solenoid valve assembly (1/2)225
Solenoid valve assembly (2/2)226
Adjustment method226
Efficient Loading System227
Efficient loading system outline227
The operation condition of ELS227
Mounting of the ELS valve228
Mounting of the variable kickout sensor229
Efficient loading system operation230
Fan Motor System231
Mounting of fan motor231
Fan Motor Line232
Hydraulic circuit (fan motor normal rotation)234
Make-up valve234
Proportional relief valve (S/N 9001~9150)236
Proportional relief valve operation236
Proportional relief valve (S/N 9151~)238
Fan motor240
Fan motor specifications240
Fan motor structure241
Fan motor function and the operation principle242
Reversing Fan Motor Line (OPT)243
Reversing fan motor function243
Reversing fan motor (OPT)244
Reversing fan control chart246
Hydraulic circuit (Reverse rotation)247
Secondary Steering248
Secondary steering operation248
Secondary steering motor and pump250
43 Check & Adjustment Hydraulic Group252
Loading/Steering Circuit Relief Valve/Ride Control Circuit Reducing Valve (OPT)253
Loading circuit relief valve setting pressures253
Measuring loading circuit main relief pressure255
Measuring loading circuit overload relief pressure256
Measuring pilot circuit relief pressure257
Ride control circuit reducing valve setting pressures (OPT)258
Measuring ride control circuit reducing pressure259
Steering circuit relief valve setting pressures260
Measuring steering circuit main relief pressure262
Measuring steering circuit overload relief pressure263
Measuring pilot circuit relief pressure (reducing pressure)264
Hydraulic Cylinder265
Cylinder natural drift265
Possible causes of excessive cylinder drift267
Stop Valve268
Stop valve adjustment procedure268
52 Function & Structure Brake Group270
Brake System Outline271
Service brake271
Parking brake271
Adjustment of axle internal pressure271
Brake Units Layout272
Unloader Valve273
Unloader valve operation275
Valve Unit276
Accumulator low pressure sensor277
Accumulator278
Brake Valve279
Brake valve performance chart280
Brake valve outline281
While the valve is not operating281
While the valve is operating282
While the valve is releasing282
Service Brake283
Service brake operation283
Service brake friction plate284
Service brake steel plate285
Service brake piston286
Service brake pedal stroke adjusting mechanism (S/N 9001~9014)287
Tolerance ring288
Brake circuit air bleeding procedure289
Bleeding air from brake pipes and axle housing hubs290
Bleeding air from parking brake housing290
Parking Brake291
Parking brake operation294
Operation of parking brake295
Parking brake friction plate296
Parking brake steel plate296
Parking brake solenoid valve297
Solenoid valve operation297
Solenoid valve specifications297
Parking Brake Manual Release298
Brake Circuit Check Valve300
Auto Brake301
Auto brake circuit301
Auto brake operation set value301
Solenoid valve (for Autobrake circuit)302
Solenoid specifications302
Pressure Sensor (for stop lamp and declutch)303
Pressure sensor (for declutch)303
Pressure sensor (for stop lamp)303
53 Check & Adjustment Brake Group306
Brake Circuit Oil Pressure307
Unloader valve setting pressure307
Unloader valve setting pressure measurement308
Brake valve oil pressure309
Brake valve oil pressure measurement309
Brake valve performance310
Service Brake311
Service brake performance check311
Service brake friction plate wear measurement312
Measurement procedure313
Cautions on installing brake discs314
Parking Brake315
Parking brake performance check315
62 Function & Structure Electrical Group316
How to Use Electrical Wiring Diagram317
Utilisation des schémas des câblages électriques (FRANÇAIS)318
Verwendung des elektrischen Schaltplans (DEUTSCH)319
Modalità di utilizzo dello schema dei collegamenti elettrici (ITALIANO)320
Cómo utilizar un Diagrama de Alambrado Eléctrico (ESPAÑOL)321
Como Utilizar o Diagrama de Ligações Eléctricas (PORTUGUÊS)322
Electrical Cable Color Codes323
Electrical Circuit Symbols324
Sensor Mount325
Fuse326
Fuse box326
Fusible link328
Engine Start Circuit329
Engine start circuit diagram329
Neutral starter330
Shift lever neutral (N) position330
Shift lever forward/reverse (F/R) position330
Starter switch331
ECM safety features332
Battery relay332
Battery relay operation332
Alternator I terminal wire333
Diode unit333
Neutral relay334
Magnetic switch335
Voltage relay336
Power Generating/Charging Circuit337
Alternator337
ECM (Engine Controller)338
Function of ECM338
Connection diagram338
Monitor lamp test339
Failure diagnosis340
Engine diagnostic switch (option)340
Failure diagnostic chart341
Increment decrement switch (option)342
Quantum fault code information343
Accelerator pedal349
Accelerator pedal installation351
Transmission Control Circuit and Monitor Circuit352
Machine control unit (MCU)352
Connector353
Machine control unit (MCU) connection diagram354
Machine control unit (MCU) function356
Forward/reverse (F/R) shifting and speed change356
Automatic shift358
Automatic shift (with lock-up solenoid)359
Machine speed sensor360
Switching from automatic to manual361
Downshift button operation361
Modulation at clutch switching362
Adjustable declutch preset switch365
Back-up alarm366
Parking brake367
Auto brake369
Machine control unit (MCU) failure warning372
Secondary steering function (OPT)373
Monitoring system375
Items to be monitored and operation condition375
Operation monitor lamps377
Instrument Panel and Switch378
Instrument panel378
Instrument panel rear surface379
Gauge circuit380
Fuel gauge circuit382
MODM383
MODM function383
Monitor Changeover383
Changing display from one function to next384
Information Monitor386
Information monitor display386
Unit conversion and language selection389
Replacement Monitor390
Replacement time check390
Replacement interval set (timer reset)394
Replacement interval pop-up395
Display language396
Fault Log Monitor396
Fault log history check396
Selection of machine fault log and engine fault log397
Machine fault log navigation398
Engine fault log navigation398
Clear fault log398
Clear active fault log (error pop up) (S/N 9001~9166)399
Input/Output Monitor403
Input/Output monitor display403
Parameter Setting Monitor407
Parameter setting monitor display407
Parameter change415
Specification Setting Monitor416
Specification setting monitor display416
All setting reset419
Default position of specification setting monitor421
Electrical Detent Circuit422
Bucket leveler422
Proximity switch422
Detent solenoid423
Lift kickout & lower kickout424
Lift kickout425
Lower kickout425
Sensor assy426
Detent solenoid428
Preset height adjustment428
Diode429
Diode check method430
Caution for diode check method430
Continuity check mode430
Diode check mode430
Resistance check mode431
Surge voltage and surge suppression diodes432
72 Function & Structure Operator Station Group434
Cabin435
Glass436
Wiper mount439
Front wiper439
Rear wiper439
Wiper motor440
Operator Seat442
Steering and Transmission Shift Lever443
Tilt case444
Column shaft445
Shift lever445
Air Conditioner446
Denso air conditioner components446
Air conditioner specifications (system performance)446
Denso air conditioner structure447
Cooling unit447
Heater and accessories449
Air distributor (hood & defroster selection box)449
Air compressor (with magnetic clutch)450
Condenser unit450
Control unit451
Function of cooling mechanism452
Principle of cooling452
Refrigerant453
Refrigerant characteristics454
Cooling circuit455
Electrical circuit456
Control schematic drawing456
Air conditioner functions of components457
Control panel457
Air conditioner unit464
Compressor and magnetic clutch473
Condenser unit476
Receiver dryer478
Sight glass480
Pressure switches480
Pressure relief valve482
Relay A483
Relay B483
Refrigerant hose484
Charge of refrigerant485
Work procedure486
Refrigerant charging tools488
Refrigerant charging procedure491
Troubleshooting using the gauge manifold497
Air conditioner troubleshooting502
Fault diagnosis procedure502
73 Check & Adjustment Operator Station Group510
Air Conditioner511
Adjustment of lubricating oil quantity when components of air conditioner are replaced511
When the compressor is replaced512
When the evaporator is replaced513
When the condenser is replaced513
Adjustment of air gap (between hub and rotor) in compressor magnetic clutch514
Compressor V-belt adjustment515
Parts to be replaced periodically516
Air filters516
Receiver dryer516
INDEX518
Maintenance Log523
Notes527
Axle Assembly532
Torque Converter and Transmission533
Hydraulic & Brake Circuit (S/N 9001~9250)534
Hydraulic & Brake Circuit (S/N 9251~)535
Brake Circuit536
Electrical Wiring Diagram (S/N 9001~9048)537
(1/3)537
(2/3)538
(3/3)539
Electrical Wiring Diagram (S/N 9049~9250)540
(1/3)540
(2/3)541
(3/3)542
Electrical Wiring Diagram (S/N 9251~)543
(1/3)543
(2/3)544
(3/3)545
Electrical Wiring Diagram546
Way of looking at connectors546
Electrical wiring diagram abbreviation chart548
Electrical Wiring Diagram (CAB)549
Electrical Connection Diagram (S/N 9001~9250)552
Electrical Connection Diagram (S/N 9251~)554
Cabin Air Conditioner556
Electrical Wiring Diagram556
Electrical Circuit Diagram557
Equipment Operation Table558
Electrical Equipment Layout559
Front chassis559
Rear chassis561
Floor board565
Floor board (Control box, S/N 9001~9250)566
Floor board (Control box, S/N 9251~)567
Electrical Equipment Layout (K-Lever)570
Outline of MODM (Machine Operation Diagnostic Module) Operation571
Main Menu572
Information Monitor573
Replacement Monitor574
Fault Log Monitor575
Input/Output Monitor576
Parameter Setting Monitor577
Specification Setting Monitor578
MODM: Input/Output Monitor – Input/Output Signal Correspondence Table580

S.M 4/2/2025