KCM 95ZV WHEEL LOADER SHOP MANUAL 93215-00242 – PDF DOWNLOAD

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KCM 95ZV WHEEL LOADER SHOP MANUAL 93215-00242 – PDF DOWNLOAD

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KCM 95ZV WHEEL LOADER SHOP MANUAL 93215-00242 – PDF DOWNLOAD

Language :English
Pages :614
Downloadable : Yes
File Type : PDF

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KCM 95ZV WHEEL LOADER SHOP MANUAL 93215-00242 – PDF DOWNLOAD

Disassembly & Reassembly
Service Standard
Powered by CUMMINS QSX15 ENGINE
Serial No. 97C4-0101 and up
97C4-9001 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.
Disassembly & Reassembly
Service Standard
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 methods.
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 precautions

TABLE OF CONTENTS:

KCM 95ZV WHEEL LOADER SHOP MANUAL 93215-00242 – PDF DOWNLOAD

Disassembly & Reassembly
Service Standard
Powered by CUMMINS QSX15 ENGINE
Serial No. 97C4-0101 and up
97C4-9001 and up

Foreword 2
Safety precautions 3
Safety Symbols 4
CONTENTS 6
00 General Information 12
Symbols 13
Weight of Main Components 14
Bolt Tightening Torque 15
Hose Band Tightening Torque 19
Liquid Gasket and Screw Lock Agent 20
Cautions regarding parts removal 20
Cautions regarding reassembly 20
Screw lock agent application procedure 21
How to wind a seal tape 21
Cautions Regarding Welding Repair Service 22
Cautions Regarding Handling of Bearing 24
Bearing installation cautions 24
Interference fits for a bearing 24
Bearing operation test after installation 25
Bearing removal cautions 25
Applying and Storing Articulation Stopper 26
Applying articulation stopper 26
Storing articulation stopper 27
14 Disassembly & Reassembly Chassis Group 28
Deck 29
Deck removing and installing 29
Deck removing 29
Deck installing 29
Fuel Tank 30
Fuel tank removing and installing 30
Fuel tank removing 30
Fuel tank installing 31
Fuel tank installation cautions 31
Hydraulic Tank 32
Hydraulic tank removing and installing 32
Hydraulic tank removing 32
Hydraulic tank installing 33
Hydraulic tank installation cautions 33
Engine Room 34
Engine room removing and installing 34
Engine room removing 34
Engine room installing 35
Engine room installation cautions 35
Cab 36
Cab removing and installing 36
Cab removing 36
Cab installing 37
Floor Board 38
Floor board removing and installing 38
Floor board removing 38
Floor board installing 39
Floor board installation cautions 39
Boom 40
Boom removing and installing 40
Boom removing 40
Boom installing 42
Boom installation cautions 42
Center Pin 43
Upper center pin 43
Center pin shim adjustment 43
Lower center pin 44
Center pin removing and installing 45
Center pin removing 45
Center pin installing 48
Center pin assembly cautions 48
15 Service Standard Chassis Group 50
Linkage 51
Linkage Pin Standard Clearance Values 52
Liner clearance adjustment 52
Center Pin 53
Center pin shim adjustment 53
Bearing cover installing 53
Lower center pin bearing outer ring installing 54
Bucket Positioner and Boom Kick-Out 55
Bucket positioner 56
Bucket positioner adjustable angle 56
Boom kick-out 57
Boom kick-out hoist angle 57
24 Disassembly & Reassembly Power Group 60
Power Line 61
Power line tightening torque 61
Radiator 62
Radiator tightening torque 62
Radiator removing and installing 63
Radiator removing 63
Radiator installing 65
Engine 66
Engine removing and installing 66
Engine removing 66
Engine installing 68
Engine installation cautions 68
Propeller Shaft 69
Propeller shaft removing and installing 69
Second propeller shaft removing 69
Third propeller shaft removing 70
Propeller shaft installing 70
Propeller shaft installation cautions 70
Air Cleaner 71
Air cleaner removing and installing 71
Air cleaner removing 71
Air cleaner installing 72
Air cleaner installation cautions 72
Muffler 73
Muffler removing and installing 73
Muffler removing 73
Muffler installing 73
Muffler installation cautions 73
Fan 74
Fan removing and installing 74
Fan removing 74
Fan installing 74
Front Axle Assembly 75
Front axle assembly tightening torque 75
Axle nut tightening procedure 76
Floating seal installing 76
Front axle assembly removing and installing 77
Front axle assembly removing 77
Front axle assembly installing 78
Front axle assembly installation cautions 78
Service brake air bleeding procedure 79
Front axle disassembling and assembling 80
Front axle disassembling 80
Front axle assembling 83
Front axle assembly cautions 84
Floating Seal 90
Floating seal location 90
Internal Gear Hub 92
Internal gear hub disassembling and assembling 92
Internal gear hub disassembling 92
Internal gear hub assembling 94
Internal gear hub assembly cautions 94
Spider Assembly 96
Spider assembly disassembling and assembling 96
Spider assembly disassembling 96
Spider assembly assembling 96
Spider assy assembly cautions 97
Special Tool 98
Special tool for axle 98
Rear Axle Assembly 104
Rear axle assembly tightening torque 104
Axle nut tightening procedure 105
Floating seal installing 105
Rear axle assembly removing and installing 106
Rear axle assembly removing 106
Rear axle assembly installing 108
Rear axle disassembling and assembling 108
Axle Support 109
Axle support tightening torque 109
Axle support disassembling and assembling 111
Axle support disassembling (S/N 0101~0290, 9001~9080) 111
Axle support disassembling (S/N 0291~, 9081~) 112
Axle support assembling 113
Axle support assembly cautions 113
Differential Assembly 116
Differential assembly removing and installing 116
Differential assembly removing 116
Differential assembly installing 117
Differential assembly installation cautions 117
Differential assembly disassembling and assembling 118
Front differential tightening torque 118
Rear differential tightening torque 119
Differential assembly disassembling 120
Differential assembly assembling 123
Differential assy assembly cautions 124
25 Service Standard Power Group 130
Propeller Shaft Service Standard 131
Axle and Differential Service Standard 132
Axle group 132
Differential 133
34 Disassembly & Reassembly T/C and T/M Group 134
Torque Converter and Transmission Assembly 135
Torque converter and transmission assembly tightening torque 135
Torque converter and transmission assembly removing and installing 136
Torque converter and transmission assembly removing 136
Torque converter and transmission assembly installing 140
Transmission assembly installation cautions 141
Torque Converter Assembly 143
Torque converter assembly bolt tightening torque 143
Torque converter assembly disassembling and assembling 144
Torque converter assembly disassembling 144
Torque converter assembly assembling 148
Torque converter assy assembly cautions 148
Transmission Assembly 149
Transmission assembly bolt tightening torque 149
Transmission assembly disassembling and assembling 150
Transmission assembly disassembling 150
Transmission assembly assembling 152
Transmission assy assembly cautions 153
Clutch Assembly 157
Clutch assembly disassembling and assembling 157
Clutch assembly disassembling 157
Clutch assembly assembling 161
Clutch Spider Assembly 170
Low and 3rd clutch spider disassembling and assembling 170
Low and 3rd clutch spider disassembling 170
Low and 3rd clutch spider assembling 170
2nd clutch spider disassembling and assembling 171
2nd clutch spider disassembling 171
2nd clutch spider assembling 171
Reverse Clutch Spider 172
Reverse clutch spider disassembling and assembling 172
Reverse clutch spider disassembling 172
Reverse clutch spider assembling 172
1st Clutch Assembly 173
1st clutch assembly disassembling and assembling 173
1st clutch assembly disassembling 173
1st clutch assembly assembling 174
High Clutch Assembly 177
High clutch assembly disassembling and assembling 177
High clutch assembly disassembling 177
High clutch assembly assembling 179
Control Valve Assembly 182
Control valve assembly removing and installing 182
Control valve assembly removing 182
Control valve assembly installing 183
Control valve assembly installation cautions 183
35 Service Standard T/C and T/M Group 184
Transmission Assembly 185
Torque Converter Gear Pump 187
Gear pump specifications 187
Gear Train and Number of Teeth 188
Clutch specifications 188
Clutch Oil Pressure 189
Clutch oil pressure measuring port 189
44 Disassembly & Reassembly Hydraulic Group 190
Hydraulic Parts Removal and Installation Warning 191
Hydraulic Parts Disassembly and Assembly Cautions 192
Hydraulic parts disassembly cautions 192
Hydraulic parts assembly cautions 192
Hydraulic Pump Assembly 193
Hydraulic pump assembly removing and installing 193
Hydraulic pump assembly removing 193
Hydraulic pump assembly installing 194
Hydraulic pump installation cautions 195
Hydraulic pump assembly disassembling and assembling 196
Hydraulic pump assembly cross section and tightening torque 197
Oil seal replacement procedure 198
Hydraulic Cylinder 199
Boom cylinder removing and installing 199
Boom cylinder removing 199
Boom cylinder installing 201
Boom cylinder installation cautions 201
Bucket cylinder removing and installing 202
Bucket cylinder removing 202
Bucket cylinder installing 203
Bucket cylinder installation cautions 203
Hydraulic cylinder disassembling and assembling 204
Hydraulic cylinder cross section and tightening torque 204
Hydraulic cylinder disassembling 206
Hydraulic cylinder assembling 209
Hydraulic cylinder assembly cautions 209
Pilot Valve 211
Pilot valve removing and installing 211
Pilot valve removing (S/N ~0290, ~9080) 211
Pilot valve removing (S/N 0291~, 9081~) 213
Pilot valve installing 214
Pilot valve installation cautions 214
Pilot valve disassembling and assembling (S/N ~0290, ~9080) 215
Pilot valve tightening torque 215
Pilot valve disassembling 216
Pilot valve assembling 219
Pilot valve assembly cautions 219
Pilot valve disassembling and assembling (S/N 0291~0410, 9081~) 220
Pilot valve cross section and tightening torque 220
Pilot valve disassembling 221
Pilot valve assembling 228
Pilot valve assembly cautions 229
Pilot valve disassembling and assembling (S/N 0411~) 231
Pilot valve cross section and tightening torque 231
Pilot valve disassembling 232
Pilot valve assembling 238
Pilot valve assembly cautions 238
Multiple Control Valve 239
Multiple control valve removing and installing 239
Multiple control valve removing 239
Multiple control valve installing 241
Multiple control valve installation cautions 241
Multiple control valve disassembling and assembling 242
Multiple control valve cross section and tightening torque 242
Multiple control valve disassembling 243
Multiple control valve assembling 245
Multiple control valve assembly cautions 245
Orbitrol® 246
Orbitrol® removing and installing 246
Orbitrol® removing 246
Orbitrol® installing 247
Orbitrol® installation cautions 247
Orbitrol® disassembling and assembling 248
Orbitrol® cross section and tightening torque 248
Orbitrol® disassembling 249
Orbitrol® assembling 252
Steering Valve 256
Steering valve removing and installing 256
Steering valve removing 256
Steering valve installing 257
Steering valve installation cautions 257
Steering valve disassembling and assembling 258
Steering valve cross section and tightening torque 258
Steering valve cross section and tightening torque (S/N 0186~, 9004~) 259
Steering valve disassembling 260
Steering valve assembling 261
Stop Valve 262
Stop valve removing and installing 262
Stop valve removing 262
Stop valve installing 262
Stop valve installation cautions 263
Stop valve disassembling and assembling 264
Stop valve cross section and tightening torque 264
Stop valve disassembling 266
Stop valve assembling 266
Fan Motor 267
Fan motor removing and installing 267
Fan motor removing 267
Fan motor installing 268
Fan motor installation cautions 268
45 Service Standard Hydraulic Group 270
Hydraulic Cylinder 271
Pilot Valve 273
Steering Valve 275
54 Disassembly & Reassembly Brake Group 276
Unloader Valve 277
Unloader valve removing and installing 277
Unloader valve removing 277
Unloader valve installing 278
Unloader valve installation cautions 278
Unloader valve disassembling and assembling 279
Unloader valve cross section and tightening torque 279
Unloader valve disassembling 282
Unloader valve assembling 282
Manifold Valve Assembly 283
Valve assembly removing and installing 283
Valve assembly removing 283
Valve assembly installing 284
Valve assembly installation cautions 284
Valve assembly disassembling and assembling 285
Valve assembly cross section and tightening torque 285
Accumulator 286
Accumulator removing and installing 286
Accumulator removing 286
Accumulator installing 287
Accumulator installation cautions 287
Accumulator disassembling and assembling 287
Accumulator disassembling 287
Accumulator assembling 288
Nitrogen gas charging 289
Nitrogen gas charging procedure 289
Brake Valve 291
Brake valve removing and installing 291
Brake valve removing 291
Brake valve installing 292
Brake valve installation cautions 292
Brake valve disassembling and assembling 293
Brake valve cross section and tightening torque (main valve) 293
Brake valve disassembling 294
Brake valve assembling 296
Service Brake 298
Service brake disassembling and assembling 298
Service brake installation cautions 298
Parking Brake (Rear) 300
Parking brake (rear) disassembling and assembling 300
Parking brake (rear) removing and disassembling 300
Parking brake (rear) assembling and installing 301
Parking Brake Actuator 302
Parking brake actuator removing and reinstalling 302
Parking brake actuator removing 302
Parking brake actuator installing 302
Parking brake actuator installation cautions 302
Parking brake actuator disassembling and assembling 303
Parking brake actuator cross section and tightening torque 303
Parking brake actuator disassembling 304
Parking brake actuator assembling 305
Parking brake actuator assembly cautions 305
Parking Brake (Front) (for Europe only) 306
Parking brake (front) removing and reinstalling 306
Parking brake (front) removing 306
Parking brake (front) installing 307
Parking brake (front) installation cautions 308
Parking brake (front) disassembling and assembling 309
Parking brake (front) cross section and tightening torque 309
Parking brake (front) disassembling and assembling 310
55 Service Standard Brake Group 312
Brake Valve 313
Service Brake 317
Parking Brake 318
74 Disassembly & Reassembly Operator Station Group 320
Air Conditioner 321
Air conditioner removing and installing 321
Air conditioner removing 321
Air conditioner installing 322
Air conditioner disassembling and assembling 323
Air conditioner tightening torque 323
Air conditioner disassembling 326
Air conditioner assembling 330
Compressor V-belt 331
75 Service Standard Operator Station Group 332
Air Conditioner 333
Periodical Inspection/Servicing 333
Tightening Torque 333
Tightening torque for hose and pipes 333
Tightening torque for screws and bolts in special control regions 333
INDEX 334
Maintenance Log 339
Notes 343

S.M 7/2/2025