Kawasaki Wheel Loader 135ZV2 Workshop Manual + Parts Catalog Manual
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Kawasaki Wheel Loader 135ZV2 Workshop Manual + Parts Catalog Manual
Language : English
Pages : 500+
Size : 130 MB
Downloadable : Yes
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Table of Contents:
Kawasaki Wheel Loader 135ZV2 Workshop Manual + Parts Catalog Manual
135ZV-2 General Information ……………………………………………………………………………………………………………….. 00-1
Symbols ………………………………………………………………………………………………………………………………………… 00-2
Weight of Main Components …………………………………………………………………………………………………………….. 00-3
Bolt Tightening Torque …………………………………………………………………………………………………………………….. 00-4
Hose Band Tightening Torque …………………………………………………………………………………………………………… 00-8
Liquid Gasket and Screw Lock Agent ………………………………………………………………………………………………… 00-9
Cautions regarding parts removal ………………………………………………………………………………………………… 00-9
Cautions regarding reassembly …………………………………………………………………………………………………… 00-9
Screw lock agent application procedure ……………………………………………………………………………………… 00-10
How to wind a seal tape ……………………………………………………………………………………………………………. 00-10
Cautions Regarding Welding Repair Service ………………………………………………………………………………………00-11
Cautions Regarding Handling of Bearing ………………………………………………………………………………………….. 00-13
Bearing installation cautions ……………………………………………………………………………………………………… 00-13
Interference fits for a bearing …………………………………………………………………………………………………….. 00-13
Bearing removal cautions …………………………………………………………………………………………………………. 00-14
Applying and Storing Articulation Stopper …………………………………………………………………………………………. 00-15
Applying articulation stopper ……………………………………………………………………………………………………… 00-15
Storing articulation stopper ……………………………………………………………………………………………………….. 00-15
135ZV-2 Disassembly & Reassembly Chassis Group ……………………………………………………………………………… 14-1
Deck ……………………………………………………………………………………………………………………………………………… 14-2
Deck removing and installing ………………………………………………………………………………………………………. 14-2
Fuel Tank ………………………………………………………………………………………………………………………………………. 14-4
Fuel tank removing and installing ………………………………………………………………………………………………… 14-4
Hydraulic Tank ……………………………………………………………………………………………………………………………….. 14-6
Hydraulic tank removing and installing …………………………………………………………………………………………. 14-6
Engine Room …………………………………………………………………………………………………………………………………. 14-8
Engine room removing and installing ……………………………………………………………………………………………. 14-8
ROPS ………………………………………………………………………………………………………………………………………….. 14-12
ROPS removing and installing …………………………………………………………………………………………………… 14-12
Cab …………………………………………………………………………………………………………………………………………….. 14-13
Cab removing and installing ………………………………………………………………………………………………………. 14-13
Floor Board ………………………………………………………………………………………………………………………………….. 14-15
Floor board removing and installing ……………………………………………………………………………………………. 14-15
Boom …………………………………………………………………………………………………………………………………………… 14-19
Boom removing and installing ……………………………………………………………………………………………………. 14-19
Center Pin ……………………………………………………………………………………………………………………………………. 14-22
Upper center pin ……………………………………………………………………………………………………………………… 14-22
Lower center pin ……………………………………………………………………………………………………………………… 14-23
Center pin removing and installing ……………………………………………………………………………………………… 14-24
135ZV-2 Service Standard Chassis Group …………………………………………………………………………………………….. 15-1
Linkage …………………………………………………………………………………………………………………………………………. 15-2
Linkage Pin Standard Clearance Values …………………………………………………………………………………………….. 15-3
Liner clearance adjustment …………………………………………………………………………………………………………. 15-3
Shim adjustment ……………………………………………………………………………………………………………………….. 15-4
Center Pin ……………………………………………………………………………………………………………………………………… 15-6
Center pin shim adjustment ………………………………………………………………………………………………………… 15-6
Bearing cover installing ………………………………………………………………………………………………………………. 15-6
Lower center pin bearing outer ring installing ………………………………………………………………………………… 15-7
Attachment Leveler …………………………………………………………………………………………………………………………. 15-8
Attachment leveler …………………………………………………………………………………………………………………….. 15-9
Attachment leveler adjustable angle …………………………………………………………………………………………….. 15-9
135ZV-2 Disassembly & Reassembly Power Group ………………………………………………………………………………… 24-1
Power Line …………………………………………………………………………………………………………………………………….. 24-2
Power line tightening torque ……………………………………………………………………………………………………….. 24-2
Radiator …………………………………………………………………………………………………………………………………………. 24-3
Radiator tightening torque …………………………………………………………………………………………………………… 24-3
Radiator removing and installing ………………………………………………………………………………………………….. 24-4
Torque Converter Oil Cooler …………………………………………………………………………………………………………….. 24-7
Torque converter oil cooler removing and installing ………………………………………………………………………… 24-7
Fan ……………………………………………………………………………………………………………………………………………….. 24-9
Fan removing and installing ………………………………………………………………………………………………………… 24-9
Engine …………………………………………………………………………………………………………………………………………..24-11
Engine removing and installing ……………………………………………………………………………………………………24-11
Propeller Shaft ……………………………………………………………………………………………………………………………… 24-14
Propeller shaft removing and installing ……………………………………………………………………………………….. 24-14
Air Cleaner …………………………………………………………………………………………………………………………………… 24-17
Air cleaner removing and installing …………………………………………………………………………………………….. 24-17
Muffler …………………………………………………………………………………………………………………………………………. 24-19
Muffler removing and installing ………………………………………………………………………………………………….. 24-19
Front Axle Assembly ……………………………………………………………………………………………………………………… 24-20
Front axle assembly tightening torque ………………………………………………………………………………………… 24-20
Front axle assembly removing and installing ……………………………………………………………………………….. 24-22
Front axle disassembling and assembling …………………………………………………………………………………… 24-25
Front axle assembly cautions ……………………………………………………………………………………………………. 24-29
Spider Assembly …………………………………………………………………………………………………………………………… 24-33
Spider assembly disassembling and assembling ………………………………………………………………………….. 24-33
Special Tool ………………………………………………………………………………………………………………………………….. 24-34
Special tool for axle ………………………………………………………………………………………………………………….. 24-34
Rear Axle Assembly ………………………………………………………………………………………………………………………. 24-38
Rear axle assembly tightening torque …………………………………………………………………………………………. 24-38
Rear axle assembly removing and installing ………………………………………………………………………………… 24-40
Rear axle disassembling and assembling ……………………………………………………………………………………. 24-43
Axle Support ………………………………………………………………………………………………………………………………… 24-44
Axle support tightening torque …………………………………………………………………………………………………… 24-44
Axle support disassembling and assembling ……………………………………………………………………………….. 24-45
Axle support assembly cautions ………………………………………………………………………………………………… 24-46
Differential Assembly …………………………………………………………………………………………………………………….. 24-47
Differential assembly removing and installing ………………………………………………………………………………. 24-47
Differential assembly disassembling and assembling ……………………………………………………………………. 24-50
135ZV-2 Service Standard Power Group ……………………………………………………………………………………………….. 25-1
Propeller Shaft Service Standard ………………………………………………………………………………………………………. 25-2
Axle and Differential Service Standard ……………………………………………………………………………………………….. 25-3
Axle group ………………………………………………………………………………………………………………………………… 25-3
Differential ………………………………………………………………………………………………………………………………… 25-4
135ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group ……………………………………… 34-1
Torque Converter and Transmission Assembly …………………………………………………………………………………… 34-2
Torque converter and transmission assembly tightening torque ……………………………………………………….. 34-2
Torque Converter Assembly ……………………………………………………………………………………………………………… 34-3
Torque converter removing and installing ……………………………………………………………………………………… 34-3
Torque converter assembly bolt tightening torque ………………………………………………………………………….. 34-6
Torque converter assembly disassembling and assembling …………………………………………………………….. 34-7
Transmission Assembly …………………………………………………………………………………………………………………. 34-13
Transmission removing and installing …………………………………………………………………………………………. 34-13
Transmission assembly bolt tightening torque ……………………………………………………………………………… 34-18
Transmission assembly disassembling and assembling ………………………………………………………………… 34-19
Clutch Assembly …………………………………………………………………………………………………………………………… 34-28
Clutch assembly disassembling and assembling ………………………………………………………………………….. 34-28
Clutch Spider Assembly …………………………………………………………………………………………………………………. 34-42
Forward and 3rd clutch spiders disassembling and assembling ……………………………………………………… 34-42
2nd Clutch Spider ………………………………………………………………………………………………………………………….. 34-44
2nd clutch spider disassembling and assembling …………………………………………………………………………. 34-44
Reverse Clutch Spider …………………………………………………………………………………………………………………… 34-46
Reverse clutch spider disassembling and assembling ………………………………………………………………….. 34-46
1st Clutch Assembly ………………………………………………………………………………………………………………………. 34-48
1st clutch assembly disassembling and assembling ……………………………………………………………………… 34-48
Input Gear Box Assembly ………………………………………………………………………………………………………………. 34-51
Input gear box disassembling and assembling …………………………………………………………………………….. 34-51
Control Valve Assembly …………………………………………………………………………………………………………………. 34-53
Control valve removing and installing …………………………………………………………………………………………. 34-53
Control valve disassembling and assembling ………………………………………………………………………………. 34-56
Special Tool ………………………………………………………………………………………………………………………………….. 34-58
135ZV-2 Service Standard Torque Converter and Transmission Group …………………………………………………….. 35-1
Transmission Assembly …………………………………………………………………………………………………………………… 35-2
Transmission …………………………………………………………………………………………………………………………….. 35-2
Torque converter ……………………………………………………………………………………………………………………….. 35-3
Torque Converter Gear Pump …………………………………………………………………………………………………………… 35-6
Gear pump specifications …………………………………………………………………………………………………………… 35-7
Clutch Train and Number of Teeth …………………………………………………………………………………………………….. 35-8
Clutch specifications ………………………………………………………………………………………………………………….. 35-9
Clutch Oil Pressure ……………………………………………………………………………………………………………………….. 35-10
135ZV-2 Disassembly & Reassembly Hydraulic Group ……………………………………………………………………………. 44-1
Hydraulic Parts Removal and Installation Warning ………………………………………………………………………………. 44-2
Hydraulic Parts Disassembly and Assembly Cautions ………………………………………………………………………….. 44-3
Hydraulic parts disassembly cautions …………………………………………………………………………………………… 44-3
Hydraulic parts assembly cautions ……………………………………………………………………………………………….. 44-3
Hydraulic Pump ………………………………………………………………………………………………………………………………. 44-4
Hydraulic pump removing and installing ……………………………………………………………………………………….. 44-4
Hydraulic pump assembly disassembling and assembling …………………………………………………………….. 44-10
Regulator disassembling and assembling …………………………………………………………………………………… 44-16
Hydraulic pilot (triple) pump disassembling and assembling ………………………………………………………….. 44-23
Pilot Valve (for Loading) …………………………………………………………………………………………………………………. 44-24
Pilot valve (for loading) removing and installing ……………………………………………………………………………. 44-24
Pilot valve (for loading) disassembling and assembling ………………………………………………………………… 44-26
Pilot Valve (for Steering) ………………………………………………………………………………………………………………… 44-33
Pilot valve (for steering) removing and installing ………………………………………………………………………….. 44-33
Pilot valve (for steering) disassembling and assembling ……………………………………………………………….. 44-35
Steering Valve ………………………………………………………………………………………………………………………………. 44-39
Steering valve removing and installing ………………………………………………………………………………………… 44-39
Steering valve disassembling and assembling …………………………………………………………………………….. 44-42
Multiple Control Valve ……………………………………………………………………………………………………………………. 44-46
Multiple control valve removing and installing ………………………………………………………………………………. 44-46
Multiple control valve disassembling and assembling …………………………………………………………………… 44-49
Stop Valve ……………………………………………………………………………………………………………………………………. 44-54
Stop valve removing and installing ……………………………………………………………………………………………… 44-54
Stop valve disassembling and assembling ………………………………………………………………………………….. 44-56
Hydraulic Cylinder …………………………………………………………………………………………………………………………. 44-58
Hydraulic cylinder removing and installing …………………………………………………………………………………… 44-58
Boom cylinder removing and installing ……………………………………………………………………………………….. 44-58
Bucket cylinder removing and installing ………………………………………………………………………………………. 44-61
Steering cylinder removing and installing …………………………………………………………………………………….. 44-63
Hydraulic cylinder disassembling and assembling ………………………………………………………………………… 44-66
Special tool for hydraulic cylinder disassembling ………………………………………………………………………….. 44-73
135ZV-2 Service Standard Hydraulic Group …………………………………………………………………………………………… 45-1
Hydraulic Cylinder …………………………………………………………………………………………………………………………… 45-2
135ZV-2 Disassembly & Reassembly Brake Group ………………………………………………………………………………… 54-1
Brake Valve ……………………………………………………………………………………………………………………………………. 54-2
Brake valve removing and installing …………………………………………………………………………………………….. 54-2
Brake valve disassembling and assembling ………………………………………………………………………………….. 54-4
Unloader Valve ……………………………………………………………………………………………………………………………… 54-10
Unloader valve removing and installing ………………………………………………………………………………………. 54-10
Unloader valve disassembling and assembling ……………………………………………………………………………. 54-12
Manifold Valve Assembly ……………………………………………………………………………………………………………….. 54-14
Valve assembly removing and installing ……………………………………………………………………………………… 54-14
Valve assembly disassembling and assembling …………………………………………………………………………… 54-16
Accumulator …………………………………………………………………………………………………………………………………. 54-17
Accumulator removing and installing ………………………………………………………………………………………….. 54-17
Accumulator disassembling and assembling ……………………………………………………………………………….. 54-19
Nitrogen gas charging ………………………………………………………………………………………………………………. 54-25
Service Brake ……………………………………………………………………………………………………………………………….. 54-27
Service brake disassembling and assembling ……………………………………………………………………………… 54-27
Parking Brake ……………………………………………………………………………………………………………………………….. 54-31
Parking brake removing and installing ………………………………………………………………………………………… 54-31
Parking brake disassembling and assembling ……………………………………………………………………………… 54-32
135ZV-2 Service Standard Brake Group ……………………………………………………………………………………………….. 55-1
Brake Valve ……………………………………………………………………………………………………………………………………. 55-2
Service Brake …………………………………………………………………………………………………………………………………. 55-4
Parking Brake …………………………………………………………………………………………………………………………………. 55-5
135ZV-2 Disassembly & Reassembly Operator Station Group …………………………………………………………………. 74-1
Air Conditioner ……………………………………………………………………………………………………………………………….. 74-2
Air conditioner removing and installing …………………………………………………………………………………………. 74-2
Air conditioner disassembling and assembling ………………………………………………………………………………. 74-4
135ZV-2 Service Standard Operator Station Group ………………………………………………………………………………… 75-1
Air Conditioner ……………………………………………………………………………………………………………………………….. 75-2
Periodical Inspection/Servicing ……………………………………………………………………………………………………. 75-2
Tightening Torque ……………………………………………………………………………………………………………………… 75-2
Description:
Kawasaki Wheel Loader 135ZV2 Workshop Manual + Parts Catalog Manual
- 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.
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]