Kawasaki KCM WHEEL LOADER 65TMV-2 SHOP MANUAL 93207-00871 – PDF DOWNLOAD
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Kawasaki KCM WHEEL LOADER 65TMV-2 SHOP MANUAL 93207-00871 – PDF DOWNLOAD
Language :English
Pages :566
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Kawasaki KCM WHEEL LOADER 65TMV-2 SHOP MANUAL 93207-00871 – PDF DOWNLOAD
General Information
Standard Measurement Values for
Performance Check
Function & Structure
Check & Adjustment
Powered by Isuzu 4HK1X Engine
Serial No. 65J4-4001 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 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 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 KCM WHEEL LOADER 65TMV-2 SHOP MANUAL 93207-00871 – PDF DOWNLOAD
General Information
Standard Measurement Values for
Performance Check
Function & Structure
Check & Adjustment
Powered by Isuzu 4HK1X Engine
Serial No. 65J4-4001 and up
Foreword 4
Safety Symbols 5
CONTENTS 6
00 General Information 18
How to Use Manual 19
Safety precautions 19
Symbols 20
Outline 21
Layout of main components 21
Inspection and maintenance table 22
Recommended Lubricants 25
Coolant 27
Coolant specification 27
Recommended mixture of antifreeze 27
Lubrication chart 28
Weight of main components 29
Bolt tightening torque 30
Hexagon bolt 30
Flanged hexagon bolt 33
Hose band tightening torque 34
Liquid gasket and screw lock agent 35
Cautions regarding parts removal 35
Cautions regarding reassembly 35
Screw lock agent application procedure 36
How to wind a seal tape 36
Cautions regarding welding repair service 37
03 Measurement for Performance Check 40
Cautions on Safety 41
Standard Measurement Values for Performance Check 42
12 Function & Structure Chassis Group 46
Front Chassis 47
Loading linkage 47
Loading linkage pin 49
Rear Chassis 50
Fuel tank (S/N 4001~4064) 50
Fuel tank (S/N 4065~) 51
Floor board mount 52
Floor board 52
Viscous mount 52
Center Pin 53
Upper center pin 53
Lower center pin 53
Dust seal 54
13 Check & Adjustment Chassis Group 56
Linkage Pin 57
Liner 57
Adjustment 59
Center Pin 60
Adjusting shim 60
22 Function & Structure Power Group 62
Power Line 63
Engine / Transmission 64
Engine / transmission mount 64
Radiator 65
Radiator mount 66
Propeller Shaft 67
Second propeller shaft assembly 68
Front differential – Transmission 68
Third propeller shaft assembly 69
Transmission – Rear differential 69
Axle Assembly 70
Axle Support 71
Differential Gear 73
Function of TPD 77
Difference in gear shapes 77
Contact between pinion and side gear 77
Operation of TPD 78
Limited Slip Differential (option) 79
LSD function 82
LSD operation 82
23 Check & Adjustment Power Group 84
Engine 85
Measuring engine speed 85
Measuring engine oil pressure 85
Propeller Shaft 86
Propeller shaft phase 86
Second propeller shaft alignment 86
Tightening torque 87
32 Function & Structure Torque Converter and Transmission Group 88
Torque Converter 89
Torque converter structure 89
Power flow path 89
Torque multiplication 89
Torque Converter Gear Pump 90
Pump specifications 90
Transmission 91
Clutch combination 91
Shift lever position 91
Downshift button operation 91
Gear train and number of teeth 92
Valve location 93
Clutch specifications 95
Friction plate: mm (in) 95
Clutch Pack 97
Forward and reverse clutch 97
1st and 2nd speed clutch 98
3rd and 4th speed clutch 99
Power Flow Path in the Transmission100
Forward 1st speed power flow path100
Forward 2nd speed power flow path101
Forward 3rd speed power flow path102
Forward 4th speed power flow path103
Reverse 1st speed power flow path104
Reverse 2nd, 3rd, and 4th speeds power flow path104
Hydraulic System Diagram105
Hydraulic Circuit Diagram106
Oil Flow107
Oil flow in the torque converter line107
From torque converter gear pump to torque converter107
Return oil from torque converter107
Return oil from cooler107
Oil flow to the clutches107
To forward and reverse clutches107
To speed clutches107
T/C and T/M Oil Circulation108
Control Valve110
Main control valve110
3rd, 4th speed control valve110
Oil port layout111
Layout of ports on mounting surface of control valve (at T/M case side)111
Modulation Mechanism112
Clutch control oil pressure curve112
Modulation mechanism operation113
Before the shift lever is moved (traveling or stop condition) (high pressure holding)113
When the shift lever is moved (1) (Initial oil feeding to clutch piston chamber)114
When the shift lever is moved (2) (clutch oil pressure increase)115
Accumulator116
Accumulator for 1st and 2nd speed clutch116
Clutch Solenoid Valve117
For forward/reverse and speed clutches117
After power-off (clutch disengaged status)117
After power-on (clutch engaged status)118
33 Check & Adjustment Torque Converter and Transmission Group120
Clutch Oil Pressure121
Measuring clutch oil pressure121
42 Function & Structure Hydraulic Group124
Flushing Hydraulic Circuit125
Purpose of flushing125
Cautions on Hydraulic Parts Replacement126
Hydraulic Circuit Symbols127
Hydraulic lines127
Pumps & motors127
Cylinders127
Operation methods128
Pressure control valve128
Flow control valve128
Directional control valve129
Check valve129
Miscellaneous hydraulic symbols130
Hydraulic System Operation131
Hydraulic system operation outline131
Loading system131
Steering system131
Fan motor system132
Ride control system (OPT)132
Secondary steering (OPT)132
Layout of Hydraulic Units133
Hydraulic Tank134
Hydraulic Tank (S/N 4001~4100)134
Hydraulic tank breather valve (tank cap)(S/N 4001~4100)135
Hydraulic Tank (S/N 4101~)136
Hydraulic tank breather valve (tank cap)(S/N 4101~)137
Hydraulic tank specifications138
Hydraulic oil level check139
Hydraulic Pump140
Hydraulic pump specifications140
Hydraulic pump principle141
Hydraulic pump wear plate142
Hydraulic pump bushing lubrication142
Hydraulic Cylinder143
Boom cylinder143
Bucket cylinder143
Steering cylinder144
Hydraulic cylinder specifications145
Loading System146
Reducing Valve (for Pilot Pressure)147
Pilot Valve (TH40MS)148
Pilot valve specifications149
Pilot valve performance chart149
Pilot valve operation151
Multiple Control Valve (KML22/2T)153
Multiple control valve specifications154
Multiple control valve main relief valve155
Main relief valve operation155
Adjusting set pressure156
Multiple control valve overload relief valve (with make-up function)157
Overload relief valve operation157
Adjusting set pressure158
Multiple control valve make-up valve159
Make-up valve operation159
Multiple control valve bucket spool160
Bucket spool operation160
Multiple control valve boom spool162
Boom spool operation162
Two-speed dump feature165
Operation165
Pilot valve (for two-speed dump)167
Structure167
Operation167
Adapter (Orifice)168
Ride Control (OPT)169
Ride control hydraulic circuit170
Ride control function170
Ride control operation171
Preparation mode (ride control switch is OFF)171
Running mode (ride control switch is ON)172
Ride control valve assembly173
Solenoid valve176
Accumulator (for ride control)178
Accumulator function178
Steering System179
Priority Valve181
Priority valve operation182
Orbitrol®185
Valve System185
1 Load-sensing system185
2 Non-load reaction system185
3 Dynamic signal185
4 Q/Amp185
Orbitrol® structure185
Valve part186
Rotor part186
Orbitrol® specification186
Orbitrol® operation187
Neutral187
Turn188
Orbitrol® feed-back mechanism operation189
Steering speed and flow rate control190
Hydraulic pump oil amount and steering force190
Oil flow change when Q/Amp is operated191
Orbit rotor operation principle192
Auxiliary valves193
Overload relief valve and make-up valve194
Emergency check valve195
Inlet check valve195
Accumulator196
Efficient Loading System (OPT)198
Efficient loading system outline198
The operation condition of ELS198
Mounting of the ELS valve199
Mounting of the variable kickout sensor201
Efficient loading system operation202
While the ELS is not operating202
While the ELS is operating203
Fan Motor System204
Mounting of fan motor204
Fan Motor Line205
Hydraulic circuit (fan motor normal rotation)208
Safety valve (with suction function)209
Flow control valve209
Flow control solenoid valve210
Fan motor (S/N 4001~4030)211
Fan motor (S/N 4031~)213
Reversing Fan Motor Line216
Reversing fan motor function216
Reversing fan motor216
Reversing fan control chart217
Hydraulic circuit (Reverse rotation)218
Secondary Steering (OPT)219
Secondary steering operation220
Secondary steering motor and pump221
43 Check & Adjustment Hydraulic Group222
Loading/Steering Circuit Relief Valve/Ride Control Circuit Reducing Valve (OPT)223
Loading circuit relief valve setting pressures223
Measuring loading circuit main relief pressure224
Measuring loading circuit overload relief pressure225
Measuring pilot circuit relief pressure226
Ride control circuit reducing valve setting pressures (OPT)227
Measuring ride control circuit reducing pressure228
Steering circuit relief valve setting pressures229
Measuring steering circuit main relief pressure230
Adjusting steering line main pressure230
Measuring steering circuit overload relief pressure231
Hydraulic Cylinder232
Cylinder natural drift232
52 Function & Structure Brake Group234
Brake System Outline235
Service brake235
Parking brake235
Adjustment of axle internal pressure235
Brake Units Layout236
Unloader Valve237
Unloader valve operation238
Valve Unit239
Accumulator low pressure sensor240
Accumulator241
In-Line Filter242
Brake Valve243
Brake valve performance chart244
Brake valve outline245
While the valve is not operating245
Service Brake247
Service brake operation247
Service brake friction plate248
Service brake steel plate248
Brake circuit air bleeding procedure249
Bleeding air from brake pipes249
Parking Brake250
Parking brake operation251
Parking brake solenoid valve252
Solenoid valve operation252
Solenoid valve specifications252
Parking Brake Manual Release253
Parking Brake Spring Chamber255
Brake Circuit Check Valve256
Pressure Sensor (for stop lamp and declutch)257
Pressure sensor (for declutch)257
Pressure sensor (for stop lamp)257
53 Check & Adjustment Brake Group260
Brake Circuit Oil Pressure261
Unloader valve setting pressure261
Unloader valve setting pressure measurement262
Brake valve oil pressure263
Brake valve oil pressure measurement263
Brake valve performance264
Service Brake265
Service brake performance check265
Service brake friction plate wear measurement266
Parking Brake267
Parking brake performance check267
Parking brake clearance adjustment269
Adjustment procedure269
Brake lining abrasion check270
62 Function & Structure Electrical Group272
How to Use Electrical Wiring Diagram273
Electrical Cable Color Codes274
Electrical Circuit Symbols275
Sensor Mount276
Fuse277
Fuse box277
Fusible link279
Engine Start Circuit280
Engine start circuit diagram280
Neutral starter281
Shift lever neutral (N) position281
Shift lever forward/reverse (F/R) position281
Starter switch282
Battery relay283
Battery relay operation283
Alternator L terminal wire283
Diode unit284
Neutral relay285
Safety relay286
Power Generating/Charging Circuit287
Alternator287
ECM (Engine Controller)288
Function of ECM288
Connection diagram288
Monitor lamp test289
Diagnosis trouble code (DTC) information290
Accelerator pedal293
Transmission Control Circuit and Monitor Circuit295
Machine control unit (MCU)295
Connector296
Machine control unit (MCU) connection diagram (S/N 4001~4200)297
Machine control unit (MCU) connection diagram (S/N 4201~)299
Machine control unit (MCU) function301
Forward/reverse (F/R) shifting and speed change301
Automatic shift303
Machine speed sensor304
Switching from automatic to manual305
Downshift button operation305
Adjustable declutch preset switch306
Right brake pedal (brake only pedal)307
Back-up alarm308
Parking brake309
Machine control unit (MCU) failure warning311
Secondary steering function (OPT)312
Monitoring system313
Items to be monitored and operation condition313
Operation monitor lamps314
Instrument Panel and Switch315
Instrument panel315
Instrument panel rear surface317
Gauge circuit319
Fuel level sensor321
MODM324
MODM function324
Monitor Changeover324
Changing display from one function to next325
Information Monitor327
Information monitor display327
Unit conversion and language selection330
Replacement Monitor331
Replacement time check331
Replacement interval set (timer reset)335
Replacement interval pop-up336
Display language337
Fault Log Monitor337
Fault log history check337
Selection of machine fault log and engine fault log338
Machine fault log navigation339
Engine fault log navigation339
Clear fault log339
Clear active fault log (error pop up) (S/N 4001~4010 only)340
Input/Output Monitor344
Input/Output monitor display344
Parameter Setting Monitor348
Parameter setting monitor display348
Parameter change356
Specification Setting Monitor357
Specification setting monitor display357
All setting reset360
Electrical Detent Circuit363
Bucket leveler363
Proximity switch364
Detent solenoid365
Lift kickout & lower kickout366
Location366
Lift kickout366
Lower kickout366
Sensor assy367
Detent solenoid369
Preset height adjustment369
Diode370
Diode check method371
Caution for diode check method371
Continuity check mode371
Diode check mode371
Resistance check mode372
Surge voltage and surge suppression diodes373
72 Function & Structure Operator Station Group374
Air Conditioner (S/N 4001~4030)375
Air conditioning systems375
Air conditioning unit375
Bergstrom air conditioner structure376
Coil box unit377
Fan box unit378
134A refrigerant compressor379
Compressor details380
Compressor electro-magnetic drive clutch380
Condenser381
Thermostatic expansion valve381
Receiver / Drier382
Evaporator core and temperature sensor383
Evaporator383
Evaporator thermal switch384
Pressure switch385
High pressure switch385
Low pressure switch385
Defroster/Operator ventilation and heater valve actuator motors386
Control panel387
Plug in interface388
Electrical pins locations389
Panel switches391
Air conditioner troubleshooting392
Diagnostic step – Electrical circuit396
Checking voltage at connectors397
Checking actuators398
Water valve actuator check398
Maintenance399
Helpful hints399
General tips for working on A/C systems399
Basic tools needed to work on air conditioning401
Pressure temperature chart402
What do you know about temperature?402
Temperature scales403
What is temperature?404
Temperature ranges404
A/C Charging405
Disclaimer405
General charging procedure405
Leak check406
Charge amounts406
Final inspection407
General inspection points407
Appendix408
Table 1: Abbreviations408
Table 2: General air conditioning system operating parameters409
Air Conditioner (S/N 4031~)410
Denso air conditioner components410
Air conditioner specifications (system performance)410
Denso air conditioner structure411
Cooling unit411
Heater and accessories413
Air distributor (hood & defroster selection box)413
Air compressor (with magnetic clutch)414
Condenser unit414
Control unit415
Function of cooling mechanism416
Principle of cooling416
Refrigerant417
Refrigerant characteristics418
Cooling circuit419
Electrical circuit420
Control schematic drawing420
Air conditioner functions of components421
Control panel421
Air conditioner unit428
Compressor and magnetic clutch437
Condenser unit440
Receiver dryer442
Sight glass444
Pressure switches444
Pressure relief valve446
Relay A447
Relay B447
Refrigerant hose448
Charge of refrigerant449
Work procedure450
Refrigerant charging tools452
Refrigerant charging procedure455
Troubleshooting using the gauge manifold461
Air conditioner troubleshooting466
Fault diagnosis procedure466
73 Check & Adjustment Operator Station Group474
Air Conditioner475
Adjustment of lubricating oil quantity when components of air conditioner are replaced475
When the compressor is replaced476
When the evaporator is replaced477
When the condenser is replaced477
Adjustment of air gap (between hub and rotor) in compressor magnetic clutch478
Compressor V-belt adjustment (S/N 4001~4030) (Bergstrom)479
Belt adjustment procedure480
Belt adjustment value480
Compressor V-belt adjustment (S/N 4031~) (DENSO)481
Belt adjustment procedure482
Belt adjustment value482
Parts to be replaced periodically483
Air filters483
Receiver dryer483
INDEX484
Maintenance Log491
Notes495
92 Drawing & Diagrams499
Axle Assembly500
Torque Converter and Transmission502
Hydraulic & Brake Circuit503
Brake Circuit504
Electrical Wiring Diagram (1/4) (S/N 4001~4030)505
Electrical Wiring Diagram (2/4) (S/N 4001~4030)506
Electrical Wiring Diagram (3/4) (S/N 4001~4030)507
Electrical Wiring Diagram (4/4) (S/N 4001~4030)508
Electrical Wiring Diagram (1/4) (S/N 4031~4050)509
Electrical Wiring Diagram (2/4) (S/N 4031~4050)510
Electrical Wiring Diagram (3/4) (S/N 4031~4050)511
Electrical Wiring Diagram (4/4) (S/N 4031~4050)512
Electrical Wiring Diagram (1/4) (S/N 4051~4200)513
Electrical Wiring Diagram (2/4) (S/N 4051~4200)514
Electrical Wiring Diagram (3/4) (S/N 4051~4200)515
Electrical Wiring Diagram (4/4) (S/N 4051~4200)516
Electrical Wiring Diagram (1/4) (S/N 4201~)517
Electrical Wiring Diagram (2/4) (S/N 4201~)518
Electrical Wiring Diagram (3/4) (S/N 4201~)519
Electrical Wiring Diagram (4/4) (S/N 4201~)520
Electrical Wiring Diagram521
Way of looking at connectors521
Electrical wiring diagram abbreviation chart523
Electrical Wiring Diagram (CAB)525
Electrical Connection Diagram (1/2) (S/N 4001~4030)528
Electrical Connection Diagram (2/2) (S/N 4001~4030)529
Electrical Connection Diagram (1/2) (S/N 4031~4050)530
Electrical Connection Diagram (2/2) (S/N 4031~4050)531
Electrical Connection Diagram (1/2) (S/N 4051~4200)532
Electrical Connection Diagram (2/2) (S/N 4051~4200)533
Electrical Connection Diagram (1/2) (S/N 4201~)534
Electrical Connection Diagram (2/2) (S/N 4201~)535
Electrical Connection (Cabin Air Conditioner) (S/N 4001~4030)536
Electrical Wiring Diagram (Cabin Air Conditioner) (S/N 4031~)537
Electrical Circuit Diagram (Cabin Air Conditioner) (S/N 4031~)538
Equipment Operation Table (Cabin Air Conditioner) (S/N 4031~)539
Electrical Equipment Layout540
Outline of MODM (Machine Operation Diagnostic Module) Operation557
MODM: Input/Output Monitor – Input/Output Signal Correspondence Table566
S.M 2/2/25
