Kawasaki Wheel Loader 115ZV2 Workshop Manual + Parts Catalog Manual
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Kawasaki Wheel Loader 115ZV2 Workshop Manual + Parts Catalog Manual
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Table of Contents:
Kawasaki Wheel Loader 115ZV2 Workshop Manual + Parts Catalog Manual
FRONT CHASSIS GROUP………………………………………………………………….. 1
LIFT ARM GROUP …………………………………………………………………………… 3
PIN MOUNT…………………………………………………………………………………… 5
REAR CHASSIS GROUP……………………………………………………………………. 7
CENTER PIN GROUP……………………………………………………………………….. 11
FUEL TANK GROUP…………………………………………………………………………. 13
OIL TANK GROUP……………………………………………………………………………. 17
FLOOR BOARD GROUP ……………………………………………………………………. 21
SEAT STAND & CONTROL BOX MOUNT …………………………………………………. 23
CONTROL BOX COVER MOUNT ………………………………………………………….. 25
OPERATION STAND GROUP ………………………………………………………………. 27
DECK & FENDER GROUP………………………………………………………………….. 29
STEP & HANDRAIL GROUP ……………………………………………………………….. 35
SCREEN BOARD MOUNT ………………………………………………………………….. 39
ENGINE ROOM MOUNT ……………………………………………………………………. 41
RADIATOR GUARD MOUNT………………………………………………………………… 43
REAR GRILLE GROUP ……………………………………………………………………… 45
WIND SHIELD GROUP <AIR BAFFLE GROUP>…………………………………………. 47
COVER MOUNT ……………………………………………………………………………… 51
SEAT GROUP ………………………………………………………………………………… 53
SEAT…………………………………………………………………………………………… 55
SUSPENSION………………………………………………………………………………… 57
GREASE PIPING <FRONT>………………………………………………………………… 59
GREASE PIPING <REAR>………………………………………………………………….. 63
GREASE PIPING …………………………………………………………………………….. 65
GREASE GUN MOUNT……………………………………………………………………… 69
GAUGE GROUP ……………………………………………………………………………… 71
ELECTRICAL PARTS MOUNT ……………………………………………………………… 73
FRONT LAMP MOUNT………………………………………………………………………. 79
REAR LAMP MOUNT………………………………………………………………………… 81
WORKING LAMP MOUNT ………………………………………………………………….. 85
BATTERY MOUNT……………………………………………………………………………. 87
RELAY & SWITCH MOUNT …………………………………………………………………. 89
INSTRUMENT PANEL MOUNT …………………………………………………………….. 93
HORN & BUZZER MOUNT………………………………………………………………….. 95
MIRROR MOUNT…………………………………………………………………………….. 97
ELECTRICAL WIRING – FRONT CHASSIS……………………………………………….. 99
ELECTRICAL WIRING – REAR CHASSIS…………………………………………………. 101
ELECTRICAL WIRING – FLOOR BOARD …………………………………………………. 107
• POWER SYSTEM
POWER GROUP……………………………………………………………………………… 113
DRAIN LINE…………………………………………………………………………………… 115
DRAIN LINE…………………………………………………………………………………… 117
1ST PROPELLER SHAFT…………………………………………………………………… 121
2ND PROPELLER SHAFT ………………………………………………………………….. 123
3RD PROPELLER SHAFT ………………………………………………………………….. 125
RADIATOR MOUNT………………………………………………………………………….. 127
RADIATOR GROUP………………………………………………………………………….. 131
RADIATOR GROUP………………………………………………………………………….. 135
FAN MOTOR ………………………………………………………………………………….. 139
RADIATOR ……………………………………………………………………………………. 141
RADIATOR ……………………………………………………………………………………. 143
RADIATOR ……………………………………………………………………………………. 145
WATER LINE………………………………………………………………………………….. 147
AIR COOLER LINE…………………………………………………………………………… 149
AIR CLEANER GROUP……………………………………………………………………… 151
EXHAUST GROUP…………………………………………………………………………… 155
FUEL LINE ……………………………………………………………………………………. 159
FILTER MOUNT <E/G FILTER>…………………………………………………………….. 163
COLD STARTER GROUP …………………………………………………………………… 167
• TORQUE CONVERTER AND TRANSMISSION SYSTEM
TRANSMISSION HYDRAULIC LINE……………………………………………………….. 171
TRANSMISSION GROUP …………………………………………………………………… 173
TORQUE CONVERTER……………………………………………………………………… 177
TRANSMISSION……………………………………………………………………………… 181
INPUT SHAFT GROUP ……………………………………………………………………… 185
HIGH & REVERSE CLUTCH ……………………………………………………………….. 187
SOLENOID VALVE & VALVE UNIT …………………………………………………………. 195
TRANSMISSION PIPE MOUNT…………………………………………………………….. 199
CONTROL VALVE GROUP………………………………………………………………….. 203
VALVE ASSY………………………………………………………………………………….. 207
ACCUMULATOR GROUP …………………………………………………………………… 209
REPAIR KIT …………………………………………………………………………………… 213
• AXLE AND DIFFERENTIAL
FRONT AXLE GROUP ………………………………………………………………………. 215
REAR AXLE GROUP ………………………………………………………………………… 219
AXLE SUPPORT GROUP …………………………………………………………………… 223
FRONT DIFFERENTIAL …………………………………………………………………….. 225
REAR DIFFERENTIAL ………………………………………………………………………. 231
TIRE & WHEEL GROUP…………………………………………………………………….. 233
• BRAKE SYSTEM
BRAKE LINE – FLOOR BOARD <HOSE> …………………………………………………. 235
BRAKE LINE – REAR CHASSIS ……………………………………………………………. 239
BRAKE LINE – FRONT AXLE……………………………………………………………….. 241
BRAKE LINE – REAR AXLE…………………………………………………………………. 243
BRAKE LINE – ACCUMULATOR……………………………………………………………. 245
PARKING BRAKE LINE ……………………………………………………………………… 247
AIR BREATHER MOUNT ……………………………………………………………………. 249
UNLOADER VALVE MOUNT………………………………………………………………… 251
COMBINATION VALVE MOUNT ……………………………………………………………. 253
BRAKE VALVE GROUP……………………………………………………………………… 255
BRAKE VALVE ……………………………………………………………………………….. 257
BRAKE VALVE ……………………………………………………………………………….. 261
BRAKE VALVE ……………………………………………………………………………….. 265
UNLOADER VALVE ………………………………………………………………………….. 269
• CONTROL SYSTEM
STEERING WHEEL MOUNT ……………………………………………………………….. 273
SHIFT LEVER GROUP………………………………………………………………………. 275
TILT CASE GROUP ………………………………………………………………………….. 277
VALVE CONTROL GROUP………………………………………………………………….. 279
SAFETY DEVICE ASSY …………………………………………………………………….. 283
FUEL CONTROL GROUP…………………………………………………………………… 285
STEERING CYLINDER GROUP……………………………………………………………. 287
SECONDARY STEERING GROUP ………………………………………………………… 289
SECONDARY STEERING GROUP – PUMP UNIT………………………………………… 293
SECONDARY STEERING – CABLE MOUNT ……………………………………………… 295
STEERING VALVE …………………………………………………………………………… 297
ORBITROL<TM>……………………………………………………………………………… 299
STEERING CYLINDER ……………………………………………………………………… 301
BUCKET POSITIONER GROUP……………………………………………………………. 303
SENSOR MOUNT <FOR BOOM>………………………………………………………….. 305
• LOADING HYDRAULIC SYSTEM
LOADING HYDRAULIC LINE – FRONT CHASSIS………………………………………… 309
LOADING HYDRAULIC LINE – BOOM …………………………………………………….. 313
LOADING HYDRAULIC LINE – REAR CHASSIS <F ……………………………………… 317
LOADING HYDRAULIC LINE – REAR CHASSIS <F ……………………………………… 319
LOADING HYDRAULIC LINE – REAR CHASSIS <F ……………………………………… 321
LOADING HYDRAULIC LINE – STEERING CYLIND……………………………………… 323
LOADING HYDRAULIC LINE – OIL COOLER …………………………………………….. 325
HYDRAULIC LINE – FAN MOTOR ………………………………………………………….. 329
HYDRAULIC LINE <FOR EFFICIENT LOADING SY …………………………………….. 331
PILOT HYDRAULIC LINE……………………………………………………………………. 333
PILOT HYDRAULIC LINE – FRONT CHASSIS ……………………………………………. 337
PILOT HYDRAULIC LINE – ORBITROL<TM> …………………………………………….. 339
STOP VALVE MOUNT……………………………………………………………………….. 343
OIL PUMP …………………………………………………………………………………….. 345
OIL PUMP …………………………………………………………………………………….. 347
OIL PUMP <DOUBLE>………………………………………………………………………. 349
ACCUMULATOR……………………………………………………………………………… 353
CONTROL VALVE ……………………………………………………………………………. 357
PILOT VALVE …………………………………………………………………………………. 359
PILOT VALVE …………………………………………………………………………………. 363
PILOT VALVE …………………………………………………………………………………. 367
STOP VALVE………………………………………………………………………………….. 371
RELIEF VALVE <FOR FAN> ………………………………………………………………… 373
VALVE MOUNT <EFFICIENT LOADING SYSTEM> ……………………………………… 377
LIFT CYLINDER ……………………………………………………………………………… 379
TILT CYLINDER………………………………………………………………………………. 381
TILT CYLINDER………………………………………………………………………………. 383
• BUCKET,ACCESSORIES,ETC,
BUCKET <FOR ROCK>……………………………………………………………………… 385
BUCKET OPTION PARTS …………………………………………………………………… 387
MARKING GROUP…………………………………………………………………………… 389
LOCK GROUP………………………………………………………………………………… 393
REPAIR & MAINTENANCE PARTS ………………………………………………………… 395
• CAB<OPTION>
CAB MOUNT………………………………………………………………………………….. 397
CAB ……………………………………………………………………………………………. 399
DOOR GROUP <FOR LH>………………………………………………………………….. 403
DOOR GROUP <FOR RH> …………………………………………………………………. 405
CAB ACCESSORY …………………………………………………………………………… 407
FRONT WIPER & WINDOW WASHER GROUP ………………………………………….. 409
BOX & SWITCH MOUNT ……………………………………………………………………. 411
ELECTRICAL PARTS GROUP ……………………………………………………………… 413
ELECTRICAL WIRING – CAB……………………………………………………………….. 417
ELECTRICAL EQUIPMENT MOUNT ………………………………………………………. 419
DOOR STOPPER MOUNT………………………………………………………………….. 421
MIRROR GROUP…………………………………………………………………………….. 423
REAR WIPER & WINDOW WASHER GROUP……………………………………………. 427
WINDOW GLASS MOUNT ………………………………………………………………….. 429
DISPLAY MOUNT ……………………………………………………………………………. 431
CAR RADIO <CAR STEREO MOUNT>……………………………………………………. 433
CAB OPTION PARTS………………………………………………………………………… 435
ROPS,BACK MIRROR & COVER GROUP ………………………………………………… 437
COVER GROUP – CAB………………………………………………………………………. 439
AIR DUCT MOUNT…………………………………………………………………………… 441
AIR DUCT MOUNT…………………………………………………………………………… 445
FILTER MOUNT………………………………………………………………………………. 449
AIR CONDITIONER MOUNT ……………………………………………………………….. 451
AIR CONDITIONER COVER GROUP ……………………………………………………… 453
AIR CONDITIONER COVER GROUP ……………………………………………………… 455
AIR CONDITIONER LINE – REAR CHASSIS ……………………………………………… 457
AIR CONDITIONER LINE – FLOOR BOARD………………………………………………. 459
CONDENSER & COVER MOUNT………………………………………………………….. 461
COMPRESSOR MOUNT ……………………………………………………………………. 463
COMPRESSOR ASSY ………………………………………………………………………. 465
AIR CONDITIONER UNIT MOUNT…………………………………………………………. 467
AIR CONDITIONER UNIT ASSY……………………………………………………………. 469
AIR DAMPER …………………………………………………………………………………. 471
BLOWER ASSY………………………………………………………………………………. 473
CONDENSER ………………………………………………………………………………… 475
ELECTRICAL PARTS GROUP <FOR AIR CONDITIO……………………………………. 477
SENSOR MOUNT <FOR AIR CONDITIONER>…………………………………………… 479
• 115ZV-2 <EUROPE SPEC.>
• OPTION
WEIGHT MOUNT<ALL-IN-ONE UNIT> ……………………………………………………. 481
FRONT LARGE FENDER …………………………………………………………………… 483
REAR FULL FENDER ……………………………………………………………………….. 485
COVER MOUNT<FOR REAR FULL FENDER>…………………………………………… 487
LIFT ARM<HIGH LIFT ARM SPEC.> ………………………………………………………. 489
TILT CYLINDER<HIGH LIFT ARM SPEC.> ……………………………………………….. 491
TILT CYLINDER<HIGH LIFT ARM SPEC.> ……………………………………………….. 493
HYDRAULIC LINE<HIGH LIFT ARM SPEC.> …………………………………………….. 495
CABLE MOUNT<HIGH LIFT ARM SPEC.> ……………………………………………….. 497
LIFT ARM GROUP<FOR SHORT BOOM>………………………………………………… 499
GREASE PIPING<FOR SHORT BOOM>………………………………………………….. 501
OIL CYLINDER MOUNT<FOR SHORT BOOM>………………………………………….. 505
HYDRAULIC LINE /BUCKET<FOR SHORT BOOM>…………………………………….. 507
BUCKET POSITIONER GROUP<FOR SHORT BOOM> ………………………………… 509
TILT CYLINDER<L> <FOR SHORT BOOM> ……………………………………………… 511
TILT CYLINDER<R> <FOR SHORT BOOM>……………………………………………… 513
HYDRAULIC LINE -ATTACHMENT<FOR SHORT BOO………………………………….. 515
SWITCH MOUNT<FOR SHORT BOOM> …………………………………………………. 519
LIMITED SLIP DIFFERENTIAL MOUNT…………………………………………………… 521
HYDRAULIC LINE – ATTACHMENT <FOR 3-WAY P……………………………………… 523
PILOT HYDRAULIC LINE <FOR 3-WAY PIPING>………………………………………… 527
VALVE CONTROL GROUP <FOR 3-WAY PIPING>………………………………………. 531
CONTROL VALVE <FOR 3-WAY PIPING> ………………………………………………… 533
PILOT VALVE <FOR 3-WAY PIPING> ……………………………………………………… 535
CONTROL GROUP <FOR SINGLE LEVER>……………………………………………… 537
PILOT HYDRAULIC LINE <FOR SINGLE LEVER> ………………………………………. 539
PILOT VALVE <FOR SINGLE LEVER>…………………………………………………….. 541
VIBRATION DAMPER – HYDRAULIC LINE………………………………………………… 543
VIBRATION DAMPER – ACCUMULATOR………………………………………………….. 545
VIBRATION DAMPER – ELECTRICAL WIRING…………………………………………… 549
CONTROL VALVE ASSY ……………………………………………………………………. 551
SECONDARY STEERING GROUP ………………………………………………………… 553
SECONDARY STEERING – CABLE MOUNT ……………………………………………… 557
SECONDARY STEERING – PUMP UNIT ………………………………………………….. 559
STICK STEERING – SEAT MOUNT ………………………………………………………… 561
STICK STEERING – ARMREST ASSY …………………………………………………….. 563
STICK STEERING – HYDRAULIC LINE……………………………………………………. 567
STICK STEERING – VALVE MOUNT……………………………………………………….. 569
STICK STEERING – SOLENOID VALVE ASSY …………………………………………… 571
STICK STEERING – BOX MOUNT …………………………………………………………. 573
STICK STEERING – SWITCH MOUNT…………………………………………………….. 575
STICK STEERING – CABLE MOUNT………………………………………………………. 577
HYDRAULIC LINE <FOR TWO-STEP RELIEF VALV …………………………………….. 583
CABLE MOUNT <FOR TWO-STEP RELIEF VALVE> ……………………………………. 587
HIGH POWER HORN MOUNT……………………………………………………………… 589
REAR LAMP MOUNT………………………………………………………………………… 591
AIR SUSPENSION SEAT MOUNT …………………………………………………………. 593
AIR SUSPENSION SEAT ……………………………………………………………………. 595
HEAD REST ………………………………………………………………………………….. 597
CAR RADIO/CAR STEREO MOUNT ………………………………………………………. 599
OIL MOTOR<FOR REVERSIBLE FAN> …………………………………………………… 603
CABLE MOUNT<FOR REVERSIBLE FAN>……………………………………………….. 605
OIL MOTOR <FOR REVERSIBLE FAN>…………………………………………………… 607
• 115ZV-2 <T/C LOCK-UP OPTION9
• CHASSIS AND ELECTRICAL SYSTEM
ELECTRICAL PARTS MOUNT ………………………………………………………… 609
ELECTRICAL WIRING – REAR CHASSIS …………………………………………….. 611
• TORQUE CONVERTER AND TRANSMISSION SYSTEM
TRANSMISSION HYDRAULIC LINE ………………………………………………….. 613
TORQUE CONVERTER……………………………………………………………….. 615
SOLENOID VALVE & VALVE UNIT…………………………………………………….. 619
• PARTS NO. INDEX……………………………………………………………………. 622
Description:
Kawasaki Wheel Loader 115ZV2 Workshop Manual + Parts Catalog Manual
- 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. General Information Functions and structure 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]