Kawasaki WHEEL LOADER 65ZV SHOP MANUAL 93207-00184 – PDF DOWNLOAD

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Kawasaki WHEEL LOADER 65ZV SHOP MANUAL 93207-00184 – PDF DOWNLOAD

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Kawasaki WHEEL LOADER 65ZV SHOP MANUAL 93207-00184 – PDF DOWNLOAD

Language :English
Pages :488
Downloadable : Yes
File Type : PDF

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DESCRIPTION:

Kawasaki WHEEL LOADER 65ZV SHOP MANUAL 93207-00184 – PDF DOWNLOAD

General Information
Standard Measurement Values for
Performance Check
Function & Structure
Check & Adjustment
Powered by CUMMINS 6BTAA5.9 Engine
Serial No. 65C4-9001 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.

TABLE OF CONTENTS:

Kawasaki WHEEL LOADER 65ZV SHOP MANUAL 93207-00184 – PDF DOWNLOAD

General Information
Standard Measurement Values for
Performance Check
Function & Structure
Check & Adjustment
Powered by CUMMINS 6BTAA5.9 Engine
Serial No. 65C4-9001 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 20
Recommended lubricants 23
Coolant 24
Coolant specification 24
Recommended mixture of antifreeze 24
Lubrication chart 25
Weight of main components 26
Bolt tightening torque 27
Hexagon bolt 27
Flanged hexagon bolt 30
Hose band tightening torque 31
Liquid gasket and screw lock agent 32
Cautions regarding parts removal 32
Cautions regarding reassembly 32
Screw lock agent application procedure 33
How to wind a seal tape 33
Cautions regarding welding repair service 34
Cautions 34
03 Measurement for Performance Check 36
Cautions on Safety 37
Standard Measurement Values for Performance Check 38
12 Function & Structure Chassis Group 40
Front Chassis 41
Loading linkage 41
Loading linkage pin 43
Rear Chassis 44
Fuel tank 44
Floor board mount 45
Floor board 45
Viscous mount 45
Center Pin 46
Upper center pin 46
Lower center pin 46
Dust seal 47
13 Check & Adjustment Chassis Group 48
Linkage Pin 49
Liner 49
Adjustment 50
Center Pin 51
Adjusting shim 51
Installing bearing cover 51
22 Function & Structure Power Group 52
Power Line 53
Engine / Transmission 54
Engine / transmission mount 54
Accelerator pedal 55
Fuel control 56
Radiator 58
Radiator mount 59
Thermo sensing valve mount 59
Propeller Shaft 60
Second propeller shaft assembly 61
Third propeller shaft assembly 62
Axle Assembly 63
Axle Support 65
Differential Gear 67
Function of T P D 69
Difference in gear shapes 69
Contact between pinion and side gear 69
Operation of T P D 70
Limited Slip Differential (option) 71
LSD function 72
LSD operation 72
23 Check & Adjustment Power Group 74
Engine 75
Measuring engine speed 75
Measurement instrument 75
Standard measurement value 75
Measuring engine oil pressure 75
Measurement instrument 75
Install position 75
Standard measurement value 75
Propeller Shaft 76
Propeller shaft phase 76
Second propeller shaft alignment 76
Tightening torque 77
Axle 78
Axle tightening procedure 78
Differential gear adjustment procedure 79
Preload adjustment 80
Bearing installation 80
Oil seal installation 80
Adjusting tooth contact 81
32 Function & Structure Torque Converter and Transmission Group 84
Torque Converter 85
Torque converter structure 85
Power flow path 85
Torque multiplication 85
Torque Converter Gear Pump 86
Pump specifications 86
Transmission 87
Clutch combination 87
Shift lever position 87
QUAD (Quick up and down shift) 87
Gear train and number of teeth 88
Clutch specifications 89
Friction plate: mm (in) 89
Valve location 90
Clutch Pack 92
Forward and reverse clutch 92
1st and 2nd speed clutch 93
3rd and 4th speed clutch 94
Power Flow Path in the Transmission 95
Forward 95
Forward 1st speed 95
Forward 2nd speed 96
Forward 3rd speed 97
Forward 4th speed 98
Reverse 99
Reverse 1st speed 99
Reverse 2nd, 3rd, and 4th speeds 99
Hydraulic System Diagram 100
Hydraulic Circuit Diagram 101
Oil Flow 102
Oil flow in the torque converter line 102
From torque converter gear pump to torque converter 102
Return oil from torque converter 102
Return oil from cooler 102
Oil flow to the clutches 102
To forward and reverse clutches 102
To speed clutches 102
T/C and T/M Oil Circulation 103
Control Valve 104
Main control valve 104
3rd, 4th speed control valve 104
Oil port layout 105
Layout of ports on mounting surface of control valve (at T/M case side) 105
Modulation Mechanism 106
Clutch control oil pressure curve 106
Modulation mechanism operation 107
Accumulator 110
Accumulator for 1st and 2nd speed clutch 110
Clutch Solenoid Valve 111
For forward/reverse and speed clutches 111
After power-off (clutch disengaged status) 111
After power-on (clutch engaged status) 112
33 Check & Adjustment Torque Converter and Transmission Group 114
Clutch Oil Pressure 115
Measuring clutch oil pressure 115
42 Function & Structure Hydraulic Group 118
Flushing Hydraulic Circuit 119
Purpose of flushing 119
Cautions on Hydraulic Parts Replacement 120
Hydraulic Circuit Symbols 121
Hydraulic lines 121
Pumps & motors 121
Cylinders 121
Operation methods 122
Pressure control valve 122
Flow control valve 122
Directional control valve 123
Check valve 123
Miscellaneous hydraulic symbols 124
Hydraulic System Operation 125
Hydraulic system operation outline 125
Loading system 125
Steering system 126
Fan motor system 126
Ride control system (OPT) 126
Layout of Hydraulic Units 127
Hydraulic Tank 128
Hydraulic tank breather valve (tank cap) 131
Hydraulic tank specifications 132
Hydraulic oil level check 133
Hydraulic Pump 134
Hydraulic pump specifications 134
Hydraulic pump principle 135
Hydraulic pump wear plate 136
Hydraulic pump bushing lubrication 136
Hydraulic Cylinder 137
Boom cylinder 137
Bucket cylinder 138
Steering cylinder 139
Hydraulic cylinder specifications 140
Loading System 141
Reducing Valve (for Pilot Pressure) 142
Pilot valve (S/N 65C4-9001~9040) 143
Pilot valve operation 145
Pilot valve detent magnet solenoid 147
Detent adjustment procedure 147
Pilot valve (S/N 65C4-9041~) 148
Pilot valve operation 150
Pre-detent and detent magnet solenoid 152
Multiple Control Valve (KML22/2T) 153
Multiple control valve specifications 154
Multiple control valve main relief valve 155
Main relief valve operation 155
Adjusting set pressure 156
Multiple control valve overload relief valve 157
Overload relief valve operation 157
Adjusting set pressure 158
Multiple control valve make-up valve 158
Make-up valve operation 158
Multiple control valve bucket spool 159
Bucket spool operation 159
Multiple control valve boom spool 161
Boom spool operation 161
Adapter (Orifice) 164
Vibration Damper (OPT) 165
Hydraulic circuit 165
Introduction 166
Operation 166
Preparation mode (the vibration damper switch is OFF) 166
Running mode (the vibration damper switch is ON) 166
Vibration Damper (D/D) Valve Assembly 167
Structure 167
Outline drawing 167
Section drawing 168
Solenoid valve 169
Specification 169
Accumulator 170
Structure 170
Function 170
Specification 170
Steering System 171
Orbitrol® 172
Orbitrol® structure 172
Valve part 172
Rotor part 173
Orbitrol® specification 173
Orbitrol® operation 174
Neutral 174
Turn 175
Orbitrol® feed-back mechanism operation 176
Steering speed and flow rate control 177
Hydraulic pump oil amount and steering force 177
Orbit rotor operation principle 178
Steering Valve (KVS25-A3 0/20) 179
Steering valve operation 181
Neutral position 181
Left turn position 182
Steering plunger variable throttle 183
Steering valve flow control plunger 184
Steering valve main relief valve 185
When the pressure is at the preset value or less 185
When the pressure exceeds the preset value 186
Steering valve overload relief valve 187
Overload relief valve operation 188
Steering pilot circuit and its operation 189
Flow amplifier notch and pilot orifice 190
Stop Valve 191
Stop valve function 192
Stop valve operation 193
Reducing Valve (for Orbitrol®) 194
Steering Line Filter 195
Secondary Steering 196
Secondary steering circuit 196
Secondary steering operation 196
Secondary steering motor and pump 198
Fan Motor System 199
Fan Motor Line 200
Fan motor 202
Fan motor (GM20W-1T7T8-B70A61L) (S/N 9001~9041) 202
Fan motor (GM20W-1T7T8-K70A61L) (S/N 9042~) 203
Fan motor relief valve assembly 204
Fan motor relief valve 205
Fan motor check valve (Make-up valve) 205
Thermo sensing valve 206
Thermo sensing valve specifications 206
Thermo sensing valve operation 207
Reversing Fan Motor (OPT) 208
Reversing Fan Motor Line (OPT) 210
Reversing fan motor (PI-GM25B-1Q23D) 213
Thermo sensing valve (for reversing fan) 213
Reversing fan motor valve 214
43 Check & Adjustment Hydraulic Group 216
Loading/Steering Circuit Relief Valve 217
Loading circuit relief valve setting pressures 217
Measurement instruments 217
Standard measurement value 217
Gauge port 218
Measuring loading circuit main relief pressure 219
Measuring loading circuit overload relief pressure 219
Adjusting overload relief pressure 220
Measuring pilot circuit pressure 220
Adjusting pilot line pressure 221
Steering circuit relief valve setting pressures 222
Measurement instruments 222
Standard measurement value 222
Gauge port 223
Measuring steering circuit main relief pressure 224
Measuring steering circuit overload relief pressure 225
Measuring pilot circuit relief pressure (Reducing pressure) 226
Hydraulic Cylinder 227
Cylinder natural drift 227
Measurement instrument 227
Standard measurement value (mm/min) (in/min) 227
Measurement procedure 227
Stop Valve 229
Stop valve adjustment procedure 229
Fan Revolution 230
Fan maximum revolution measurement 230
Fan revolution measurement procedure 230
Fan revolution adjustment procedure 231
52 Function & Structure Brake Group 232
Brake System Outline 233
Service brake 233
Parking brake 233
Adjustment of axle internal pressure 233
Brake Units Layout 234
Unloader Valve 235
Unloader valve operation 237
Valve Unit 238
Brake Accumulator Line 239
Accumulator 240
In-Line Filter 241
Brake Valve 242
Brake main valve (left pedal) 242
Brake pilot valve (right pedal) 243
Brake valve performance chart 244
Brake valve outline 245
Main valve (tandem type) operation 245
Pilot valve operation 246
Stop lamp pressure switch 247
Pressure switch (for Declutch) 248
Service Brake 249
Service brake operation 249
Service brake friction plate 250
Brake circuit air bleeding procedure 251
Bleeding air from the brake valves 252
Bleeding air from brake pipes 252
Parking Brake 253
Parking brake operation 254
Parking brake solenoid valve 255
Solenoid valve operation 255
Solenoid valve specifications 255
Parking Brake Manual Release 256
Parking Brake Spring Chamber 258
Brake Circuit Check Valve 259
53 Check & Adjustment Brake Group 260
Brake Circuit Oil Pressure 261
Unloader valve setting pressure 261
Measurement procedure 262
Brake valve oil pressure 263
Measurement instrument 263
Gauge port 263
Measurement procedure 263
Brake valve performance 264
Service Brake 265
Service brake performance check 265
Condition 265
Standard measurement value 265
Service brake friction plate wear measurement 266
Measurement procedure 266
Parking Brake 267
Parking brake performance check 267
Parking brake clearance adjustment 269
Adjustment procedure 269
Brake lining abrasion check 270
62 Function & Structure Electrical Group 272
How to Use Electrical Wiring Diagram 273
Utilisation des schémas des câblages électriques (FRANÇAIS) 274
Verwendung des elektrischen Schaltplans (DEUTSCH) 275
Modalità di utilizzo dello schema dei collegamenti elettrici (ITALIANO) 276
Cómo utilizar un Diagrama de Alambrado Eléctrico (ESPAÑOL) 277
Como Utilizar o Diagrama de Ligações Eléctricas (PORTUGUÊS) 278
Electrical Cable Color Codes 279
Electrical Circuit Symbols 280
Sensor Mount 281
Fuse 282
Fuse box location 282
Fuse box 283
Fusible link 284
Engine Start Circuit 286
Engine start circuit diagram 286
Neutral starter 287
Shift lever neutral (N) position 287
Shift lever forward/reverse (F/R) position 287
Neutral starter 289
Shift lever neutral (N) position 289
Shift lever forward/reverse (F/R) position 289
Starter switch 290
Fuel solenoid valve 291
Fuel solenoid valve specification 291
Fuel solenoid relay 291
Battery relay 292
Battery relay operation 292
Alternator I (R) terminal wire 292
Diode unit 293
Neutral relay 293
Magnet switch (S/N 9001~9021) 294
Voltage relay (S/N 9001~9021) 294
Safety relay (S/N 9022~) 295
Power Generating/Charging Circuit 296
Alternator 296
Transmission Control Circuit and Monitor Circuit 297
Controller 297
LED inspection windows 298
Controller connection diagram 300
Controller function 301
Forward/reverse (F/R) shifting and speed change 301
Automatic shift 303
Machine speed sensor 304
QUAD (downshift) switch operation 305
Switching from automatic to manual 306
Transmission cut off (Declutch) 307
Pressure switch for inching (declutch) 308
Back-up alarm 309
Parking brake 310
Transmission controller failure warning 312
Secondary steering function 313
Monitoring system 314
Items to be monitored and operation condition 314
Operation monitor lamps 315
Instrument Panel and Switch 316
Instrument panel 316
Instrument panel rear surface 317
Gauge circuit 318
Temperature sensor 318
Fuel level sensor 319
Electrical Detent Circuit 320
Bucket leveler 320
Boom kick-out 321
Float 321
Proximity switch 321
Detent solenoid 322
Diode 323
Diode check method 324
Caution for diode check method 324
Continuity check mode 324
Diode check mode 324
Resistance check mode 325
Surge voltage and surge suppression diodes 326
Diagnostic System 327
Diagnostic system flow 327
Diagnostic failure history memory data 328
Warning monitor/control 328
Failure code 329
Malfunction mode symbol 330
Diagnostic (T/M controller) failure code detection condition 331
Diagnostic failure history indication and deletion 332
Failure history indication 332
Failure history deletion 332
Diagnostic switch 334
63 Check & Adjustment Electrical Group 336
Cautions Regarding Electric Circuit Check 337
Disconnecting or reinstalling connector 337
How to attach the probes of the circuit tester 339
Electrical Transmission Control System Troubleshooting Flowchart 340
Standard troubleshooting flowchart 340
Transmission Controller Abnormal Operation Judgment 341
Transmission controller check 341
When the “controller failure” monitor lamp lights: 341
When the output units (solenoid valve, etc ) do not operate properly: 341
If the input units or circuit are not defective 342
Transmission controller LED indicator 343
Electrical Circuit Check 345
Shift lever input electrical circuit check 345
Inching (Declutch) input electrical circuit check 347
QUAD switch input electrical circuit check 349
Machine speed sensor input electrical circuit check 350
Clutch solenoid valve output electrical circuit check 351
Neutral relay electrical circuit check 354
Parking brake electrical circuit check 355
Gauge circuit electrical circuit check 357
Bucket positioner electrical circuit check 359
72 Function & Structure Operator Station Group 362
Cabin 363
Glass 364
1 Part number 32011-21690 365
2 Part number 32011-21700 365
3 Part number 32011-21500 366
Wiper mount 367
Front wiper 367
Rear wiper 367
Wiper motor 368
Operator Seat 370
Steering and Transmission Shift Lever 371
Tilt case 372
Column shaft 373
Shift lever 373
Air Conditioner 374
Air conditioner components 374
Air conditioner specifications (system performance) 374
Air conditioner structure 375
Cooling unit 375
Heater and accessories 377
Air distributor (hood & defroster selection box) 377
Air compressor (with magnetic clutch) 378
Condenser unit 378
Control unit 379
Cooling mechanism 380
Principle of cooling 380
Refrigerant 380
Refrigerant characteristics 381
Cooling circuit 382
Electrical circuit 383
Control schematic drawing 383
Air conditioner functions of components 384
Control panel 384
Air conditioner unit 391
Compressor and magnetic clutch 400
Condenser unit 403
Receiver dryer 405
Sight glass 407
Pressure switches 407
Pressure relief valve 408
Relay A 409
Relay B 409
Refrigerant hose 410
Charge of refrigerant 411
Work procedure 412
Refrigerant charging tools 413
Refrigerant charging procedure 416
Troubleshooting using the gauge manifold 421
Air conditioner troubleshooting 426
Fault diagnosis procedure 426
73 Check & Adjustment Operator Station Group 434
Air Conditioner 435
Adjustment of lubricating oil quantity when components of air conditioner are replaced 435
When the compressor is replaced 436
When the evaporator is replaced 437
When the condenser is replaced 437
Adjustment of air gap (between hub and rotor) in compressor magnetic clutch 438
Compressor V-belt adjustment 439
Belt adjustment procedure 439
Adjustment value 439
Parts to be replaced periodically 440
Air filters 440
Receiver dryer 440
INDEX 442
Maintenance Log 447
Notes 451
92 Cross-section drawing & Diagrams 455
Axle Assembly 456
Torque Converter and Transmission 457
Loading/Steering Hydraulic Line 458
Brake Circuit 459
Electrical Wiring Diagram (1/2) (S/N 9001~9010) 460
Electrical Wiring Diagram (2/2) (S/N 9001~9010) 461
Electrical Wiring Diagram (1/2) (S/N 9011~9021) 462
Electrical Wiring Diagram (2/2) (S/N 9011~9021) 463
Electrical Wiring Diagram (1/2) (S/N 9022~9040) 464
Electrical Wiring Diagram (2/2) (S/N 9022~9040) 465
Electrical Wiring Diagram (1/2) (S/N 9041~) 466
Electrical Wiring Diagram (2/2) (S/N 9041~) 467
Electrical wiring diagram abbreviation chart 468
Electrical Wiring Diagram (CAB) 469
Electrical Connection Diagram (S/N 9001~9021) 472
Electrical Connection Diagram (S/N 9022~) 473
Electrical Wiring (Reversal Fan) (OPT) 474
Electrical Equipment Layout 475
Electrical Circuit Diagram (Cabin Air Conditioner) 486
Electrical Wiring Diagram (Cabin Air Conditioner) 487
Equipment Operation Table (Cabin Air Conditioner) 488

S.M 5/2/2025