Kawasaki Wheel Loader 135Z5-2 parts + service manual

Description Kawasaki Wheel Loader 135Z5-2 parts + service manual

06.2009 / All Regions / 1 CD / Windows OS, MacOS, Linux / 32 & 64 bit

Kawasaki WHEEL LOADER 135Z5-2 PDF PARTS MANUAL + WORKSHOP SERVICE & REPAIR MANUAL

MANUAL CONTENT:

PARTS CATALOG ENGINE (CUMMINS QST30-C)

PARTS CATALOG (EQUIPMENT)

SERVICE MANUAL

General Information

Safety precautions

Outline

Layout of main components

Inspection and maintenance table

Recommended lubricants

Coolant

Lubrication chart

Weight of main components

Bolt tightening torque

Hose band tightening torque

Liquid gasket and screw lock agent

Cautions regarding welding repair service

Hydraulic Pressure Test Kit

Measurement for Performance Check

Cautions on Safety

Standard Measurement Values for Performance Check

Function & Structure Chassis Group

Front Chassis

Loading linkage

Loading linkage pin

Rear Chassis

Fuel tank

Floor board mount

Center Pin

Upper center pin

Lower center pin

Dust seal

Check & Adjustment Chassis Group

Linkage Pin

Liner

Center Pin

Adjusting shim

Installing bearing cover

Installing bearing outer ring

Function & Structure Power Group

Power Line

Engine / Transmission

Engine mount

Transmission mount

Radiator

Radiator mount

T/C cooler mount

Propeller Shaft

First propeller shaft assembly

Second propeller shaft assembly

Third propeller shaft assembly

Axle Assembly

Axle Support

Differential Gear

Conventional type

Function of differential gear

Operation of differential gear

Check & Adjustment Power Group

Engine

Measuring engine speed

Measuring engine oil pressure

Propeller Shaft

Propeller shaft phase

Second propeller shaft alignment

Tightening torque

Axle

Differential gear adjustment procedure

Function & Structure Torque Converter and Transmission Group

Torque Converter

Torque converter structure

Power flow path

Torque multiplication

Lock-up clutch function (only forward)

Torque Converter Gear Pump

Gear pump specifications

Transmission

Clutch combination

Planetary gear

Shift lever position

Downshift button operation

Gear train and number of teeth

Clutch Pack

Power Flow Path in the Transmission

Hydraulic System Diagram

Hydraulic Circuit Diagram

Oil Flow

Oil flow in torque converter line

Oil flow in transmission line

T/C and T/M Oil Circulation

Modulator Valve Unit

Interior schematic (not exact representation)

Modulation Mechanism

Modulator valve operation

Control Valve Assembly

Clutch solenoid valve assembly

Clutch valve assembly

Check valve assembly

Lock-up clutch solenoid valve

Accumulator assembly

Check & Adjustment Torque Converter and Transmission Group

Measuring Clutch Oil Pressure

Priority valve adjusting procedure

Function & Structure Hydraulic Group

Flushing Hydraulic Circuit

Purpose of flushing

Cautions on Hydraulic Parts Replacement

Hydraulic Circuit Symbols

Hydraulic lines

Pumps & motors

Cylinders

Operation methods

Pressure control valve

Flow control valve

Directional control valve

Check valve

Miscellaneous hydraulic symbols

Hydraulic System Operation

Hydraulic system operation outline

Layout of Hydraulic Units

Hydraulic Tank

Hydraulic tank breather valve (tank cap)

Hydraulic tank sub tank

Hydraulic tank suction filter

Hydraulic tank return filter

Hydraulic tank specifications

Hydraulic oil level check

Hydraulic Pump

Steering pump (K3V)

Loading pump (K5V)

Triple pump

Hydraulic pump principle

Hydraulic pump wear plate

Hydraulic pump bushing lubrication

Hydraulic Cylinder

Boom cylinder

Bucket cylinder

Steering cylinder

Hydraulic cylinder specifications

Loading System

Reducing Valve (for Pilot Pressure)

Pilot Valve (TH40MS)

Pilot valve (TH40MS) function

Pilot valve (TH40MS) Installation position detail

Pilot valve (TH40MS) performance chart

Pilot valve (TH40MS) structure

Pilot valve (TH40MS) operation

Boom soft landing hydraulic connection

Power boost circuit

Steering unloader circuit

Hydraulic line connection

Steering unloader circuit structure

Steering unloader circuit outline

Steering unloader circuit function

Solenoid valve

Solenoid valve structure (Not activated)

Solenoid valve operation

Slow return check valve (Boom soft landing circuit)

Adapter (Orifice)

Slow return check valve (Boom raise)

Multiple Control Valve (KML35A/2T401A)

Multiple control valve specifications

Multiple control valve main relief valve (MRV) (2 stage relief)

Multiple control valve overload relief valve (with make-up function)

Multiple control valve make-up valve

Multiple control valve bucket spool

Multiple control valve boom spool

Pilot valve

Pilot valve structure

Pilot valve operation

Ride Control (OPT)

Ride control hydraulic circuit

Ride control operation

Ride control valve assembly (Reducing valve circuit)

Ride control valve assembly (Accumulator circuit)

Accumulator (for ride control)

Steering System

Pilot valve (for steering) operation

Steering Valve (KVS32-A1.0/31)

Steering valve operation

Steering spool variable throttle

Steering valve flow control spool

Steering valve main relief valve

Steering valve overload relief valve

Steering pilot circuit and its operation

Stop Valve

Stop valve operation

Slow Return Check Valve

Slow return check valve specifications

Steering Lock Line

Efficient Loading System

Efficient loading system outline

Hydraulic line

Mounting of the variable kickout sensor

Check & Adjustment Hydraulic Group

Loading/Steering Circuit Relief Valve

Loading circuit relief valve setting pressures

Steering circuit relief valve setting pressures

Hydraulic Cylinder

Cylinder natural drift

Stop Valve

Stop valve adjustment procedure

Function & Structure Brake Group

Brake System Outline

Service brake

Parking brake

Auto brake

Brake Units Layout

Unloader Valve

Unloader valve operation

Valve Unit

Reducing Valve (for Parking/Pilot Pressure/Power Boost)

Accumulator

Brake Valve

Brake valve performance chart

Brake valve outline

Line Filter

Service Brake

Service brake operation

Service brake disc

Service brake piston

Service brake pedal stroke adjusting mechanism

Service brake warning system

Brake circuit air bleeding procedure

Parking Brake

Parking brake operation

Parking brake friction disc

Parking brake solenoid valve

Parking Brake Manual Release

Brake Circuit Check Valve

Auto Brake

Auto brake circuit

Auto brake operation set value

Reducing valve (for Autobrake circuit)

Solenoid valve (for Autobrake circuit)

Pressure Sensor (for stop lamp and declutch)

Pressure sensor (for stop lamp)

Pressure sensor (for Declutch)

Check & Adjustment Brake Group

Brake Circuit Oil Pressure

Unloader valve setting pressure

Brake valve oil pressure

Service Brake

Service brake performance check

Service brake friction plate wear detection

Parking Brake

Parking brake performance check

Function & Structure Electrical Group

How to Use Electrical Wiring Diagram

Electrical Cable Color Codes

Electrical Circuit Symbols

Sensor Mount

Fuse

Fuse box

Fusible link

Engine Start Circuit

Engine start circuit diagram

Neutral starter

Starter switch

Battery relay

Alternator I terminal wire

Diode unit

Neutral relay

Magnetic switch

Voltage

Power Generating/Charging Circuit

Alternator

ECM (Engine Controller)

Function of ECM

Connection diagram

Monitor lamp test

Failure diagnosis

Quantum fault code information

Accelerator pedal

Transmission Control Circuit and Monitor Circuit

Machine control unit (MCU)

MCU connection diagram

Machine control unit (MCU) function

Modulator valve operation

Adjustable declutch preset switch

Monitoring system

Operation monitor lamps

Instrument Panel and Switch

Instrument panel

Instrument panel rear surface

Gauge circuit

Fuel gauge circuit

MODM

MODM function

Monitor Changeover

Information Monitor

Replacement Monitor

Fault Log Monitor

Input/Output Monitor

Parameter Setting Monitor

Specification Setting Monitor

Electrical Detent Circuit

Bucket leveler

Detent solenoid

Lift kickout & lower kickout/boom soft landing

Sensor assy

Preset height adjustment

Boom soft landing

Float

Diode

Diode check method

Caution for diode check method

Surge voltage and surge suppression diodes

Drawing & Diagrams

Axle Assembly

Torque Converter and Transmission

Hydraulic & Brake Circuit

Brake Circuit

Gauge Mount

Electrical Wiring Diagram

Way of looking at connectors

Electrical wiring diagram abbreviation chart

Electrical Wiring Diagram (CAB)

Electrical Connection Diagram

Electrical Equipment Layout

Outline of MODM (Machine Operation Diagnostic Module) Operation

MODM: Input/Output Monitor - Input/Output Signal Correspondence Table