Kawasaki Wheel Loader 60Z5-2 parts + service manual

Description Kawasaki Wheel Loader 60Z5-2 parts + service manual

11.2012 / All Regions / 1 CD / Windows OS, MacOS, Linux / 32 & 64 bit

Kawasaki WHEEL LOADER 60Z5-2 PDF PARTS MANUAL + WORKSHOP SERVICE & REPAIR MANUAL

MANUAL CONTENT:

PARTS CATALOG ENGINE (CUMMINS QSB4.5)

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

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

Function & Structure Power Group

Power Line

Engine / Transmission

Engine / transmission mount

Radiator

Propeller Shaft

Second propeller shaft assembly

Third propeller shaft assembly

Axle Assembly

Axle Support

Differential Gear

Function of T.P.D

Operation of T.P.D

Check & Adjustment Power Group

Engine

Measuring engine oil pressure

Propeller Shaft

Propeller shaft phase

Second propeller shaft alignment

Tightening torque

Axle

Differential gear

Function & Structure Torque Converter and Transmission Group

Torque Converter

Torque converter structure

Power flow path

Torque multiplication

Torque Converter Gear Pump

Gear pump specifications

Transmission

Gear arrangement

Clutch specifications

Valve location

Clutch Pack

Forward and 2nd speed clutch

Reverse and 1st speed clutch

3rd speed clutch

Power Flow Path in the Transmission

Hydraulic System Diagram

Hydraulic Circuit Diagram

Oil Flow

Oil flow in the torque converter line

Oil flow to the clutch

T/C and T/M Oil Circulation

Control Valve

System diagram

Modulation Mechanism

Clutch control oil pressure curve

Accumulator

Accumulator for 1st speed clutch

Clutch Solenoid Valve

For forward/reverse and speed clutches

Check & Adjustment Torque Converter and Transmission Group

Clutch Oil Pressure

Function & Structure Hydraulic Group

Flushing Hydraulic Lines

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

Layout of Hydraulic Units

Hydraulic Tank

Hydraulic tank breather valve (tank cap)

Hydraulic tank specifications

Hydraulic oil level check

Hydraulic Pump

Hydraulic pump specifications

Hydraulic pump principle

Hydraulic pump wear plate

Hydraulic pump bushing lubrication

Hydraulic Cylinder

Boom cylinder

Bucket cylinder

Steering cylinder

Hydraulic cylinder specifications

Return Filter

Loading System

Relief Valve Assembly

Relief valve operation

Check valve operation

Accumulator

Accumulator specifications

Pilot Valve (TH40MS)

Pilot valve specifications

Pilot valve performance chart

Pilot valve operation

Multiple Control Valve (KVS-120H-2)

Multiple control valve specifications

Multiple control valve main relief valve

Multiple control valve overload relief valve

Multiple control valve make-up valve

Multiple control valve bucket spool

Multiple control valve boom spool

Elbow Adapter

Pilot Valve Filter

Steering System

Priority Valve

Priority valve specifications

Priority valve operation

Orbitrol®

Orbitrol® construction

Orbitrol® specification

Orbitrol® operation

Orbitrol® feed-back mechanism operation

Steering speed and flow rate control

Hydraulic pump oil amount and steering force

Orbit rotor operation principle

Auxiliary valves

Emergency check valve

Inlet check valve

Cushion Valve

Cushion valve specifications

Cushion valve operation

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

Function & Structure Brake Group

Brake Circuit

Brake Units Layout

Hydraulic Servo Master Cylinder

Hydraulic servo master cylinder specifications

Performance diagram

Hydraulic servo master cylinder operation

Pressure Difference Switch

Service Brake

Service brake operation

Service brake friction plate

Service brake steel plate

Brake circuit air bleeding procedure

Parking Brake

Brake Control

Service brake linkage

Parking brake linkage

Brake Oil Reservoir

Brake oil reservoir specifications

Check & Adjustment Brake Group

Hydraulic Servo Master

Hydraulic servo master performance inspection

Service Brake

Service brake performance check

Service brake friction plate wear measurement

Parking Brake

Parking brake performance check

Parking brake clearance adjustment

Brake Control

Adjusting brake pedal and switch

Parking brake linkage adjustment

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

Magnet switch

Voltage relay

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)

Machine control unit (MCU) connection diagram

Machine control unit (MCU) function

Monitoring system

Instrument Panel and Switch

Instrument panel

Instrument panel rear surface

Gauge circuit

Fuel level sensor

Electrical Detent Circuit

Bucket leveler

Boom kick-out

Detent solenoid

Diode

Diode check method

Caution for diode check method

Surge voltage and surge suppression diodes

Diagnostic System

Diagnostic system flow

Diagnostic failure history memory data

Diagnostic failure history indication and deletion

Diagnostic switch

Check & Adjustment Electrical Group

Cautions Regarding Electric Circuit Check

Disconnecting or reinstalling connector

How to attach the probes of the circuit tester

Electrical Transmission Control System Troubleshooting Flowchart

Standard troubleshooting flowchart

MCU Abnormal Operation Judgment

MCU check

Electrical Circuit Check

Shift lever input electrical circuit check

Declutch input electrical circuit check

Downshift button input electrical circuit check

Machine speed sensor input electrical circuit check

Clutch solenoid valve output electrical circuit check

Neutral relay electrical circuit check

Checking parking brake circuit

Gauge circuit electrical circuit check

Bucket leveler electrical circuit check

Drawing & Diagrams

Axle Assembly

Torque Converter and Transmission

Loading/Steering Hydraulic Line

Brake Circuit

Electrical Wiring Diagram

Electrical wiring diagram abbreviation chart

Electrical Connection Diagram

Electrical Wiring Diagram (CAB)

Electrical Equipment Layout