Kawasaki Wheel Loader 95Z5 parts + service manual

Description Kawasaki Wheel Loader 95Z5 parts + service manual

02.2006 / All Regions / 1 CD / Windows OS, MacOS, Linux / 32 & 64 bit

Kawasaki WHEEL LOADER 95Z5 PDF PARTS MANUAL + WORKSHOP SERVICE & REPAIR MANUAL

MANUAL CONTENT:

PARTS CATALOG (EQUIPMENT)

SERVICE MANUAL

General Information

Safety precautions

Symbols

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

Installing bearing outer ring

Function & Structure Power Group

Power Line

Engine / Transmission

Engine / transmission mount

Radiator

Radiator mount

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

Differential Gear (Limited Slip Differential)

Check & Adjustment Power Group

Engine

Measuring engine speed

Measuring engine oil pressure

Propeller Shaft

Propeller shaft phase

Second propeller shaft alignment

Tightening torque

Axle

Axle nut tightening procedure

Differential gear adjustment procedure

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

Clutch combination

Shift lever position

QUAD (Quick up and down shift)

Gear train and number of teeth

Clutch specifications

Clutch Pack

Power Flow Path in the Transmission

Forward

Reverse

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

Traveling at forward 1st speed

Changing from forward 1st speed to reverse 1st speed

Trimmer engagement

Clutch engagement starting

Clutch Solenoid Valve

For forward/reverse and speed clutches

For trimmer

Check & Adjustment Torque Converter and Transmission Group

Clutch Oil Pressure

Measuring clutch oil pressure

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 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

Loading System

Reducing Valve (for Pilot Pressure)

Pilot Valve

Pilot valve operation

Pilot valve detent magnet solenoid

Detent adjustment procedure

Pilot Valve  

Pilot valve operation

Pre-detent and detent magnet solenoid

Multiple Control Valve (KML35A/2T202)

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

Adapter (Orifice)

Vibration Damper (OPT)

Vibration damper hydraulic circuit

Vibration damper function

Vibration damper operation

Vibration damper valve assembly

Accumulator (for vibration damper)

Vibration damper hydraulic line

Steering System

Orbitrol

Orbitrol specification

Orbitrol structure

Orbitrol operation

Orbitrol feed-back mechanism operation

Steering speed and flow rate control

Hydraulic pump oil amount and steering force

Orbit rotor operation principle

Steering Valve

Steering valve operation

Steering plunger variable throttle

Steering valve flow control plunger

Steering valve main relief valve

Steering valve overload relief valve

Steering pilot circuit and its operation

Stop Valve

Stop valve function

Stop valve operation

Reducing Valve (for Orbitrol®)

Steering Line Filter

Fan Motor System

Fan Motor Line

Fan Motor

Fan motor specifications

Thermo Sensing Valve

Thermo sensing valve specifications

Thermo sensing valve operation

Fan Motor Relief Valve Assembly

Fan motor relief valve

Fan motor check valve (Make-up valve)

Emergency Steering

Emergency steering circuit

Emergency steering motor and pump

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

Fan Revolution

Fan maximum revolution measurement

Function & Structure Brake Group

Brake System Outline

Service brake

Parking brake

Secondary brake

Adjustment of axle internal pressure

Brake Units Layout

Unloader Valve

Unloader valve operation

Valve Unit

Accumulator

In-Line Filter

Brake Valve

Brake main valve (left pedal)

Brake pilot valve (right pedal)

Brake valve performance chart

Brake valve outline

Service Brake

Service brake operation

Service brake friction plate

Service brake steel plate

Service brake piston

Service brake pedal stroke adjusting mechanism

Brake circuit air bleeding procedure

Parking Brake

Parking brake operation

Parking brake solenoid valve

Parking Brake Manual Release

Parking Brake Spring Chamber

Secondary Brake

Secondary brake structure

Secondary brake operation

Dry type disc brake auto adjuster mechanism

Manual release of secondary brake

Solenoid valve for brake

Secondary brake line air bleeding procedure

Brake Circuit Check Valve

Pressure Switch

Pressure switch (for stop lamp)

Pressure switch (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 measurement

Parking Brake

Parking brake performance check

Parking brake clearance 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

Accelerator pedal

Transmission Control Circuit and Monitor Circuit

Controller

Controller connection diagram

Controller function

Emergency steering function

Monitoring system

Instrument Panel and Switch

Instrument panel

Instrument panel rear surface

Gauge circuit

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

Transmission Controller Abnormal Operation Judgment

Transmission controller check

Transmission controller LED indicator

Electrical Circuit Check

Shift lever input electrical circuit check

Inching (Declutch) input electrical circuit check

QUAD switch input electrical circuit check

Machine speed sensor input electrical circuit check

Clutch solenoid valve output electrical circuit check

Transmission trimmer plug solenoid valve electrical circuit check

Neutral relay electrical circuit check

Parking brake electrical circuit check

Gauge circuit electrical circuit check

Bucket positioner electrical circuit check

Function & Structure Operator Station Group

Cabin

Glass

Wiper mount

Wiper motor

Operator Seat

Steering and Transmission Shift Lever

Tilt case

Column shaft

Shift lever

Air Conditioner

Air conditioner components

Air conditioner structure

Cooling mechanism

Cooling circuit

Electrical circuit

Air conditioner functions of components

Charge of refrigerant

Check & Adjustment Operator Station Group

Air Conditioner

Adjustment of lubricating oil quantity when components of air conditioner are replaced

Adjustment of air gap (between hub and rotor) in compressor magnetic clutch

Compressor V-belt adjustment

Parts to be replaced periodically