PDF Shop Manual Kawasaki 135ZV-2 Wheel Loader - 4 MB
This comprehensive shop manual is the definitive guide for servicing the Kawasaki 135ZV-2 Wheel Loader.
It contains detailed instructions for every aspect of repair and maintenance, from the engine to the hydraulic and electrical systems.
Technicians will find the step-by-step procedures, specifications, and diagrams invaluable for complex repairs.
This manual is essential for keeping your wheel loader in peak operating condition.
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--- Page 1 ---
93217-00210
135ZV-2
March 2012
SHOP MANUAL
SHOP MANUAL
WHEEL LOADER
Service Standard
Disassembly & Reassembly
135ZV-2
Disassembly & Reassembly
Service Standard
93217-00210
Powered by CUMMINS QST30-C ENGINE
©2012 KCM Corporation All rights reserved. Printed in Japan (K)
( アメリカ・輸出一般・ヨーロッパ用 ) Serial No. 13C1-9501~
--- Page 3 ---
Unloader Valve ................................................................................................................................................ 54-10
Unloader valve removing and installing .................................................................................................... 54-10
Unloader valve disassembling and assembling ........................................................................................ 54-12
Manifold Valve Assembly ................................................................................................................................ 54-14
Valve assembly removing and installing ................................................................................................... 54-14
Valve assembly disassembling and assembling ....................................................................................... 54-16
Accumulator .................................................................................................................................................... 54-17
Accumulator removing and installing ........................................................................................................ 54-17
Accumulator disassembling and assembling ............................................................................................ 54-19
Nitrogen gas charging ............................................................................................................................... 54-25
Service Brake .................................................................................................................................................. 54-27
Service brake disassembling and assembling .......................................................................................... 54-27
Parking Brake .................................................................................................................................................. 54-31
Parking brake removing and installing ...................................................................................................... 54-31
Parking brake disassembling and assembling .......................................................................................... 54-32
135ZV-2 Service Standard Brake Group .............................................................................................................. 55-1
Brake Valve ....................................................................................................................................................... 55-2
Service Brake .................................................................................................................................................... 55-4
Parking Brake .................................................................................................................................................... 55-5
135ZV-2 Disassembly & Reassembly Operator Station Group ............................................................................ 74-1
Air Conditioner .................................................................................................................................................. 74-2
Air conditioner removing and installing ....................................................................................................... 74-2
Air conditioner disassembling and assembling ........................................................................................... 74-4
135ZV-2 Service Standard Operator Station Group ............................................................................................. 75-1
Air Conditioner .................................................................................................................................................. 75-2
Periodical Inspection/Servicing ................................................................................................................... 75-2
Tightening Torque ....................................................................................................................................... 75-2
--- Page 4 ---
00-10
135ZV-2 General Information
Liquid Gasket and Screw Lock Agent
Screw lock agent application pro- How to wind a seal tape
cedure
Through-hole
Apply screw lock agent one or two lines on the male
threads.
Seal tape
Screw lock agent Leave 1~2 screw
65ZV00004a
As the screw is tightened by turning clockwise, seal
tape must be wound up clockwise direction as shown
65ZV00002 above. If not, the tape will be loosened or removed
while tightening the screw, resulting in oil leakage.
To avoid a piece of seal tape left in the circuit, leave 1 or
2 screws from the end of the thread and start threading
it clockwise.
Slightly stretch the tape when cutting it out, and press to
fit the tape onto the screw thread.
--- Page 5 ---
14-4
135ZV-2 Disassembly & Reassembly Chassis Group
Fuel Tank
Fuel Tank
Fuel tank removing and installing
3
Fuel tank removing
1
WARNING
Unexpected movement of the machine could cause
an accident resulting in injury or death. Be sure to
observe the following items before starting fuel tank
2
removal: 4
- Position the machine on level ground, and apply
the parking brake.
- Lower the attachment onto the ground, and block
the tires with chocks, etc. to prevent them from
moving.
- Remove the engine key, and hang a "DO NOT
35C14003
START ENGINE!" tag on the operation board.
Before starting work: 1. Disconnect level sensor electrical line coupler (1).
- Drain fuel from the fuel tank.
(Fuel tank capacity: 1,050 L (280 gal)) 2. Temporarily sling fuel tank (2).
- Remove the right side deck.
: Fuel tank: 610 kg (1,345 lbs) (when empty)
3. Remove retainer bolts (3)(4).
: Bolt (3)(4): 765 N-m (78.0 kgf-m) (564 lb-ft)
--- Page 6 ---
14-14
135ZV-2 Disassembly & Reassembly Chassis Group
Cab
5. Remove bolt (5) and install the eye bolt (M24 x 3.0)
Floor board on the cab instead.
Attach sling and remove the cab slowly.
3 : Cab: 335 kg (740 lbs)
3
Cab installing
For reinstallation, follow the above procedure in reverse
order.
K135V214004
3. Disconnect hoses (3) for the window washer liquid
at the floor board. Cab installation cautions
Note - Check the movement of the wiper and adjust the
Cover the disconnected hoses with vinyl to protect them moving angle, if needed.
from dust and dirt. - Tune the clock and the radio.
- Apply the antiseize agent (Loctite® 767) between
sponges (6) and the floor board (on the floor board
5
side).
6 6
4 K135V214005
4. Remove bolt (4) with plain washer.
: Bolt (4): 721 N-m (73.5 kgf-m) (532 lb-ft)
--- Page 7 ---
14-24
135ZV-2 Disassembly & Reassembly Chassis Group
Center Pin
Center pin removing and installing
Center pin removing
3
WARNING
Unexpected movement of the machine could cause
an accident resulting in injury or death. Be sure to
observe the following items before starting center pin 4
removal:
- Place the machine on level and paved ground. Steering cylinder
- Lower the attachment onto the ground, and block K135V2U14031
the front tires with chocks, etc. to prevent them
from moving.
- Apply the stopper to the rear wheel oscillation sec- 2. Remove right and left steering cylinder retainer pins
tion to prevent the machine from oscillation. (3) and shims (4).
- Release the residual pressure from the hydraulic Inspect them for wear or damage, and replace if
line, and also release the internal pressure from necessary.
the hydraulic tank.
- Cover the steering cylinder rod to prevent it from Note
being scratched. Wrap the steering cylinder rods to prevent accidental
damage to the chrome rods.
5
2
Front differential
1
Transmission
K135V2U14032
K135V214013
3. Remove brake line hose (5) at the front chassis.
1. Remove bolt (1) and disconnect second propeller
shaft (2) from the transmission. : Brake line oil: Approx. 2 L (0.5 gal)
: Bolt (1): 221 N-m (22.5 kgf-m) (163 lb-ft) Note
: Screw lock agent (Loctite® 262) application Cover the disconnected hoses with vinyl to protect them
from dust and dirt.
Note
If the retainer bolt is too tight due to the screw lock
agent, heat the bolt head using slow flame of a gas
burner to about 235 ºC (450 ºF).
Keep the flame away from the seals of the coupling.
Do not reuse the bolts, and always replace with new
ones.
--- Page 8 ---
15-6
135ZV-2 Service Standard Chassis Group
Center Pin
Center Pin
Center pin shim adjustment Bearing cover installing
20
T1
Front
Bearing cover
45º
Shim adjustment
Front chassis
PT 1/8 hole direction
K135V2U14041
Rear chassis
Install bearing cover (20) so that the PT 1/8 hole is posi-
T2 L1 tioned at the specified angle as shown in the figure
K135V2U14027
above.
The clearance between the front chassis and bearing
cover is 0.75±0.5 mm (0.0295±0.0197 in) before shim
adjustment.
Add shims so that the clearance is 0.1±0.05 mm
(0.0039±0.0020 in).
:
T1: 721 N-m (73.5 kgf-m) (532 lb-ft)
T2: 1,128 N-m (115 kgf-m) (832 lb-ft)
L1: With lubrication oil (Engine oil or gear oil)
--- Page 9 ---
24-6
135ZV-2 Disassembly & Reassembly Power Group
Radiator
Radiator installing
21
16 For reinstallation, follow the above procedure in reverse
order.
23
22
K135V2U24008
8. Temporarily sling radiator (21) with duct (16).
Remove retainer bolt (22), and lift the radiator assy
(21). Take out the radiator backward while taking
care not to interfere the parts and units around,
such as fan.
: Bolt (22): 441 N-m (5.0 kgf-m) (36 lb-ft)
: Radiator assy: 970 kg (2,140 lbs)
Duct assy: 105 kg (230 lbs)
Note
Radiator assy (21) with duct (16) should be slightly tilted
back while being slung up to remove from the rear chas-
sis. In order to avoid any damage or for easier work, you
may remove the fan from the engine beforehand.
If you remove duct (16) before taking out radiator assy
(21), remove fan, and then, remove bolt (23) to separate
duct (16) from radiator assy (21).
Refer to "Fan" pages to remove the fan.
--- Page 10 ---
24-16
135ZV-2 Disassembly & Reassembly Power Group
Propeller Shaft
Propeller shaft installing Propeller shaft installation cautions
For reinstallation, follow the above procedure in reverse
order.
A B C
[ View from top ] K135V2U24018
- When reinstalling the second propeller shaft, make
sure the center of three flange yokes (points A,B and
C) are aligned straight. (Also refer to the figure on
page 24-11)
mm (in) First propeller shaft
Transmission
(3.25)
82.55
120.65
(4.75)
46.05
(1.81)
82.55
(3.25)
(1.81) 46.05 46.05 (1.81)
Second propeller shaft Third propeller shaft
135ZV24008
- During reinstallation, align the direction of the flange
yokes on the second and third propeller shaft sides
of the transmission. (Refer to 135ZV-2 Shop Manual,
Function and Structure, Section 22.)
[Difference in the yoke phase (direction) will cause
the propeller shaft damage and "knocking" during a
turn.]
- Clean all threads with a primer before applying the
screw lock agent (Loctite® 262). This assures the
quicker and stronger bonding.
- Align the grease nipples of the propeller shafts so
that they face to the same direction.
--- Page 11 ---
24-26
135ZV-2 Disassembly & Reassembly Power Group
Front Axle Assembly
A
TOP
6
Remover bolt
3 Remover bolt
4
7
97K24045 135ZV24019
3. Turn drain plug (4) to the bottom of wheel hub (3) to 5. Temporarily sling the spider using hoisting tool (A).
drain oil. Remove spider retainer bolts (6) (7 pcs) and install
remover bolts to remove spider assembly (7).
: Gear oil: Approx. 70 L (18.5 gal)
: Bolt (6): 86 N-m (8.8 kgf-m) (64 lb-ft)
Note : Spider assembly: 525 kg (1160 lbs)
To replace the oil, refer to the oil amount described
below.
Wheel hub section:
50 L (13 gal) for left side,
50 L (13 gal) for right side
Differential section (front): 220 L (58 gal)
9
Total oil amount for front axle: 320 L (85 gal)
8
TOP
Retainer bolt 135ZV24020
6. Remove snap ring (8), and remove sun gear (9).
5
135ZV24018
4. Remove cover (5).
: Cover bolt: 94 N-m (9.6 kgf-m) (69 lb-ft)
: Screw lock agent (Loctite® 262) application
--- Page 12 ---
24-36
135ZV-2 Disassembly & Reassembly Power Group
Special Tool
(D) Bearing insertion tool
mm (in) (Material: SS41)
(0.47)
12
326 (12.83)
286 (11.26)
510 (20.08)
530 (20.87)
135ZV24041
--- Page 13 ---
24-46
135ZV-2 Disassembly & Reassembly Power Group
Axle Support
Axle support assembly cautions
IMPORTANT
- Replace all the O-rings and seals with new ones.
- Clean and check all the parts. If a part is damaged,
replace it.
Bushing installation
[ Front axle support ] - Before installing, put bushing (5)(16) into dry ice.
Install cooled bushing (5)(16) to the front axle sup-
Grease Grease port and the rear axle support, respectively, as
5 shown in the illustration.
After installing, be sure to press bushing (5)(16) until
(Swing shaft)
stopped by the stopper of the axle support.
2
Note
The side with a groove on bushing (16) should come to
Stopper 7 the rear side.
1 4 The side with a groove on bushing (16) should come to
(Axle support side) the rear side.
Front
K135V2U24030
IMPORTANT
When installing the bushing onto the axle support,
[ Rear axle support ]
make sure no oil is left on the outer surface of the
bushing or the axle support surface.
16
Grease If oil is left on them, the bushing may turn alone caus-
ing the bushing and axle support wear.
15
14 (Swing shaft)
- Carefully install the axle support onto the swing
shaft.
Stopper (Side with groove) - Avoid damage to lip seal packings (2)(7)(15).
- When installing the axle support, fill enough grease
(Axle support side) between the packing and the axle support as shown
Front
K135V2U24031 in the illustration.
--- Page 14 ---
24-56
135ZV-2 Disassembly & Reassembly Power Group
Differential Assembly
Shim adjustment Backlash adjustment
Front Rear 36
Trunnion
28 28
A
Differential Differential
case case 16
Shim 18 Shim 18
135ZV24065 1 35C24068
1. Install O-ring (28) and the shims (the one(s) Adjust the backlash as follows:
removed during disassembly) to the cage.
1. Tighten adjustment nut (1) on the bevel gear side
2. Insert the cage into differential case, and tighten until the backlash is "0". Then back off the adjust-
retainer bolt (18) temporarily. ment nut 2 to 3 notches.
3. After adjusting tooth contact, tighten bolts (18) with 2. Tighten opposite side adjustment nut (36). After
the specified tightening torque. you feel that the nut is tight, turn it one more notch.
: Bolt (18): 314 N-m (32.0 kgf-m) (232 lb-ft) 3. Attach the dial gauge stand to the carrier. Attach
: Screw lock agent (Loctite® 262) application dial gauge (A) to a tooth of bevel gear (16). Read
the backlash value indicated on the dial gauge.
Note
Shims should be selected to adjust the tooth contact. 4. Adjust the backlash.
For adjusting tooth contact, refer to "Adjusting tooth
contact". Standard backlash:
0.46~0.66 mm (0.018~0.026 in)
- Tighten adjustment nut (1) on the bevel gear side or
loosen adjustment nut (36) on the opposite side to
reduce the backlash.
- Loosen adjustment nut (1) on the bevel gear side or
tighten adjustment nut (36) on the opposite side to
increase the backlash.
--- Page 15 ---
34-2
135ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group
Torque Converter and Transmission Assembly
Torque Converter and Transmission Assembly
Torque converter and transmission assembly tightening torque
T1 L1
T2 L1
T5 L3
T4 L3
T1 L1
T3 L1
1st propeller shaft
T1 L1
T1 L 3 T6 L 3
T1 L 3
T1
L3
Front differential
T3 L 1
T3 L 1
T1 L3
Transmission
Rear differential
2nd propeller shaft 3rd propeller shaft
K135V224001
:
T1: 765 N-m (78 kgf-m) (564 lb-ft) L1: Screw lock agent (Loctite® 262)
T2: 441 N-m (45 kgf-m) (325 lb-ft) L3: With lubrication oil (Engine oil or gear oil)
T3: 221 N-m (22.5 kgf-m) (163 lb-ft)
T4: 196 N-m (20 kgf-m) (145 lb-ft) Always replace drive shaft bolts with new ones - never
T5: 97 N-m (9.9 kgf-m) (72 lb-ft) reuse them.
T6: 94 N-m (9.6 kgf-m) (69 lb-ft)
Note
The bolt (T5) and the washer installing the fan to the
engine are the accessory parts of the engine.
--- Page 16 ---
34-12
135ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group
Torque Converter Assembly
6 7
5
9
11 8
10
135ZV34024
- Clinch the three edges of lock plate (5) after tighten-
ing bolts (6) to fasten the bolts (6) for turbine shaft
fixing plate (7).
- After reassembling the torque converter assembly,
check that the drive cover turns smoothly.
--- Page 17 ---
34-22
135ZV-2 Disassembly & Reassembly Torque Converter and Transmission Group
Transmission Assembly
Transmission assembly assembling
24 For reassembling, follow the above procedure in
reverse order.
4 Shim 5
3
135ZV34052
1
18. Pull out output shaft (24).
2
: Output shaft: 55 kg (115 lbs)
Transmission housing 135ZV34054
1. Install taper roller bearing (2) to gear (1), and install
25 it to the transmission housing.