PDF Shop Manual Kawasaki 65ZIV-2 Wheel Loader - 361 KB
This professional shop manual provides complete service and repair information for the Kawasaki 65ZIV-2 Wheel Loader.
It includes step-by-step instructions, detailed illustrations, and specifications for disassembly, assembly, and testing of all major components.
This guide is indispensable for mechanics performing complex repairs or comprehensive maintenance.
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--- Page 1 ---
AAA-S65C3V01-012
(93207-00081)
WHEEL LOADER SHOP MANUAL
65 Z
Powered by CUMMINS B5.9-C Engine.
SERIAL NUMBERS
65C3-5501 and up.
Troubleshooting
Measurement for Performance Check
--- Page 3 ---
Safety Precautions
WARNING WARNING
Unexpected operation of the machine may cause Do not enter the articulation area of the machine if
an accident resulting in injury or death. the engine is operating. An accident resulting in
Therefore, to provide repair service during engine injury or death may occur.
running, be sure to observe the following items: To enter the articulation area, be sure to stop the
・Park the machine on level ground. engine, and remove the starter key. In addition,
・Apply the parking brake. hang a "DO NOT START THE ENGINE!" tag on the
・Brace the tires with chocks to prevent steering wheel.
accidental movement.
・Determine the signals between the service
technicians. WARNING
・Prohibit any person from walking into
dangerous areas. Unexpected operation of the machine may cause
・ Near articulation area of the machine an accident resulting in injury or death.
・ Under the machine To crawl under the machine, be sure to stop the
・ Around the engine engine, and brace the tires with the chocks to
・ In front of or behind the machine prevent them from rotation. Give signals to the
person in the cab during the work.
WARNING
Standing under the boom or bucket during service CAUTION
work is dangerous. An accident resulting in injury Do not touch the fan or V-belt of the engine or a
or death may be caused. high-temperature section if the engine is running.
To prevent such an accident: An accident resulting in injury may occur.
・Lock the boom and bucket control levers in Be sure to stop the engine before you open the
the cab. side cover of the engine room.
・Remove the starter key.
・Hang a "DO NOT OPERATE!" tag on the
steering wheel.
・Securely brace the boom / attachment in the
raised position.
CAUTION
Be careful, injury may occur if high pressure oil
sprays out. To prevent such an accident, before
removing the plug from the pressure
measurement port, be sure to:
・Release the residual pressure from the pipe.
・Open the cap of the hydraulic oil tank.
01-5
--- Page 4 ---
PUS(QUAD) switch does not work 65Z Ⅳ -2 QUICK TROUBLESHOOTING TABLE 01
Torque Converter and Transmission Group
Controller input LED "S" indicator does not light when the PUS(QUAD) switch is
10. PUS(QUAD) switch does not work
Controller input LED "S" indicator lights when the PUS(QUAD) switch is turned
Check before starting work
(1) Check that the PUS(QUAD) switch is actuated at
the 2nd forward/reverse speed position.
ｔ
At other positions, shifting down is not possible.
ｉ
ｏｍｓ／ｃｈｅｃｋ ｐｏｎ
(2) Check the fuses.
ｔ
Ｓｙｍｐ
on but output does not change
turned on
Ｐｏｓｓ
ｉｂｌ
ｅ ｃａｕｓｅ Ｓ ｏ ｌ ｕ ｔｉｏ ｎ
Defective switch ○ Switch replacement
Disconnected switch or wiring ○ Repair wire
Defective controller ○ Controller replacement
01-15
--- Page 5 ---
Bucket positioner(kick-out) doesn't work 65Z Ⅳ -2 QUICK TROUBLESHOOTING TABLE 01
Hydraulic Group
Remove the connector of the proximity switch, and connect the red and white wires of the
5. Bucket positioner (kick-out) does not work
connector to each other on the chassis side. Check that the lever is held properly.
Check before starting work
(1) Check the fuses.
(2) Check that the distance between the proximity
ｔ
switch and detection bar is properly adjusted.
ｎ
Magnet coil resistance value is indicated as infinity or 0
ｉ
ｏｍｓ／ｃｈｅｃｋ ｐｏ
(5mm ± 2)
(3) Check all the connectors of the electrical power
LED lamp of the proximity switch does not light
line to be sure they are properly connected.
ｔ
Ｓｙｍｐ
Ｐｏｓｓ
ｉｂｌ
ｅ ｃａｕｓｅ Ｓ ｏ ｌ ｕ ｔｉｏ ｎ
Proximity switch
Defective proximity switch ○ ○ replacement
Broken magnet coil inside multiple control valve ○ Magnet replacement
Disconnected electrical power line ○ Repair
01-25
--- Page 6 ---
rising.
is too small.)
Defective sensor
hoses for damage.
Ｐｏｓｓ
Defective air governor
ｉｂｌ
Defective pressure gauge
Short circuit in gauge wiring
Check before starting work:
Moisture / ice build-up in system
Defective compressor inlet valve
ｅ ｃａｕｓｅ
Defective compressor outlet valve
Worn compressor piston ring or liner
Defective compressor unloader valve
valve, and piping line for air leakage.
Air pressure does not rise, or too slow
Safety valve is leaking or opening too early
(1) Check the air tank drain cock, automatic drain
(2) Check the compressor inlet and outlet piping, and
5. Air pressure does not rise, or too slow in
(Pressure indicated on the pressure gauge
Ｓｙｍｐ
ｔｏｍｓ／ｃｈｅｃｋ ｐｏ
ｉｎｔ
During operation, remove the pipe from the governor unloader port. Air will blow out of the port.
○
During operation, remove the pipe from the governor unloader port. Air will not blow out of the port.
○
01-35
65Z Ⅳ -2
○
During operation, air blows out of the compressor inlet valve
○
During operation, air blows out of the compressor outlet valve
○
Open the drain cock of the air tank. Oil will be drained from the cock.
Ground the sensor power line on the gauge side. The pointer of the gauge will be deflected to the limit.
Brake Group
○ ○
Resistance value of the sensor is not correct
Ground the T-terminal of the gauge. The pointer of the gauge will be deflected to the limit.
Voltage between the chassis and the A-terminal of the gauge is 24V or less
○ ○ ○
Ground the E-terminal of the gauge. The gauge will properly indicate the value.
Ground the T-terminal of the gauge. The pointer of the gauge will not be deflected to the limit.
○ ○
Resistance value between the gauge terminals is not appropriate
○
Air temperature below freezing when problem occurs
Air leaking out from safety valve below pressure setting
system
&repair
&repair
&repair
&repair
&repair
Ｓｏｌｕｔ
Repair cable
Disassembly
Disassembly
Disassembly
Disassembly
Disassembly
Replacement
Replacement
ｉｏｎ
Warm & dry out
○ Adjust or replace
QUICK TROUBLESHOOTING TABLE 01
--- Page 7 ---
Standard Measurement Values 65ZIV-2 MEASUREMENT FOR PERFORMANCE CHECK 03
Item Standard measure-
ment values for Remarks
System Measurement item performance check
Slowly increase the Right brake pedal fully
Shift lever position 2nd speed reverse engine speed, and depressed and held
Performance of
check that the down during test.
service brake machine does not
Engine speed Maximum (HI)
move at the
Before brake check, be
Shift lever position 3rd speed reverse sure to disconnect the
Performance of