T/C and T/M Group Materials Models 50 90ZV-2: This Manual Covers For

KCM300-08/2006-00
Kawasaki Service Training Manual

This Manual covers T/C* and T/M** Group Materials for Models 50~90ZV-2
This
Current for 70/80/85/90ZV-2 production; August 10, 2006
• Safety and General Information
• Torque Coverter (*T/C)
• Transmission (**T/M)
• Control Valve
• Testing
ARL
Important
Read and understand the Operation and Maintenance Manual. It will familiarize you
better with the product you are supporting.
This Training Manual supplements materials found in the Shop Manual.
This is section 300 of the Product Support Service Training Manual. Pages in this
section are numbered from 301~400 [with lettered suffixes].
Consult the Shop Manual for specific details on each machine.

Transmission Group Materials for 70~90ZV-2
WARNING
CALIFORNIA PROPOSITION 65
BATTERY WARNING
Battery posts, terminals and related accessories contain
lead and lead compounds, chemicals known to the
State of California to cause cancer and reproductive harm.
WASH HANDS AFTER HANDLING !
CALIFORNIA
Proposition 65 warning
Diesel engine exhaust and some of its constituents are known to the
State of California to cause cancer, birth defects, and other reproductive harm.
301
302
IMPORTANT
To ensure good machine performance, reduce failures or problems & prolong service life of each component,
it is necessary to operate and maintain the machine as is directed in the Operator and Maintenance Manual.
Some references may be made to 50/60/65ZV-2 or 65TMV-2, although these units have not yet gone into prod-
uction. Materials referring to these units mention only what is known at time of publishing this training manual.
References may be updated at any time as further information becomes available.
This is a Kawasaki Service Training Manual that is intended for use with Kawasaki Service Training.
Materials in this manual are based on the Shop Manual. Periodically information may change and
information in this Training Manual may be superceded by the newest Shop Manual. Always verify
that you have the most current information available by reviewing the latest Shop Manual.
While taking notes for future reference, make it a point to write down concepts to teach to others when
you return to the repair shop or to the region where you work.
If you share information with others, the following will happen:
1. You will retain better what you have to be able to explain. Think about it; if you cannot explain it,
you do not thoroughly understand it.
2. If you teach something to others, you must also apply what you teach. You become a more depend-
able and safer worker. (Get ready to set the example for the ones you teach also.)
3. You help others; you'll help the "other guy" you share this with to learn something.
Get involved in the learning process and you will never forget this information!
You will get out what you put into this course.
303
Safety Symbols
An accident may occur if you disregard safety rules.
In this manual, several expressions are used according to levels of danger for inspection and repair work as shown
below. Read the work procedures and cautions described in this manual, and take preventive measures against
possible problems before starting service work.
DANGER
This danger symbol identifies special warnings or
procedures which, if not strictly observed, will result
in death or serious injury.
WARNING
This warning symbol identifies special warnings or
procedures which, if not strictly observed, could result
in death or serious injury.
CAUTION
This caution symbol identifies special instructions or
procedures which, if not strictly observed, may result
in minor or moderate injury.
IMPORTANT
This important symbol identifies special instructions
or procedures which, if not correctly followed, may
result in serious machine damage.
We cannot predict all possible accidents or incidents that may occur during service work. Therefore, an accident that
is not specifically mentioned in this manual may occur. To protect yourself from all accidents, be careful when doing
service work.
304
Contents
Prologue ............................................................................ 303
Safety ................................................................................. 304
Things to consider when repairing ..................................... 308
Dealer and customer call form ........................................... 309
T/M and T/C Function and Structure .................................. 312
Colored illustration ............................................................... 313
Torque converter ................................................................. 314
Pump ................................................................................... 315
Clutch combinations ............................................................ 316
QUAD .................................................................................. 316
Gear train ............................................................................ 317
Clutch specifications ............................................................ 318
Clutch packs ........................................................................ 319
Power flow ........................................................................... 323
T/M hyd diagram .................................................................. 326
Oil flow .................................................................................. 328
Oil circulation ........................................................................ 330
Control valve ........................................................................ 333
Modulation mechanism ......................................................... 335
Checks and adjustments ....................................................... 345
305
General Information
306
Warning
Safety precautions
The most important point in providing repair service is - Contact tire manufacturer's local dealer for tire ser-
safety. To ensure safety, observe the general cautions vicing and changing.
described below.
- Always store the tools in good condition, and use
- This manual is intended for properly trained and them properly.
equipped service technicians.
- Keep the work area clean. Clean up spills immedi-
- Any work on the machine must be performed by the ately.
trained personnel only.
- Avoid the use of flammable solvents and cleaners.
- Carefully read this manual to thoroughly understand
the operation method before you operate or repair - When working outdoors keep work areas, ladders,
the machine. steps, decks and work platforms clear of snow, ice,
and mud.
- Be sure to wear appropriate clothes and protectors,
such as safety boots, hard hat and goggles. - Use safe work platforms to reach higher areas of the
machine.
- Place the machine on level and solid ground, and
place chocks against the wheels to prevent move-
ment.
- Remove the cables from batteries before starting

the service work, and attach a "DO NOT OPERATE!"
tag to the steering wheel.
- Be sure to release the internal pressure before you

remove a pipe, such as the hydraulic oil, air, or
engine coolant pipe.
- Be sure to apply the articulation stopper before start-

ing work.
- While supporting the bottom of the chassis using a

jack, be sure to support the chassis using the blocks.
- When the boom or bucket is raised or when a unit is

lifted by a crane, be sure to place a stand or ade-
quate cribbing under the unit to prevent unexpected
dropping.
- Do not start to work in an enclosed area if adequate

ventilation is not provided.
- To remove a heavy unit (20 kgf (40 lbs) or more), be

sure to use a crane or other lifting tool.
- Just after stopping operation, be careful not to

directly touch a hot component. You may get burned.
307
THINGS TO CONSIDER WHEN MAKING WARRANTY REPAIRS
Warranty Coverage
• Standard Warranty is 1 year (12 months) or 1,500 hours -- whichever occurs first.
• For rental fleet machines, warranty coverage is 2 years (24 months) or 1,500 hours,
whichever occurs first. (These machines do not get the same amount of use at times as a
non-rental machine.)
• There are a variety of extended warranties available. These may be Extended Base
Machine type (same as Base Warranty but longer), or Extended Powertrain type.
• Replacement rental machine, down-time, lost production, and transportation of machine
to a service facility for repairs are not covered by Kawasaki Warranty.
Important Points to Remember
1. Do your homework. Do not arrive at the jobsite “cold turkey”. Get the facts about the
symptoms of the troubles the customer is experiencing prior to going to the jobsite.
There is a Kawasaki Dealer Call Form in this manual for this purpose that is also
available on the KCM website. This can be saved, emailed or faxed to customer, and
returned to you, or you can get the facts to fill in while on the phone with the customer.
Help the customer understand that this is to help everyone save money in the long run.
• USE THE DEALER CALL FORM TO ESTABLISH WHAT IS WRONG PRIOR TO LEAVING TO A JOBSITE.
TAKE ALL NECESSARY LITERATURE WITH YOU PRIOR TO GOING TO A JOBSITE.
• Kawasaki Warranty will only pay for one round trip to and from the jobsite.
2. You are a student that takes pride in your talent. This is reflected in the quality of your
work. Your goal is to establish yourself as a technically sound and well-trained
journeyman in your field.
• Find, Confirm, and Fix any problem(s). (You may have more than one.)
• Provide details on what was wrong in your work order.
i. What was the symptom?
ii. Why did the problem happen?
1. What caused it to fail?
2. Was the machine modified in any way that may have contributed
to the failure?
3. What is the application? Is it caustic or corrosive? Are there
constant machine impacts as with a hammer? Is there intense
heat in the application?
iii. What was done to keep from repeating the same problem again?
iv. Was the customer satisfied? If not, why not?
• Do not relegate yourself to the position of becoming a parts changer! That
position we hope is already being occupied by the competition. And once a part
is installed on a machine, it cannot be returned to Kawasaki for a credit.
3. Do not indiscriminately discard parts.

Keep all parts until the claim is resolved, or we have asked that you return the part to us.
Securely identify the part with a tag that indicates the work order number, machine serial
number, hours on machine, and file any related photos and supportive notes that will
serve to support any issues that may arise in processing the claim. If there are no notes
or supportive parts, the claim may automatically be rejected!
In summary, you are the person that can gather information better than anyone else, because
you are the on-site specialist. A warranty clerk or manager who submits the claim will not be able
to answer the questions that you can, so please provide them with the needed information so
they can get the claim processed. Use the Parts Catalogs and Shop Manual to help with this task.
308
Kawasaki Loader Dealer / Customer call form Date: ________________________

Time of Call: __________________
Customer's name: ____________________________________________________
Customer's address: ____________________________________________________

____________________________________________________
Machine Serial No. Hrs.
____________________________________________________
Description of problem:
Important! A clear description of problem needs to be given, so technician will be equipped to go
to jobsite. A lack of information will cause technician to leave ill equipped, and cause customer to
feel not properly attended in the long run.
1. What system(s) is giving trouble? Hydraulic, Transmission, Electrical, etc.?
____________________________________________________
____________________________________________________
2. What did the operator hear, see, feel or smell that seemed different than
normal? Provide exact symptoms IN DETAIL, not what operator thinks is wrong.
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
3. What is the machine application? Where is it working, and what is it doing?
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
4. Name of person that gave information _______________________________
309
Clear directions of how to arrive at the jobsite:

Attach map if needed.
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
Other notes:
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
Required support publications or Service / Parts News documents:
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
310
Symbols
For safe and effective service work, the following sym-
bols are used for notes and useful information in this
manual.
Symbol Item Description
Shows the condition or procedure that will be useful

Reference
or efficient in doing service work.
Shows the weight of a part or unit. The weight

should be considered in selecting wire rope or cable
Weight
for slinging work or determining the working pos-
ture.
Tightening Shows the tightening torque of a section that should

torque be carefully tightened during assembly work.
Shows the type of coating or adhesive and the coat-

Coating
ing section.
Oil or
Shows the oil or water supply port and the refill
water
amount.
supply
Shows the oil or water drain port and the drain

Drainage
amount.
IMPORTANT
If the specified conditions are not satisfied or the specified procedure is not
observed, there is a strong possibility that the product will be damaged or the per-
formance of the product will be reduced.
The message shows the preventive measures.
Abbreviation
To save space, abbreviations are used in sentences. To understand the contents of this manual, refer to the follow-
ing abbreviation list. Additional abbreviations are listed in Z fold sections.
E/G ........... Engine RH ............Right hand side 3rd ............3rd speed

T/C ........... Torque converter LH ............Left hand side 4th ............4th speed
T/M ........... Transmission H ............High M/C ............Machine
SOL ........... Solenoid valve L ............Low min-1 ............RPM
SW or S/W.. Switch GND (or E)..Ground ELS ............Efficient loading system
F ........... Front or Forward OPT ............Option MODM ........Machine operation diag-
A/M ........... Auto/Manual Assy ............Assembly nostic module
B ........... Battery 1st ............1st speed C/W ........... Counterweight
R ........... Rear or Reverse 2nd ............2nd311
speed CW ............ Clockwise
CAC ........... Charge Air Cooler CCW ......... Counter Clockwise
Function & Structure

Torque Converter and Transmission Group
Although there are minor differences, this material
based on 70ZV-2 and 70TMV-2
applies to models 80~90ZV-2.
Illustrations showing oil routing, and port locations

is included for 70~90ZV-2.
312
Color guide
Transmission Case ............................

Pistons ...............................................
Trapped Piston Oil .............................
70ZV-2 Lubrication Oil ....................................

Torque Converter Entry Oil ................
Torque Converter Exit Oil (to cooler)..
80~90ZV-2 are similar Atmospheric Air Inside Case .............
Fasteners ..........................................
Bearings ............................................
Rubber Hoses or Seals .....................
Note: Electrical section has more info on ground speed sensor
313
Torque Converter
Torque multiplication
Torque ratio (t)

Output Input
3
P T 1
95ZV32002
0.5 1.0
Speed ratio (e)
95ZV32003
Torque converter structure
If the engine speed/pump impeller speed stays the
The torque converter is between the engine and trans- same but the turbine impeller speed is reduced due to
mission, and consists of three impellers as shown in the the transmission load-output torque is increased. This is
figure. The three impellers are pump (P), turbine (T), "torque multiplication". Heat is also generated.
and stator (S) impellers.
Turbine impeller speed (min –1 ) (rpm)
Speed ratio(e)= ------------------------------------------------------------------------------------------------
-
Pump impeller speed (min – 1 ) (rpm)
Power flow path

The pump is connected to the engine flywheel, and
rotates together with the engine.
The turbine is connected to the torque converter output

shaft to transmit the power to the transmission.
The stator is fixed to the torque converter case. The

area of the impellers is filled with oil. When the engine is
started, the pump impeller rotates, therefore the oil will
circulate to rotate the turbine impeller (circulation order:
pump→turbine→stator→pump). Oil is redirected by the
fixed stator impeller back to the pump impeller. When
the turbine impeller rotates, the power will be transmit-
ted to the output shaft.
314
Torque Converter Gear Pump

Gear pump specifications
Theoretical 64.5 cc/rev (3.9 in3/rev)

1 Maximum
2 MPa (20 kgf/cm2) (284 psi)
operation pressure
2
Maximum
2,400 min-1 (rpm)
operation speed
7
Approx. 120 L/min (31.7 gpm)
3
Conditions:
Pump speed 2,200 min-1
Oil temp. 80 to 100 °C (176 ~ 212 °F)
Actual discharge
Oil viscosity 40CST (SAE10W)
4 Discharge pressure 1.4 to 1.6 MPa
(14 to 16 kgf/cm2)
(199 ~ 228 psi)
8 5
1. Driven gear
2. Needle bearing
3. Driven gear shaft
4. Oil seal
5. Drive gear
6. Housing
7. Pump cover
8. Dowel pin
9. Gasket
315
Transmission
Clutch combination QUAD (Quick Up And Down ) shift button
Clutch F R 1 2 3 4
This feature permits quick up and down shifting when in
Speed range 2nd and Automatic.
F1
F2 It operates from 2nd to 1st, and 1st to 2nd.
F3
F4
N * * * (Either 1st, 2nd or 3rd)
R1
R2
R3
R4
The transmission is equipped with six clutches:
Forward range, reverse, and 1st, 2nd, 3rd and 4th

speeds. Combining the clutches as shown in the table
here provides four forward speeds, and four reverse
speeds for a total of eight speeds. Two clutches must be
engaged at the same time to move the machine.
Shift lever position

Position of shift
Function
lever
Held in 1st speed range
1
for both forward and reverse.
Held in 2nd speed range
2 for both forward and reverse. Downshift button
operation.
Held in 3rd speed range
3
for both forward and reverse.
Automatic speed change according to shift map
A (computer) for 2nd through 4th speeds forward
and reverse. Downshift button operation.
Automatic or manual speed change is available

depending on the position of the shift lever, as shown in
the table.
Automatic speed change refers to one where the best

speed range is determined by a computer according to
the machine speed detected.
316
Gear train and number of teeth

9
8
14
16
12
12 9
18
58
70
29 20 8 20
23 68
32
30
27 4
26
31 24
34 12
20 16 18 14
82 66 39
52
38
23
4 3 F
24
Gear arrangement 3
4 F 31
25
26 29
1 2 R
27
1 2 R
31
23 39
34 53
67 32 31
52
Note
Numbers below correspond to above
Number Number
No. Gear name No. Gear name
of teeth of teeth
4 Turbine shaft gear 30 23 4th speed clutch gear 82
8 PTO drive gear A 68 24 1st speed clutch gear 67
9 PTO drive gear B 58 26 Counter gear C 25
12 Idle gear 39 27 Counter shaft C gear 23
14 Forward clutch gear 31 29 Reverse clutch gear 31
16 3rd speed clutch gear 66 31 Counter gear D 53
18 Counter gear A 52 32 2nd speed clutch gear 39
20 Counter gear B 38 34 Output shaft gear 52
317
Clutch specifications
Friction plate Steel plate

Piston stroke Outer Inner Outer Inner Number of
Name of clutch Number Thickness (mm) Number Thickness (mm) return spring
(mm) dia. dia. dia. dia.
of plate New/Wear limit of plate New/Wear limit
(mm) (mm) (mm) (mm)
Forward clutch 3.8 ± 0.3 8 7 20
Reverse clutch 4.3 ± 0.3 8 7 20
1st speed clutch 3.8 +0.5
-1.0 10 167ø 104.8 ø 9 182 ø 116 ø 16
2.0 ± 0.1 / 1.8 1.8 ± 0.1 / 1.6
2nd speed clutch 3.0 ± 1.0 5 (6.57 in) (4.12 in) 4 (7.16 in) (4.57 in) 16
3rd speed clutch 3.0 ± 1.0 5 4 16
4th speed clutch 2.95 ± 1.0 5 4 16
Note: All friction plates, steel plates and return springs are the same for each clutch.
Friction plate: mm (in)
1. Plate
2. Facing
Detailed drawing of groove
318
Clutch Pack
Forward and 3rd speed clutches
3 11 6 4 8
5 7 12 9
2
3 1
F
13
14 14
10
1. Counter shaft
2. Forward clutch gear
3. 3rd speed clutch gear (Helical type)
4. Forward clutch
5. 3rd speed clutch
6. Forward clutch piston
7. 3rd speed clutch piston
8. Steel plate
9. Friction plate
10. Return spring
11. Clutch drum (with counter gear) (Helical type)
12. Residual pressure prevention orifice
13. Seal rings
14. Needle bearings
319
Reverse and 2nd speed clutches
11 6 4 8
5 7 12 9
3 2
15
2
1
R
13
14
10
1. Counter shaft
2. Reverse clutch gear (Helical type)
3. 2nd speed clutch gear
4. Reverse clutch
5. 2nd clutch
6. Reverse clutch piston
7. 2nd speed clutch piston
8. Steel plate
9. Friction plate
10. Return spring
11. Clutch drum (also used as counter gear)
(Helical type)
12. Residual pressure preventive orifice
13. Seal rings
14. Needle bearings
15. Thrust bearing
320
1st speed clutch
4 10 5 7 6
1 2 3
1. Counter shaft
2. Counter gear A (Helical type)
3. Counter gear B (Helical type)
4. Clutch drum
5. Clutch piston
6. Steel plate
7. Friction plate
8. 1st speed clutch gear (Helical type)
9. Return spring
321
4th speed clutch
6 5 4 9
3
4
1
1. Counter shaft
2. Counter gear (Helical type)
3. Clutch drum
4. Clutch piston
5. Steel plate
6. Friction plate
7. 4th speed clutch gear (Helical type)
8. Return spring
322
Power Flow Path in the Transmission
Forward Forward 2nd speed
Forward 1st speed
The idle gear shown here is also

connected to the reverse clutch gear.
18 15
12
20 19 15
26
24
25
26 14
34
35
27
34 32
33 31
35
80ZV32002 1. The power from the torque converter is transmitted

to the forward clutch (15). The forward clutch trans-
1. The power from the torque converter is transmitted mits the power to the counter gear A (18) and then
to the idle gear (12) and to the forward clutch gear to the counter gear D (31).
(14) where the forward clutch (15) is connected.
The forward clutch then transmits the power to the 2. When the 2nd speed clutch (33) is engaged, the
counter shaft A (19). power will be transmitted to the 2nd speed clutch
gear (32).
2. The counter shaft A (19) is spline-connected to the
counter gear B (20), therefore the power is then 3. Since the 2nd speed clutch gear (32) is spline-con-
transmitted to the 1st speed clutch gear (24). nected to the counter shaft C (27), the power is
transmitted to the counter gear C (26) and then to
3. The 1st speed clutch gear is connected to the 1st the output shaft gear (34). After that, the power is
speed clutch (25) that transmits the power to the finally transmitted to the output shaft (35).
counter gear C (26) and then to the output shaft
gear (34). After that, the power is finally transmitted
to the output shaft (35).
323
Forward 3rd speed Forward 4th speed
23 21 20 19 18 15
16 17 15
32
27
26 26
27
34 34
35 35
80ZV32004
1. The power from the torque converter is transmitted 1. The power from the torque converter is transmitted
to the forward clutch (15) and then to the 3rd speed to the forward clutch (15). The forward clutch (15)
clutch (17) that is connected to the 3rd speed clutch transmits the power to the counter gear A (18) and
gear (16). The power is then transmitted to the 2nd then to the counter shaft A (19).
speed clutch gear (32).
2. The counter shaft A (19) is spline-connected to the
2. Since the 2nd speed clutch gear (32) is spline-con- counter gear B (20).
nected to the counter shaft C (27), the power is
transmitted to the counter gear C (26). 3. When the 4th speed clutch (21) is engaged, the
power will be transmitted to the 4th speed clutch
3. The counter gear C (26) transmits the power to the gear (23).
output shaft gear (34) and then to the output shaft
(35). 4. The 4th speed clutch gear (23) transmits the power
to the counter shaft gear (27), counter gear C (26),
and then to the output shaft gear (34). After that,
the power is finally transmitted to the output shaft
(35).
324
Reverse
Reverse 1st speed
19
18
31
30
29
12
The torque converter and idle gear shown in this figure are actually
identical to those shown in the forward speed diagrams.
The idle gear is engaged with both the forward and reverse clutches.
1. The power from the torque converter is transmitted

to the idle gear (12) and then to the reverse clutch
gear (29) where the reverse clutch (30) is con-
nected. The reverse clutch then transmits the
power to the counter gear D (31), the counter gear
A (18), and then to the counter shaft A (19).
2. After that, the power is transmitted to the output

shaft via the same route as forward 1st speed.
Reverse 2nd, 3rd, and 4th speeds
Refer to the transmission routes of the above reverse

1st speed and the forward 2nd, 3rd, and 4th speeds.
325
Hydraulic System Diagram

Note Parking switch
Shift lever
Numbers below correspond to page 327.
Declutch switch
Speed
sensor Downshift button
Controller
9
6
T/M 4th
Oil pan 18
F 3rd
5 17
2nd
13
R
1st
25
3 16 15
14
19
23 24
10
F 3 4
21
R 2 1
20 22
1
326
Hydraulic Circuit Diagram

Neutral position
Oil temp.
0.5 MPa
sensor
11 (4.7 kgf/cm2)
10 (67 psi)
25 M16
P T
x1.5
S
7 6 12
19 8
F 5
13
26
0.3 MPa
20 PF1/4 (3.5 kgf/cm2)
R 1.3 ± 0.2 to (50 psi)
14 1.5 ± 0.2 MPa 4
(13 ± 2 to
15 ± 2 kgf/cm2)
21 (185 ± 28 to
1 213 ± 28 psi)
15 3
22
2 2
16 1
23
3
17
24
4
18
1. Transmission oil pan 14. Reverse clutch solenoid valve

2. Strainer 15. 1st speed clutch solenoid valve
3. Torque converter gear pump 16. 2nd speed clutch solenoid valve
4. Line filter with bypass valve 17. 3rd speed clutch solenoid valve
5. Control valve 18. 4th speed clutch solenoid valve
6. Clutch pressure regulator valve 19. Forward clutch
7. Trimmer plug 20. Reverse clutch
8. Orifice (1.3 ø) 21. 1st speed clutch
9. Trimmer solenoid valve 22. 2nd speed clutch
10. Torque converter 23. 3rd speed clutch
11. T/C inlet relief valve 24. 4th speed clutch
12. Orifice (1.2 ø) 25. Torque converter oil cooler
13. Forward clutch solenoid valve 26. Residual pressure preventive orifice
327
Oil Flow
Oil flow in the torque converter Oil flow to the clutch

line
To forward and reverse clutches
From torque converter gear pump to torque
converter When the oil flows into the control valve, the oil pres-
sure is adjusted to the specified pressure 1.3 ± 0.2 to
1.5 ± 0.2 MPa (13 ± 2 to 15 ± 2 kgf/cm2) (185 ± 28 to
The oil fed from the pump (3) flows through the line filter
213 ± 28 psi) by the clutch pressure regulator valve (6).
(4) into the control valve (5). In the clutch circuit, the oil
After that, the oil flows to the forward and reverse clutch
flow rate is low, therefore, the clutch pressure regulator
solenoid valves (13) (14).
valve (6) opens the torque converter port so that the oil
flows into the torque converter circuit.
Assume that the clutch is changed from "forward" to
"reverse". When the clutch is changed to "reverse", the
At the inlet of the torque converter, there is a inlet relief
reverse clutch solenoid valve (14) is turned on, and the
valve (11) in the case. If the oil pressure exceeds 0.5
oil flows into the reverse clutch piston chamber. At the
MPa (4.7 kgf/cm2) (67 psi), the relief valve will be
same time, the forward clutch solenoid valve is turned
opened to drain oil into the transmission case.
off, and the oil in the forward clutch piston chamber is
drained. The oil then flows through the clutch solenoid
valve into the transmission case. Oil is also drained
from the forward clutch piston chamber through the
From torque converter to cooling circuit residual pressure prevention orifice in the clutch hub.
The oil returned from the torque converter flows into the
torque converter cooler (25) inside the radiator.
To speed clutch
The neutral position is available for forward/reverse.

From cooler to lubrication circuit
There is no neutral position for speed clutches.
The oil cooled by the cooler flows through the lubrica-
tion oil passages in the transmission housing to lubri- Therefore, after engine starting, the oil fed from the
cate all the bearings and to cool the clutch plates. After pump is regulated to the specified pressure by the
that, the oil is drained into the oil pan. clutch pressure regulator valve, and then directed to
one of the speed clutch piston chambers.
Note
The engine will not start if the shift lever is set to the for-
ward or reverse position. In other words, the shift lever
should be set to the neutral position to start the engine,
therefore, the machine will not move the moment the
engine is started.
When the speed is changed, the oil flows in the same
way as the forward/reverse clutch oil flow.
328
T/C and T/M Oil Circulation (70ZV-2/TMV-2)
Transmission oil filter

Rear chassis
Transmission
control valve
Torque converter
oil cooler
Transmission
Note
If torque converter oil is routed incorrectly, this will cause overheating.
The oil must flow counter to direction of the coolant in the oil cooler tank.
329
T/C and T/M Oil Circulation (80ZV-2)
Transmission
oil filter
Rear chassis
Torque converter Radiator
oil cooler
Transmission
control valve
Transmission
Note
The oil must flow counter to direction of the coolant in the bottom radiator tank.
330
Radiator
Torque converter
Rear chassis oil cooler
Transmission
oil filter
Transmission
control valve
Transmission
Note
331
Rear chassis
Radiator
Torque converter
oil cooler
Transmission
oil filter
Transmission
control valve
Transmission
Note
332
Control Valve
B
9
SKM6
G24D
A A
-
K WE6K- 22
18
17
13
15
B Section B-B
16 14
Control valve
1. — 6 Stopper Section A-A 7 8 10. —

2. — 11. —
3. — 12. —
4. — 13. Forward clutch solenoid valve
5. — 14. Reverse clutch solenoid valve
6. Clutch pressure regulator valve 15. 1st speed clutch solenoid valve
7. Trimmer plug 16. 2nd speed clutch solenoid valve
8. Orifice (1.3 ø) 17. 3rd speed clutch solenoid valve
9. Trimmer solenoid valve 333 18. 4th speed clutch solenoid valve
System diagram
From torque converter pump To torque converter
6 9 7
T.R
Drain 18
4th
13 17
F 3rd
14
16 15
R
2nd 1st
To forward To 2nd speed To reverse To 1st speed To 3rd speed To 4th speed
clutch clutch clutch clutch clutch clutch
70V2E32004
1. — 10. —
2. — 11. —
3. — 12. —
4. — 13. Forward clutch solenoid valve
5. — 14. Reverse clutch solenoid valve
6. Clutch pressure regulator valve 15. 1st speed clutch solenoid valve
7. Trimmer plug 16. 2nd speed clutch solenoid valve
8. Orifice (1.3 ø) 17. 3rd speed clutch solenoid valve
9. Trimmer solenoid valve 18. 4th speed clutch solenoid valve
334
Modulation Mechanism
When forward/reverse or speed changing, the modula-
tion mechanism works to reduce the time required for
clutch engagement (time lag), to prevent the shock at
clutch engagement, to improve the work efficiency and
durability of the power system, and to ensure operator's
comfort.
For such effects, the modulation mechanism controls

the clutch oil pressure rising time as follows:
An electrical signal from the controller controls the trim-

mer operation. For information on the controller refer to
"Electrical Group" section.
335
Clutch control oil pressure curve
ON
For trimmer
OFF
"D" LED
Electrical signals
Solenoid valve
ON
For forward
clutch OFF
"F" LED
ON
For reverse
clutch OFF
"R" LED
Main pressure
Forward clutch pressure
Reverse clutch 1.3± 0.2~1.5±0.2 MPa

pressure (13±2~15±2 kgf/cm2)
(185±28~213±28 psi)
Clutch oil 0.3~0.4 MPa (3.5~4.0 kgf/cm2)

pressure (50~57 psi)
Time
Pressure increase
Specified Initial Low-

holding oil pressure
pressure feeding holding
Initial oil feeding* Low-pressure holding Pressure increase

0~0.05 sec. 0.2 sec. Approx. 1 sec.
*Note: The initial oil feeding time depends on the capacity of the clutch piston chamber.
336
Traveling at forward 1st speed

Pressure holding
From torque To torque

converter pump converter
6 7
To each clutch solenoid valve
While the machine is traveling, the forward and 1st

ON speed clutch solenoid valves are energized on, the
For OFF clutch oil is flowing into each clutch piston chamber, and
Electrical signals
trimmer
Solenoid valve
For
ON the clutch is kept engaged.
forward OFF
clutch
For
ON The power of the trimmer solenoid valve (9), however, is
reverse
clutch
OFF off, and the clutch regulator valve (6) and trimmer plug
(7) apply pressure to the modulator spring to keep the
clutch pressure at the specified value 1.3 ± 0.2 ~ 1.5 ±
0.2 MPa (13 ± 2 ~ 15 ± 2 kgf/cm2) (185 ± 28 ~ 213 ± 28
Main pressure
psi).
Reverse clutch
pressure
Clutch oil
pressure
Time
Specified
pressure holding
337
Changing from forward 1st speed

to reverse 1st speed
Releasing forward clutch and feeding initial
oil to reverse clutch
ON
For OFF
Electrical signals
trimmer
Solenoid valve
ON
For
forward OFF
clutch
ON
For
reverse OFF
clutch
Main pressure
Reverse clutch
pressure
Clutch oil
pressure
Time
Initial oil feeding
Changing the shift lever from "forward" to "reverse",

turns off the power of the forward clutch solenoid valve.
The oil in the forward clutch piston chamber is immedi-
ately drained to release the clutch.
On the other hand, power to the reverse clutch solenoid

valve is turned on, and the oil flows into the reverse
clutch piston chamber.
After changing the shift lever, power to the trimmer sole-

noid valve is kept off for a short time, therefore the high-
pressure oil flows into the reverse clutch piston cham-
ber to rapidly operate the piston. As a result, initial oil
supply is quick, and time lag can be prevented.
338
Trimmer engagement
Low-pressure holding

6 Stopper 7
0.05 seconds after changing the shift lever, the power of

ON the trimmer solenoid valve (9) is turned on.
For OFF
trimmer
Electrical signals
Solenoid valve
ON The oil in the trimmer plug chamber is drained, and the

For
forward OFF trimmer plug (7) is returned by spring tension fully to the
clutch
For
ON right. The modulator spring is released to reduce the
reverse
clutch
OFF pressure applied to the regulator valve (6). The regula-
tor valve may move fully to the right until it contacts the
stopper screwed into the control valve housing. In this
position more oil from the torque converter charge
Main pressure pump is drained. The main pressure and reverse clutch
Forward clutch pressure pressure, therefore, falls immediately.
Reverse clutch As a result, the shock at clutch engagement will be soft-

pressure ened.
Clutch oil
pressure
Time
Low-pressure holding
339
Clutch engagement starting

Pressure increase

6 7
To soften the shock, the clutch should slip during

ON engagement.
For OFF
trimmer
Electrical signals
Solenoid valve
For
ON When the power of the trimmer solenoid valve is turned
forward
clutch
OFF off again after about 0.2 seconds, the drain port of the
For
ON trimmer plug chamber is closed, and the oil is fed into
reverse
clutch
OFF the trimmer plug chamber. Pressure is applied to the
trimmer plug and the spring to raise the clutch oil pres-
sure. The oil flow rate to the trimmer plug chamber is
limited by the orifice (8), therefore the trimmer plug (7)
Main pressure slowly shifts to the left. The clutch pressure, therefore,
Forward clutch pressure slowly rises. As a result, the clutch engagement is
smooth and causes no shock.
Reverse clutch
pressure
Clutch oil
pressure
Time
Pressure increase
340
Clutch Solenoid Valve
For forward/reverse and speed

clutches
After power-off (clutch disengaged status)
5 4
Clutch pressure 1
regulator 2
6
Transmission
C
oil pan
Clutch piston
chamber
3
1. Coil
2. Plunger
3. Push rod
4. Spring
5. Spool
6. Manual control pushbutton
When the power of the coil is turned off, the spool (5),
push rod (3), and plunger (2) are returned fully to the
right, and the line from port A to port B is closed. The
line between port B and C is opened, and the clutch is
disengaged.
Under such a condition, pressing the manual control

pushbutton (6) (for emergency) opens the line between
port A and B, and engages the clutch.
Releasing the manual control pushbutton returns the
spool fully to the right, and disengages the clutch.
341
After power-on (clutch engaged status)
Clutch pressure
regulator
Transmission
oil pan C
Clutch piston
chamber
When the power is supplied to the coil, the magnetic

power attracts the plunger to the left, and the line
between port A and B is opened. Pressure oil flows into
the clutch piston chamber. The clutch is engaged.
342
For trimmer
After power-off (high clutch pressure sta-
tus)
Trimmer plug
chamber 6
To transmission oil
pan via trimmer
spring chamber
When the power of the coil is turned off, the spring

returns the spool to the right.
The line between the trimmer plug chamber and the

transmission oil pan is closed, therefore the clutch pres-
sure is kept high. In this condition if the manual control
push button (6) is pushed by hand main clutch pressure
should be reduced to approximately 0 ~ 0.1 MPa (0 ~ 1
kgf/cm2) (0 ~ 98 psi).
343
After power-on (just after switching clutch)
Trimmer plug
chamber
To transmission oil
pan via trimmer
spring chamber
When the power is supplied to the coil, the magnetic

power attracts the plunger to the left, and the oil in the
trimmer plug chamber is discharged into the transmis-
sion oil pan.
The clutch pressure, therefore, falls.
If debris were to stick the valve in this position pressure

would remain low even if the power to the coil is turned
off.
344
Check & Adjustment

Torque Converter and Transmission Group
345
Clutch Oil Pressure (70ZV-2/TMV-2)
Measuring clutch oil pressure
PT1/8
(Main press.)
4th speed clutch oil

pressure (PF1/4)
T/C inlet oil pressure
(PF1/2)
Forward clutch oil

pressure (PF1/4)
3rd speed clutch oil

pressure (PF1/4)
2nd speed clutch oil Reverse clutch oil
pressure (PF1/4) pressure (PF1/4)
1st speed clutch oil
pressure (PF1/4)
- Pressure gauge 2 MPa (20 kgf/cm2) (284 psi)

WARNING with 2 ~ 3 m hose
Unexpected movement of the machine may cause an - Clutch oil pressure measurement value :
accident resulting in injury or death. 1.3 ± 0.2 MPa (13 ± 2 kgf/cm2) (185 ± 28 psi)
To prevent such an accident during clutch oil pres- at engine idling speed (LI)
sure measurement, be sure to closely communicate 1.5 ± 0.2 MPa (15 ± 2 kgf/cm2) (213 ± 28 psi)
with the person in the cab by giving signals to each at engine maximum speed (HI)
other. Also use a gauge with a hose long enough to - Torque converter oil temperature :
reach outside from the articulation area. 50 to 80 ºC (120 ~ 180 ºF)
346
Clutch Oil Pressure (80ZV-2)
T/C inlet oil pressure

(PF1/2)
Forward clutch oil 4th speed clutch oil

pressure (PF1/4) pressure (PF1/4)
1st speed clutch oil

pressure (PF1/4)
3rd speed clutch oil
pressure (PF1/4)
Reverse clutch oil

pressure (PF1/4)
2nd speed clutch oil

pressure (PF1/4)

347
Torque converter inlet oil pressure

measurement port : PT3/4
3rd speed clutch oil pressure

measurement port : PF1/4
Reverse clutch oil
pressure measurement
port : PF1/4
Forward clutch oil pressure
4th speed clutch oil pressure

2nd speed clutch oil measurement port : PF1/4
port : PF1/4
1st speed clutch oil pressure

348
Torque converter inlet oil pressure

measurement port : PT3/4
3rd speed clutch oil pressure

Reverse clutch oil
port : PF1/4
Forward clutch oil pressure
4th speed clutch oil pressure

2nd speed clutch oil measurement port : PF1/4
port : PF1/4
1st speed clutch oil pressure

349
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350

T/C and T/M Group Materials Models 50 90ZV-2: This Manual Covers For

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T/C and T/M Group Materials Models 50 90ZV-2: This Manual Covers For

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KCM300-08/2006-00

Kawasaki Service Training Manual

• Torque Coverter (*T/C)

This Training Manual supplements materials found in the Shop Manual.

Consult the Shop Manual for specific details on each machine.

If you share information with others, the following will happen:

Safety ................................................................................. 304

Things to consider when repairing ..................................... 308

Dealer and customer call form ........................................... 309

T/M and T/C Function and Structure .................................. 312

Colored illustration ............................................................... 313

Torque converter ................................................................. 314

Pump ................................................................................... 315

Clutch combinations ............................................................ 316

QUAD .................................................................................. 316

Gear train ............................................................................ 317

Clutch specifications ............................................................ 318

Clutch packs ........................................................................ 319

Power flow ........................................................................... 323

T/M hyd diagram .................................................................. 326

Oil flow .................................................................................. 328

Oil circulation ........................................................................ 330

Control valve ........................................................................ 333

Modulation mechanism ......................................................... 335

Checks and adjustments ....................................................... 345

- Remove the cables from batteries before starting

- Be sure to release the internal pressure before you

- Be sure to apply the articulation stopper before start-

- While supporting the bottom of the chassis using a

- When the boom or bucket is raised or when a unit is

- Do not start to work in an enclosed area if adequate

- To remove a heavy unit (20 kgf (40 lbs) or more), be

- Just after stopping operation, be careful not to

Important Points to Remember

3. Do not indiscriminately discard parts.

Kawasaki Loader Dealer / Customer call form Date: ________________________

Customer's address: ____________________________________________________

1. What system(s) is giving trouble? Hydraulic, Transmission, Electrical, etc.?

3. What is the machine application? Where is it working, and what is it doing?

4. Name of person that gave information _______________________________

Clear directions of how to arrive at the jobsite:

Required support publications or Service / Parts News documents:

Symbol Item Description

Shows the condition or procedure that will be useful

Shows the weight of a part or unit. The weight

Tightening Shows the tightening torque of a section that should

Shows the type of coating or adhesive and the coat-

Shows the oil or water drain port and the drain

E/G ........... Engine RH ............Right hand side 3rd ............3rd speed

Function & Structure

Illustrations showing oil routing, and port locations

Transmission Case ............................

70ZV-2 Lubrication Oil ....................................

Note: Electrical section has more info on ground speed sensor

Torque ratio (t)

Power flow path

The turbine is connected to the torque converter output

The stator is fixed to the torque converter case. The

Torque Converter Gear Pump

Theoretical 64.5 cc/rev (3.9 in3/rev)

Clutch combination QUAD (Quick Up And Down ) shift button

The transmission is equipped with six clutches:

Forward range, reverse, and 1st, 2nd, 3rd and 4th