KCM100~800-10;2006-51

Kawasaki Service Training Manual

This Manual covers All Group Training Materials for Models 95/115ZV-2
This
Current for 95/115ZV-2 production; Revised Feb. 20, 2007
x Safety and General Information

x Reading diagrams

x Layout of electrical pieces

x Electrical components

x Line and address diagrams

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 contains all sections of 95/115ZV-2 Product Support Service Training Manual. Pages in
this section are numbered from 1~ and are not number coded by sections.

Consult the Shop Manual for specific details on each machine.

Majority of illustrations are based on 95ZV-2. Where information has been made available for
publication on 115ZV-2, this information has been included in this training manual.
 Training Materials for Models 95/115ZV-2

IMPORTANT

This is a Kawasaki Service Training Manual that is intended for use with Kawasaki Service Training.

Materials in this manual are based on the 95ZV-2 Shop Manual. Periodically information may change
& information in this Training Manual may be superceded by newest Shop Manuals. Always verify
that you have the most current information available by reviewing the latest Shop Manual.

As noted above, this information is based on model 95ZV-2. Where there are known facts about mo-
del 115ZV-2, it is also included. As more materials become available, this manual will be revised.*

Operation and Maintenance Manual (OMM)

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.

Future machine production

Some references may be made to 92ZV-2, although this unit has not yet gone into production. Materials refer-
ring to this unit mention only what is known at time of publishing this training manual.

Key to retaining information

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.

Be a professional. NEVER GIVE IN TO THINKING THAT YOU ARE NOT SMART OR NOT GIFTED ENOUGH.
Be willing to ask the right questions to be able to find out what you need to know.

* You must attend future classes to get the revised materials.

Al Llewellyn, Training Manual Author

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 Training Materials for Models 95/115ZV-2

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.

Note that warning decals use ISO Symbols to depict hazards and hazard avoidance actions.

Read and understand the Operation and Maintenance Manuals for each machine to under-
stand the hazards.

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 Training Materials for Models 95/115ZV-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.

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Training Materials for Models 95/115ZV-2

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 Training Materials for Models 95/115ZV-2

Contents
Topic Page

Opening comments ...................................................................................................... 1

Work ethic - what to consider when making repairs - ................................................... 8

Dealer call form ............................................................................................................ 9

Safety and Decals ........................................................................................................12

Layout of components ................................................................................................. 27

Maintenance table ....................................................................................................... 28

Threadlocking materials and gaskets .......................................................................... 46

Cautions regarding welding repairs ............................................................................. 58

Measurement for performance testing ........................................................................ 61

Chassis - Function and Structure; Testing .................................................................. 70

Power and Drive Train - Function and Structure; Testing ........................................... 90

Torque Converter and Transmission Group - Function and Structure ...................... 167

Hydraulic Group - Function and Structure ................................................................. 256

Brake Group - Function and Structure ...................................................................... 410

Electrical Group - Function and Structure ................................................................. 466

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General Information

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 Training Materials for Models 95/115ZV-2

THINGS TO CONSIDER WHEN MAKING WARRANTY REPAIRS

Warranty Coverage

x Standard Warranty is 1 year (12 months) or 1,500 hours -- whichever occurs first.
x 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.)
x 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.
x 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.

x 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.

x 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.
x Find, Confirm, and Fix any problem(s). (You may have more than one.)
x 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?
x 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.

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 Training Materials for Models 95/115ZV-2

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 _______________________________

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 Training Materials for Models 95/115ZV-2

Clear directions of how to arrive at the jobsite:

Attach map if needed.
____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

Other notes:
____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

Required support publications or Service / Parts News documents:

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

____________________________________________________

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 Training Materials for Models 95/115ZV-2

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 ............2nd speed CW ............ Clockwise
CAC ........... Charge Air Cooler OMM ... Operation Maintenance Manual CCW ......... Counter Clockwise
S/S ............ K-Lever Steering

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 Training Materials for Models 95/115ZV-2

Safety Signs
All safety signs which are on the machine are
shown in following pages. Read & understand them.
They contain information which is important for safe
operation and the safe maintenance.

Follow the directions on the safety signs carefully.

It is very important that all safety signs be on the

machine in the locations shown. If any sign is miss-
ing, damaged, or worn, replace it.

NOTE
The sample safety signs in this section have part
numbers to help you and your dealer obtain the
correct replacement.

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 Training Materials for Models 95/115ZV-2

16. 13. 7. L.H, R.H

WARNING WARNING WARNING

DANGER
Removal, damage or alteration
of Roll Over Protctive Structure
(ROPS) will result in death or
Serious injury.
Always keep ROPS in place.
Do not operate this machine if
ROPS has been removed,
damaged, or altered.
44841-20870

L.H, R.H

44787-24490 44787-24430 44787-24400

Inside, L.H

115ZV2 02597-0982PV

4. 5. 1. L.H, R.H 15. L.H, R.H

DANGER WARNING DANGER WARNING

44787-24420 44787-24410 44787-24480

44787-24360

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 Training Materials for Models 95/115ZV-2

6. 11.

WARNING CAUTION
CAUTION

WARNING
Accidental movement of machine could
result in death or serious inj
ury.
Before checking transmission oil:
Park on level ground. Batteries contain lead, and acid
Lower bucket to ground. which may result in minor or
Place transmission in neutral. moderate inj ury.
Set parking brake. Avoid contact with skin or clothing.
Tag "Do Not Operate". If lead, or acid contacts skin or
clothing, immediately wash with
44841-20630
water.
44841-20690

Inside
44787-24470 44787-24370

115ZV2 02597-0982TVa

11. 8. 9. 10. Inside

CAUTION CAUTION WARNING WARNING

44787-24370 44787-24350 44787-24340 44787-24330

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 Training Materials for Models 95/115ZV-2

3. 2. 2.

WARNING WARNING WARNING

CAUTION
FLAMMABLE
PART NAME : ETHER CYLINDER
PART NO : 50401-03550
INGREDIENTS : ETHYL ETHER,
CARBONIC ACIDGAS

CAUTIONS
1.DON’T APPLY TO THE HUMAN BODY
2.DON’T USE NEAR FIRE
3.DON’T STORE IN HOT PLACE OVER 40

4.DON’T THROW EVEN EMPTY

CYLINDER INTO FIRE

44770-49180

STOP STOP Inside STOP

44787-24390 44787-24380 44787-24380

L.H, R.H L.H, R.H

115ZV2 02597-0982RE
115ZV2 02597-0983FS

RADIATOR

12. 6.

WARNING WARNING

IMPORTANT
Improper procedure of cleaning
air cleaner element can cause
severe engine damage.
Do not clean or replace
element while engine is
running.
Clean only outer element.
Never clean inner element.
44787-20950

44787-24440 44787-24470
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 Training Materials for Models 95/115ZV-2

Inside of Cab

B A
95ZV2 02597-0965ASb 95ZV2 02597-0965ASa
B A
B-B A-A
70ZV02597-0717AS

14.

WARNING

DANGER
Removal, damage or alteration
of Roll Over Protctive Structure
(ROPS) will result in death or
Serious injury.
Always keep ROPS in place.
Do not operate this machine if
ROPS has been removed,
damaged, or altered.
44841-20870

44787-24320

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 Training Materials for Models 95/115ZV-2

1. 3.

DANGER WARNING

STOP

44787-24360 44787-24390

DANGER WARNING

No room in this area when turning. Contact with moving belts or pulleys could result in
death or serious injury.
Crushing will result in death or serious injury.
Stop engine before working in this area.
Stay out of this area when machine could move or
turn.

2. 4.

WARNING DANGER

STOP
44787-24420
44787-24380

WARNING DANGER

Contact with moving fan could result in death or Sudden or accidental movement of boom will result
serious injury. in death or serious injury.

Keep all guards in place. Before walking or working under raised boom:

Keep hands away from fan area. - Securely block or brace boom.

- Remove key and tag "Do Not Operate."

- Relieve all trapped oil pressure before opening

any piping.
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 Training Materials for Models 95/115ZV-2

5. 7.

WARNING WARNING
WARNING

&
44787-24410 44787-24410

44787-24400

WARNING
WARNING
Lock articulation lock in place when working in area
of the articulation joint. Machine movement could result in death or serious
Machine will not turn with articulation stopper in injury.
locked position.
Unlock articulation stopper before operating Stay out of this area of the machine.
machine.

6. 8.

WARNING CAUTION

44787-24470 44787-24350

WARNING CAUTION

Nitrogen accumulator contains compressed gas
and fluid which could result in death or serious
injury.
Release all brake circuit oil pressure before remov-
ing any oil lines or piping.
When handling battery cable, you may get an elec-
tric shock.
Read, understand, and follow Operation & Mainte-
nance Manual before servicing machine.

Do not attempt to service or repair accumulator

unless properly trained and equipped.

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 Training Materials for Models 95/115ZV-2

9. 10.

WARNING WARNING

44787-24340 44787-24330

WARNING WARNING

Batteries produce explosive gases which could Pressurized system: spray of hot fluid could result
result in death or serious injury. in death or serious injury.

Keep flames and sparks away. Allow system to cool and vent pressure slowly
before servicing.
Vent area before servicing.

Batteries contain lead, and acid which may result in

minor or moderate injury.

Avoid contact with skin or clothing.

If lead, or acid contacts skin or clothing, immedi-

ately wash with water.

11.

CAUTION

44787-24370

CAUTION

Fall hazard.

No step.
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 Training Materials for Models 95/115ZV-2

12. 13.

WARNING WARNING

44787-24440 44787-24430

WARNING WARNING

Machine movement, if engine starts in gear, could Accidental movement of machine could result in
result in death or serious injury. death or serious injury.

- Do not start engine by shorting across starter - Before checking transmission oil:
terminals. - Park on level ground.
- Lower bucket to ground.
- Do not start engine while standing on ground. - Place transmission in neutral.
- Set parking brake.
Make sure to start engine only from operator's seat - Tag "Do Not Operate."
with transmission in neutral and parking brake
applied.

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 Training Materials for Models 95/115ZV-2

14. 16.

WARNING WARNING

44787-24320 44787-24490

WARNING WARNING

Improper operation or maintenance could result in Pressurized system: spray of hot fluid could result
death or serious injury. in death or serious injury.

Read, understand, and follow Operation & Mainte- Allow system to cool and vent pressure slowly
nance Manual before operating or servicing before servicing.
machine.

Follow all safety signs in Operation & Maintenance

Manual or on machine.

15.

WARNING

44787-24480

WARNING

Pressurized system: spray of hot fluid could result

in death or serious injury.

Allow system to cool and vent pressure slowly

before servicing.

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 Training Materials for Models 95/115ZV-2
Safety Devices
Loading Control Lever Lock
DANGER
Accidental movement of boom or machine will
result in death or serious injury.
When parking or leaving machine, or when per-
forming maintenance on it, always lower attach-
ment to ground and lock loading control levers.
Lock
Unlock
This device locks the loading control levers to pre-
vent accidental lowering of the attachment or boom.
- To lock, set the loading control levers to "NEU-
TRAL" and pull-up the lock lever to forward.
- To unlock, push down the lock lever to back-
ward.
22
K-Lever Steering System ON/OFF
Raised position
PUSH
PIN
- Push the button and lift the arm rest to the fully
raised position before getting off the machine.
- When the arm rest is fully raised the K-Lever
system is turned off automatically. Then the
green display lamp goes out.
WARNING
Accidental movement of the stick while getting
on or off the machine may cause unexpected
movement of the machine resulting in an acci-
dent, injury, or death.
Always stop, and properly park the machine and
turn off the K-Lever system while getting on or off
the machine.
The K-Lever system will be turned off by fully
raising the arm rest or turning off the key switch.
 Training Materials for Models 95/115ZV-2

Articulation Stopper
Operating
position

WARNING
With articulation stopper in LOCKED position,
machine will not steer; which, while operating,
could cause an accident, injury or death.

Do not lock Articulation Stopper during normal

operation.

Articulation stopper locks the front and rear chassis

to prevent them from sudden articulation during
inspection or transportation.
- Before operating the machine, lower the arm
rest back to the operating position. To lock:
When the arm rest is completely lowered the K-
Lever system is turned on automatically. Then
the green display lamp comes on.

"LOCKED" position

1. Align the front and rear chassis straight ahead.

2. Using a 14mm wrench remove the bolt that

fixes the articulation stopper to the storage
bracket on the rear chassis.

3. Remove the clip pin and pin from the end of

the Articulation Stopper.

4. Turn the link and fix the end to the bracket on

the front chassis (as shown).

5. Insert the pin and clip pin. (This is the LOCKED

position.)

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 Training Materials for Models 95/115ZV-2

To unlock: Neutral Start System

The transmission has a neutral start system which

allows the engine to start only when the transmis-
sion shift lever is in NEUTRAL position.

Emergency Brake

"STORED" position When the service brake does not work, emergency
brake can be applied manually (shown for 115ZV-2).

1. Remove the clip pin and pin from the end of

the articulation stopper on the front chassis
bracket.

2. Turn the link to the rear chassis bracket.

3. Insert the pin and clip pin. (This is the

STORED position.)

4. Tighten the bolt to fix the articulation stopper

on the bracket.

- Pull the emergency brake switch to engage the

emergency brake and disengage the transmis-
sion.

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 Training Materials for Models 95/115ZV-2

Emergency Steering (option) ROPS (Roll Over Protective Structure)

WARNING
Operation without normal steering could cause
loss of control and injury or death.
If emergency steering lamp lights up, steer
machine IMMEDIATELY to safe location and
stop it.
Emergency steering works automatically when the
steering hydraulic pressure goes down or the
engine stops while the machine is operating.
When the steering hydraulic pressure goes down
while the engine is running, the steering hydraulic
warning lamp lights up.
WARNING
Operating with damaged or improperly mounted
ROPS could serious injury or death. Be sure to
observe the following.
- Whenever seated, fasten the seat belt.
- Do not modify ROPS, such as drilling or weld-
ing.
- Do not use ROPS deformed.
- If any damage or loose bolts are found, do not
operate until repaired.
- Never repair or modify ROPS without manu-
facturer’s approval and instructions.

If the emergency steering works:

1. Keep the starter switch in the "ON" position

even when the engine unexpectedly stops.

2. Immediately operate the steering wheel to

bring the machine to a road shoulder or safe
location.

3. Stop the machine. If necessary, use the emer-

gency brake or lower the attachment to stop
the machine.

4. Place wheel chocks in front of and behind the

tires to prevent the machine from moving.

5. Contact your local Kawasaki dealer for neces-

sary testing and repair.

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 Training Materials for Models 95/115ZV-2

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.
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 Training Materials for Models 95/115ZV-2

MAIN COMPONENT NAME/LOCATION & LAYOUT

115ZV-2 shown

9 27 8 18 17 26 25 24
11

10
5 4
3
2

7 23 12

15 19 21 13,14 6 22 20 16

1. Bucket (Attachment) 14. Hydraulic Tank (Left hand side)

2. Boom 15. Front Axle / Differential Ass'y
3. "Z" Levers (2) (1pc. for log loader) 16. Rear Axle / Differential Ass'y
4. Boom Cylinders (2) 17. Air Cleaner (Right hand side)
5. Bucket Cylinders (2) (1pc. for log loader) 18. Precleaner (2)
6. Steering Cylinders (2) 19. Parking Brake
7. Engine 20. 1st Propeller Shaft
8. Torque Converter 21. 2nd Propeller Shaft
9. Transmission Ass'y 22. 3rd Propeller Shaft
10. Radiator & Torque Converter Cooler 23. Batteries (2)
(Lower tank) (one each side--two 12VDC=24VDC system)
11. Air Cooler (for engine intake air) 24. Cooling Fan
12. Hydraulic Oil Cooler 25. Fan Motor (hydraulic type)
13. Fuel Tank (Right hand side) 26. Exhaust Muffler
27. ROPS

NOTE
When a component or an item location is given as
"Left hand side" or "Right hand side", it is according
to the operator's left side or right side when sitting
in the seat.

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 Training Materials for Models 95/115ZV-2

Inspection and maintenance table (95ZV-2 shown; 115ZV-2 is similar)

ٌ : First time replacement or cleaning only

Operating hours
When
Section Item for check
10 50 250 500 1000 1500 2000 Required

Check Engine Oil Level ٤

Check Engine Coolant Level ٤

Check Warning Lamps ٤

Check Exhaust Gas ٤

Drain Water and Sediment from Fuel Filter ٤

Check Fuel Level ٤

Check Drive Belt ٤

Check Crankcase Breather Tube ٤

Check Air Intake System ٤

Check Cooling Fan ٤

Drain Water and Sediment from Fuel Tank ٤

Replace Engine Oil and Oil Filter Cartridge ٤

Add DCA4 Coolant Additive ٤

Engine Inspect Automatic Belt Tensioner Pulley ٤

Replace Fuel Filter Cartridge ٤

Replace DCA4 Coolant Filter Cartridge (One
year or 4,000 hours whichever comes first.) ٤

Clean Fuel Tank ٤

Check and Adjust Valve Lash Clearance ٤

Check Vibration Damper ٤

Check Engine Compression Pressure ٤

Check Injection Pressure ٤

Clean Crankcase Breather Tube ٤

Clean or Replace Air Cleaner Element ٤

Clean Radiator / Air cooler / Hydraulic oil cooler /
Fuel cooler Fins ٤

Clean or Replace Air Cleaner Element After six cleanings or once a year ٤

Replace Coolant Every 2 years or 3000 hours ٤

Check Transmission Oil Level ٤

Transmission
Replace Transmission Oil Filter Cartridge ٌ ٤
&
Torque
Replace Transmission Oil ٤
Converter
Clean or Replace Transmission Breather ٤

28
 Training Materials for Models 95/115ZV-2

(95ZV-2 shown; 115ZV-2 is similar)

ٌ : First time replacement or cleaning only

Operating hours
When
Section Item for check
10 50 250 500 1000 1500 2000 Required

Check Tire for Damage, Air and Tread Depth ٤

Greasing (Axle support) ٤

Check Tire Air Pressure* ٤

Check Differential Gear Oil ٤

Check Planetary Gear Oil ٤

Greasing (Pillow block bearing unit) ٤

Axle system
Check Tightness of Wheel Bolts ٤

Greasing (Differential seals) ٤

Greasing (2nd Propeller Shaft) Every 12000 hours ٤

Greasing (3rd Propeller Shaft) Every 12000 hours ٤

Replace Differential Gear Oil ٤

Replace Planetary Gear Oil ٤

Check Steering Wheel Operation ٤

Steering
Greasing (Steering Cylinder) ٤
system
®
Clean Filter for Orbitrol ٌ ٤

Check Service Brake Operation ٤

Check Parking Brake Operation ٤

Brake
Check Service Brake Disk Wear ٤
system
Check Brake Accumulator ٤

Clean Filter for Brake Line ٌ ٤

Check Hydraulic Oil Level ٤

Greasing ٤

Replace Hydraulic Oil Return Filter ٌ ٤

Loading
system Replace Hydraulic Oil, Clean Filter ٤

Replace Bucket Teeth (option) ٤

Replace Cutting Edge ٤

* Visually review appearance of tires before working with machine each day. Inflate or repair if needed.

IMPORTANT
The rear axle supports must be lubricated before each days use, and a generous amount of grease must
exit the axle grease vent with each lubrication of the supports.

29
 Training Materials for Models 95/115ZV-2

(95ZV-2 shown; 115ZV-2 is similar)

ٌ : First time replacement or cleaning only

Operating hours
When
Section Item for check
10 50 250 500 1000 1500 2000 Required

Adjust and Check Rear View Mirrors ٤

ROPS (Roll Over Protective Structure) Cab ٤

Greasing (Center Pin) ٤
Chassis
Check Ride Control Accumulator (option) ٤

Check and/or Replace Seat Belt ٤

Check Windshield Washer Fluid ٤

Check Monitor Panel Operation ٤

Check Horn Operation ٤

Check Back-up Alarm Operation ٤

Electrical
system
Check Wiring Harnesses ٤

Check Battery Electrolyte Level ٤

Check or Replace Fuses ٤

Check Drive Belt ٤

Clean Air Conditioner Filter Element ٤

Check Air Conditioner Refrigerant ٤

Air
Conditioner Replace Air Conditioner Filter Elements ٤

Clean Air Conditioner Condenser ٤

Replace Air Conditioner Receiver Dryer Every 3 years or 6000 hours ٤

Others Walk-Around Inspection ٤

30
 Training Materials for Models 95/115ZV-2

Recommended lubricants (95ZV-2 shown; 115ZV-2 is on next page)

Refill capacity Ambient Temperature (ºC) Change Interval

Kind of Oil -30 -20 -10 0 10 20 30 40
(Approximate) (Hours)
SAE10W-30
Engine oil 2
Engine 50 liter (13.2gal) SAE15W-40
(CH4) 500
Multi-Purpose ATF
ATF
SAE10W
Engine oil (CD)
Transmission 70 liter (18.5gal) Mobil TRANS HD-10 1,000
Mobil TRANS HD-10
Valvoline DT10 Valvoline DT10

1 ISO VG32
Hydraulic tank Hydraulic oil ISO VG46 2,000
150 liter (39.6gal)

Front: 100 liter

Differential & (26.4gal) Mobil TRANS HD-50
Planetary Rear: 100 liter Mobil TRANS HD-50
Valvoline DT50 2,000
(26.4gal) Valvoline DT50

Parking brake 3 liter (0.8gal)

465 liter ASTM D975 No.1

Fuel tank Diesel fuel ASTM D975 No.2 daily
(122.8gal)
Note: 1 shows "Hydraulic tank oil capacity at level gauge center."

Engine Use oil that meets engine oil classification API CH4 or CG4.
2. Change engine oil every 250 hours if CG4 is used.
Engine oil drain intervals need to be reduced by 50% when fuel sulfur content exceeds
0.5%.

Transmission Use engine oil classification API "CD".

Use Mobil TRANS HD-10, Valvoline DT10 or equivalent.
Multi-purpose Automatic Transmission Fluid.
Never mix engine oil, Mobil TRANS HD-10, Valvoline DT10 and/or ATF.
TO-4 SAE30W or SAE15W-40 engine oil can be used for the machines operating in high
ambient temperatures.

Hydraulic System Use industrial-type hydraulic oils which are certified by suppliers having anti-wear, anti-foam,
anti-rust and anti-oxidation additive properties for heavy duty use.

Differential & Use Mobil TRANS HD-50, Valvoline DT50 or equivalent with 5% "Antichatter" additive or fric-
Planetary tion modifier.

Lubricating Grease Use multipurpose-type EP/MOLY grease for most applications.

NLGI NO.2 grease is suitable for most temperatures.
NLGI NO.1 or NO.0 grease for extremely low temperature.
Use lithium base grease for a needle bearing.

31
 Training Materials for Models 95/115ZV-2

Recommended Lubricants (115ZV-2 shown; 95ZV-2 is on previous page)

Refill capacity Ambient Temperature (ºC) Change Interval

Kind of Oil -30 -20 -10 0 10 20 30 40
(Approximate) (Hours)

Engine oil SAE10W-30 2

Engine 66 liter (17.4gal) SAE15W-40
(CH4) 500

Engine oil (CD) or SAE10W

Transmission 90 liter (23.8gal) 1,000
ATF ATF

1 3 ISO VG32
Hydraulic tank ISO VG46
2,000
225 liter (60gal) Hydraulic oil

Front: 180 liter

Differential & (47.6gal)
Planetary Rear: 180 liter Engine oil SAE40 or SAE50
Engine oil (CD) 2,000
(47.6gal)
Parking brake 3 liter (0.8gal)
ASTM D975 No.1
Fuel tank 660 liter (174gal) Diesel fuel ASTM D975 No.2 daily

Note: 1 shows "Hydraulic tank oil capacity at level gauge center."

Engine Use oil that meets engine oil classification API CH4 or CG4.
2. Change engine oil every 250 hours if CG4 is used.
Engine oil drain intervals need to be reduced by 50% when fuel sulfur content
exceeds 0.5%.

Transmission Use engine oil classification API "CD".

Use Mobil TRANS HD-10, Valvoline DT10 or equivalent.
Multi-purpose Automatic Transmission Fluid.
Never mix engine oil, Mobil TRANS HD-10, Valvoline DT10 and/or ATF.
TO-4 SAE30W or SAE15W-40 engine oil can be used for the machines operating
in high ambient temperatures.

Hydraulic System Use industrial-type hydraulic oils which are certified by suppliers having anti-wear,
anti-foam, anti-rust and anti-oxidation additive properties for heavy duty use.
3. In a case that fire-resistant fluid is used in the hydraulic circuit, replace hydrau-
lic pump every 6,000 hrs operation.

Differential & Use Mobil TRANS HD-50, Valvoline DT50 or equivalent with 5% "Antichatter" addi-
Planetary tive or friction modifier.

Lubricating Use multipurpose-type EP/MOLY grease for most applications.

Grease NLGI NO.2 grease is suitable for most temperatures.
NLGI NO.1 or NO.0 grease for extremely low temperature.
Use lithium base grease for a needle bearing.

32
 Training Materials for Models 95/115ZV-2

Coolant
Coolant specification (95ZV-2 quantities shown)

The machine is originally filled with Long Life Coolant

(non-Amin type ethylene glycol) which need not be
replaced for the first two years or 3,000 hours.

Do not use Amin type Long Life Coolant in cooling sys-

tem. It may cause a corrosion against radiator or heater
core.

If standard antifreeze (not Long Life Coolant) is used for

the replacement, it should be replaced every six
months.

Recommended mixture of antifreeze

Quantities reflect those of 95ZV-2
Expected Minimum -35ºC -30ºC -25ºC -20ºC -15ºC
Ambient Temperature (-31ºF) (-22ºF) (-13ºF) (-4ºF) (5ºF)
(liter) 54.0 59.8 65.5 71.3 77.0
Pure Water
(gal) (14.3) (15.8) (17.3) (18.8) (20.3)
(liter) 61.0 55.2 49.5 43.7 38.0
Antifreeze
(gal) (16.1) (14.6) (13.1) (11.6) (10.1)
Mixture Ratio (%) 53 48 43 38 33

- Too much antifreeze in the coolant mixture may

cause engine overheating.
Keep 33 % antifreeze mixture (same as the mixture
for a minimum ambient temperature of -15 °C (5 °F))
if the engine overheats in a high ambient tempera-
ture.

- Do not use hard water or water with high levels of

calcium and magnesium ions as the coolant water.

IMPORTANT
Do not mix different brands of antifreeze because
they each contain special additives.
Careless mixing often diminishes the effect of these
additives that causes the packing damage or water
leakage.

33
 Training Materials for Models 95/115ZV-2

Coolant Specification (115ZV-2 shown)

The machine is originally filled with Long Life Cool-
ant (non-Amin type ethylene glycol) which need not
be replaced for the first two years or 3000 hours.

Do not use Amin type Long Life Coolant in cooling

system. It may cause a corrosion against radiator
or heater core.

If standard antifreeze (not Long Life Coolant) is

used for the replacement, it should be replaced
every six months.

Recommended Mixture of Antifreeze

Quantities reflect those of 115ZV-2
Expected Minimum -35ºC -30ºC -25ºC -20ºC -15ºC
Ambient Temperature (-31ºF) (-22ºF) (-13ºF) (-4ºF) (-5ºF)
liter 68.1 75.4 82.6 89.9 97.1
Pure Water
(gal) (18.0) (19.9) (21.8) (23.7) (25.6)
liter 76.9 69.6 62.4 55.1 47.9
Antifreeze
(gal) (20.3) (18.4) (16.5) (14.6) (12.7)
Mixture Ratio (%) 53 48 43 38 33

- Too much antifreeze in the coolant mixture may

cause engine overheating.

Keep 33% antifreeze mixture (same as the mix-

ture for a minimum ambient temperature of -15
ºC (5ºF)) if the engine overheats in a high ambi-
ent temperature.

- Do not use hard water or water with high levels

of calcium and magnesium ions as the coolant
water.

IMPORTANT
Do not mix different brands of antifreeze
because they each contain special additives.
Careless mixing often diminishes the effect of
these additives and causes packing damage or
water leakage.

34
 Training Materials for Models 95/115ZV-2

Note page is intentionally blank

35
 Training Materials for Models 95/115ZV-2

Lubrication chart for 95ZV-2

DIFF & DIFF &

EVERY 12000Hr
GEAR BOX TRANSMISSION HYD. TANK GEAR BOX

GO HO GO EVERY 2000Hr

TO EVERY 1000Hr
ENGINE OIL PAN

EO EVERY 500Hr
PILLOW UNIT

G GO GO EVERY 250Hr
LINK SYSTEM CENTER PIN
G G EVERY 50Hr
AXLE SUPPORT

TO HO EO G EVERY DAY

G G
BUCKET STEERING CYL.
G G

2ND 3RD
PROPELLER SHAFT (lube splines every 2,000 hrs) PROPELLER SHAFT

Axle supports must be generously lubricated with each days use. 95V2U00001

G HO
Grease point Multipurpose grease Hydraulic oil

GO TO
Check and add if necessary Gear oil Engine oil

EO
Oil replacement Engine oil

36
 Training Materials for Models 95/115ZV-2

Weight of main components (95ZV-2 shown)

Item Approx. Approx.

weight weight Remarks
Unit name Part name (kg) (lb)
Bucket 2,750 6,050 GSC bucket
Boom 2,130 4,690
“Z” -Lever 275/pc 605/pc
Link (Bucket to Lever) 60/pc 130/pc
Screen board 175 385
Roof 45 100
Engine room
Radiator guard 195 430
Access panel 35/pc 80/pc
Chassis Hydraulic tank 275 605 Excluding oil
Fuel tank 230 510 Excluding fuel
Floor board 285 630 Including ope. board, instrument panel and control box
Cab (Rops) 600 1,320
Left side 70 155 With handrail
Deck
Right side 50 110 With handrail
Front chassis 2,400 5,280
Rear chassis 2,550 5,610
Counter weight 1,920 4,230
Engine 1,600 3,520 Excluding oil
Radiator assembly 570 1,260 Excluding water and oil
Transmission 1,570 3,460 Excluding oil
Second propeller shaft 90 200
Power line Third propeller shaft 20 45
Front axle assembly 2,000 4,400 Excluding tires and oil
Rear axle assembly 2,030 4,470 Excluding tires and oil (Including axle support)
Front 550 1,210
Differential
Rear 370 820
Multiple control valve 90 200
Pilot valve 5 15
Steering valve 50 110
Orbitrol® 5 15
Hydraulic system Gear pump 35 80 Triple pump
Fan motor 50 110
Boom cylinder 280/pc 620/pc Excluding oil
Bucket cylinder 135/pc 300/pc Excluding oil
Steering cylinder 50/pc 110/pc Excluding oil
Tire 830/pc 1,830/pc With rim (29.5-25-22PR); No Hydro Inflation
Other
Battery 50/pc 110/pc

37
 Training Materials for Models 95/115ZV-2

Outline

Layout of main components (95ZV-2 shown)

3 8

4 9 21 3

5 6 7 8 10 22

18

11
4
16

17

12 20 14 2 15 13 1 19
95V2E00002

1. Engine assembly (Cummins QSX-15) 12. Front axle assembly

2. Transmission/Torque converter assy 13. Rear axle assembly
3. Hydraulic pump 14. 2nd propeller shaft
4. Multiple (loader) control valve 15. 3rd propeller shaft
5. Steering valve 16. Hydraulic oil cooler (air-to-oil type)
6. Pilot valve (for loading) 17. T/C oil cooler (lower tank of radiator)
7. Transmission control valve 18. Air charge cooler
8. Air cleaner 19. Fuel cooler
9. ELS valve 20. Parking brake
10. Muffler 21. Combination valve
38
11. Radiator 22. Fan motor
 Training Materials for Models 95/115ZV-2

Weight of main components (115ZV-2)

Item Approx. Approx.

Remarks
Unit name Part name weight (kg) weight (lb)

Bucket 4,985 10,970 RVT bucket

Boom 3,210 7,070
"Z" -Lever 515/pc 1,135/pc
Link (Bucket to Lever) 90/pc 200/pc
Screen board 175 385
Roof 70 155
Engine room
Radiator guard 115/pc 250
Access panel 35/pc 80/pc
Hydraulic tank 360 795 Excluding oil
Chassis Fuel tank 330 730 Excluding fuel
Floor board 285 630 Including ope. board, instrument panel and control box
Cab 270 600 Soft cab
Rops 950 2,090
Left side 105 230 With handrail
Deck Right side 80 175 With handrail
Center 35 80
Front chassis 3,800 8,360
Rear chassis 4,300 9,460
Counter weight 2,150 4,730
Engine 1,980 4,360 Excluding oil
With air cooler, hyd. cooler and duct. Excluding water
Radiator assembly 890 1,960
and oil
Torque converter 440 970 Excluding oil
Transmission 1,310 2,880 Excluding oil
First propeller shaft 20 45
Power line Second propeller shaft 130 290
Third propeller shaft 35 80
Front axle assembly 2,970 6,530 Excluding tires and oil
Rear axle assembly 2,940 6,470 Excluding tires and oil (Including axle support)
Front 745 1,640 Including parking brake
Differential
Rear 560 1,235
Hydraulic system Multiple control valve 100 220
Pilot valve 7 15
Steering valve 50 110
Orbitrol® 6 13
40 90 Switch
Gear pump
40 90 Main & pilot
Fan motor 25 55
Boom cylinder 520/pc 1,145/pc Excluding oil
Bucket cylinder 245/pc 540/pc Excluding oil
Steering cylinder 40/pc 90/pc Excluding oil
Tire 1,580/pc 3,480/pc With rim (35/65-33)
Other 39
Battery 65/pc 145/pc
 Training Materials for Models 95/115ZV-2

115ZV-2 Outline

Layout of main components

16

8 10
6 11
9 23

7 19 2

15

17 22 20 3 21 4 18 14 1 12 13

115V2E00001

1. Engine assembly 9. Air cleaner 16. Efficient loading system (ELS)

(Cummins QSK19) 10. Muffler valve
2. Torque converter assy 11. Radiator 17. Front axle assembly
3. Transmission 12. Hydraulic oil cooler 18. Rear axle assembly
4. Hydraulic pump (air-to-oil type) 19. 1st propeller shaft
5. Multiple (loader) control valve 13. T/C oil cooler 20. 2nd propeller shaft
6. Steering valve (lower tank of radiator) 21. 3rd propeller shaft
7. Pilot valve (for loading) 14. T/C oil cooler (installed on E/G) 22. Parking brake
(right side) 15. Charge air cooler 23. Fan motor
40
8. Transmission control valve
 Training Materials for Models 95/115ZV-2

Bolt tightening torque

Hexagon bolt
1. Thread type
Metric thread, Unified thread
2. Bolt strength
8.8 (8T) ~ 10.9 (11T)
3. Thread pitch
Metric thread: Coarse pitch thread (C), fine pitch thread (F)
Unified thread: Coarse pitch thread (UNC), fine pitch thread (UNF)

(N-m)
Bolt size Bolt strength
Type Nominal Nominal
Pitch 8.8 (8T) 10.9 (11T)
dimension dia.
M8 8 (C) 1.25 26 38
(C) 1.5 53 76
M10 10
(F) 1.25 55 80
(C) 1.75 90 132
M12 12
(F) 1.25 96 142
(C) 2.0 142 206
M14 14
(F) 1.5 152 221
(C) 2.0 216 314
M16 16
(F) 1.5 226 330
(C) 2.5 299 436
M18 18
(F) 1.5 324 476
Metric thread (C) 2.5 417 608
M20 20
(F) 1.5 451 662
(C) 2.5 559 814
M22 22
(F) 1.5 598 878
(C) 3.0 721 1,030
M24 24
(F) 2.0 770 1,128
(C) 3.0 1,030 1,520
M27 27
(F) 2.0 1,128 1,618
(C) 3.5 1,422 2,109
M30 30
(F) 2.0 1,569 2,256
(C) 3.5 1,912 2,844
M33 33
(F) 2.0 2,059 3,040
5/16 05 18 UNC 25 35
3/8 06 16 UNC 44 65
7/16 07 14 UNC 71 103
1/2 08 13 UNC 103 147
Unified thread 9/16 09 12 UNC 147 216
5/8 10 11 UNC 201 294
3/4 12 10 UNC 358 525
7/8 14 9 UNC 554 809
1 16 8 UNC 868 1,275

Note: Tighten the bolts according to the above list, unless otherwise specified.
41
 Training Materials for Models 95/115ZV-2

(kgf-m)
Bolt size Bolt strength
Type Nominal Nominal
Pitch 8.8 (8T) 10.9 (11T)
dimension dia.
M8 8 (C) 1.25 2.7 3.9
(C) 1.5 5.4 7.8
M10 10
(F) 1.25 5.6 8.2
(C) 1.75 9.2 13.5
M12 12
(F) 1.25 9.8 14.5
(C) 2.0 14.5 21.0
M14 14
(F) 1.5 15.5 22.5
(C) 2.0 22.0 32.0
M16 16
(F) 1.5 23.0 33.7
(C) 2.5 30.5 44.5
M18 18
(F) 1.5 33.0 48.5
Metric thread (C) 2.5 42.5 62.0
M20 20
(F) 1.5 46.0 67.5
(C) 2.5 57.0 83.0
M22 22
(F) 1.5 61.0 89.5
(C) 3.0 73.5 105.0
M24 24
(F) 2.0 78.5 115.0
(C) 3.0 105.0 155.0
M27 27
(F) 2.0 115.0 165.0
(C) 3.5 145.0 215.0
M30 30
(F) 2.0 160.0 230.0
(C) 3.5 195.0 290.0
M33 33
(F) 2.0 210.0 310.0
5/16 05 18 UNC 2.5 3.6
3/8 06 16 UNC 4.5 6.6
7/16 07 14 UNC 7.2 10.5
1/2 08 13 UNC 10.5 15.0
Unified thread 9/16 09 12 UNC 15.0 22.0
5/8 10 11 UNC 20.5 30.0
3/4 12 10 UNC 36.5 53.5
7/8 14 9 UNC 56.5 82.5
1 16 8 UNC 88.5 130.0

Note: Tighten the bolts according to the above list, unless otherwise specified.

42
 Training Materials for Models 95/115ZV-2

(lb-ft.)
Bolt size Bolt strength
Type Nominal Nominal
Pitch 8.8 (8T) 10.9 (11T)
dimension dia.
M8 8 (C) 1.25 19.5 28
(C) 1.5 39 56
M10 10
(F) 1.25 40 59
(C) 1.75 66 97
M12 12
(F) 1.25 70 105
(C) 2.0 105 150
M14 14
(F) 1.5 110 160
(C) 2.0 160 230
M16 16
(F) 1.5 165 245
(C) 2.5 220 320
M18 18
(F) 1.5 235 350
Metric thread (C) 2.5 305 450
M20 20
(F) 1.5 330 490
(C) 2.5 410 600
M22 22
(F) 1.5 440 650
(C) 3.0 530 760
M24 24
(F) 2.0 565 830
(C) 3.0 760 1,120
M27 27
(F) 2.0 830 1,190
(C) 3.5 1,050 1,550
M30 30
(F) 2.0 1,160 1,660
(C) 3.5 1,410 2,100
M33 33
(F) 2.0 1,520 2,240
5/16 05 18 UNC 18.0 26
3/8 06 16 UNC 32 47
7/16 07 14 UNC 52 76
1/2 08 13 UNC 76 105
Unified thread 9/16 09 12 UNC 110 160
5/8 10 11 UNC 150 215
3/4 12 10 UNC 265 385
7/8 14 9 UNC 410 595
1 16 8 UNC 640 940

Note: Tighten the bolts according to the above list, unless otherwise specified.

43
 Training Materials for Models 95/115ZV-2

Flanged hexagon bolt

1. Bolt type: Metric thread

2. Bolt strength: 8.8 (8T)

3. Thread pitch: Coarse pitch thread (C)

(N-m)
Bolt size Bolt strength
Type Nominal
Pitch 8.8 (8T)
dimension
M5 0.8 7
M6 1 12
M8 1.25 28
M10 1.5 53
Metric thread
M12 1.75 94
M16 2 231
M20 2.5 441
M24 3 765

(kgf-m)
Bolt size Bolt strength
Type Nominal
Pitch 8.8 (8T)
dimension
M5 0.8 0.7
M6 1 1.2
M8 1.25 2.9
M10 1.5 5.4
Metric thread
M12 1.75 9.6
M16 2 23.5
M20 2.5 45.0
M24 3 78.0

(lb-ft)
Bolt size Bolt strength
Type Nominal
Pitch 8.8 (8T)
dimension
M5 0.8 5.0
M6 1 8.6
M8 1.25 20.9
M10 1.5 38.9
Metric thread
M12 1.75 69.1
M16 2 169.2
M20 2.5 324.0
M24 3 561.6

44
 Training Materials for Models 95/115ZV-2

Hose band tightening torque

Low pressure hose

(heat resisting hose) Tightening torque Tightening torque Tightening torque
Hose band
(N-m) (kgf-cm) (lb-ft)
Inner dia. (mm) Outer dia. (mm)
6.3 16.5 HH022W
7.9 18.5 HH022W 1.6 16 1.2
9.5 20.5 HH022W
12.7 24.5 HH027W
15.9 29.9 HH031W
19.0 30.0 HH031W
25.4 38.0 HH044W
31.8 45.8 HH052W 4 40 2.9
38.1 52.1 HH057W
50.8 67.8 HH071W
60.5 76.0 HH082W
75.5 93.0 HH095W

Low pressure hose Tightening torque Tightening torque Tightening torque

Hose band
Inner dia. (mm) Outer dia. (mm) (N-m) (kgf-cm) (lb-ft)

6 16.5 HH022W
8 18.5 HH022W 1.6 16 1.2
9 20.5 HH022W
9 22.0 HH023W
12 24.5 HH027W
12 26.0 HH027W
15 29.0 HH031W
15 30.5 HH031W
19 32.0 HH038W
19 34.0 HH038W
4 40 2.9
25 39.5 HH044W
25 41.5 HH044W
32 46.0 HH052W
32 48.0 HH052W
38 54.0 HH057W
50 70.5 HH076W
50 73.0 HH076W

To connect the hose to the pipe, tighten the hose band Hose
at the following position: Pipe

Center of Hose band

pipe protrusion
10~20 mm
45
 Training Materials for Models 95/115ZV-2

Liquid gasket and screw lock Cautions regarding reassembly

agent To reassemble a screw

Completely remove the hardened lock agent from the

To reassemble the disassembled parts, be sure to use
screw and the threaded hole before reassembling the
the specified liquid gasket or screw lock agent or the
screw.
equivalent according to the following lists:

Code Manufacturer Product name

Note
A piece of hardened lock agent may be peeled off and
AA01 Loctite® Plastic Gasket 568
remain in the component. The remaining piece may
Liquid
AA02 Loctite® Hydraulic sealant cause malfunction during fastener installation.
Gasket
AA03 Three Bond Three Bond 1215
AB01 Loctite ®
Loctite® 262 To bond a plane or to fit a shaft
Screw Lock
AB02 Three Bond Three Bond 1327
Agent Remove the hardened lock agent using a wire brush or
AB03 Three Bond Three Bond 1374 the like, and polish the surface using sand paper. Use of
a loctite primer like Locquic ® Primer T cleans threads
and speeds curing time.

Cautions regarding parts removal Antiseize Agent

Code Manufacturer Product name

If a screw or shaft to be removed has been locked by
Loctite® 767
one of the above agents, remove the screw or shaft AC01 Loctite®
using a general tool, such as a wrench or puller. (Paste or spray)

If it is difficult to remove the screw or shaft, heat the bolt

to soften the agent (200 to 250°C) using a soldering iron
or small gas torch.

Caution

If there are seals near the screws or bolts to be removed,

carefully use heating method for removal, and avoid
damage to seals.

If heat has been used to remove a bolt or screw new

should be used at reassembly as it changed metal quality.

46
 Training Materials for Models 95/115ZV-2

Screw lock agent application procedure How to wind a seal tape

Through-hole

Apply screw lock agent one or two lines on the male

threads.
Seal tape

Screw lock agent

Leave 1~2 screw

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.

Blind hole

Apply screw lock agent all-round on the female threads

at 1/3 of the female thread length from the bottom.

H
Abt 1/3H

47
 Training Materials for Models 95/115ZV-2

PRODUCT SUPPORT..........................SERVICE NEWS

BULLETIN NO.: 99-026B DATE: Nov. 15, 2004 [Rev.] PAGE: 1 of 10
TITLE: Threadlocking and sealing compounds RELEASE: Dealer/Customer
SECTION: General MODEL: All
Remove and discard Service News 99-026A and replace with this Service News 99-026B
GENERAL:
Thread locking compounds will need to be procured locally. Three Bond® sealing RTV is
available through the Kawasaki Construction Machinery Parts Dept.
DETAIL:
Please review the table below to select locking or sealing compounds for work to be
performed.
Note: Description Strength Note:
Use Loctite® 262 (or 271) in place of ABO1, or ABO2. If
bolt is larger than 1” (25mm) use Loctite® 277. High Use
prepara-
Use Loctite® 277 in place of ABO3.
tive
Procure 242 before assembly, or 290 after assembly. [Wick-n-lock.] Medium primer
Locally 222 mild strength, for commonly disassembled items. Low
®
Loctite plastic gasket. Use in place of AA03. Plastic sealant.
®
See above reference to AB02 for use in place of Three Bond 1327.
See above reference to AB03 for use in place of Three Bond® 1374.
Procure from Kawasaki Room Temperature Vulcanizer [RTV] Three Bond® 1215
Construction Machinery Part No. 39651-70010 Non Acetic-Acid RTV
These should be used where required, as is specified in the Shop Manuals, and above table.
LOCTITE® THREADLOCKER QUICK SELECTOR
USE STRENGTH PRODUCT COLOR
Small Screws Low 222 Purple
Nuts and Bolts Medium 242 [may use semi-solid 248 stick] Blue
Pre-Assembled Medium 290 Green
Nuts and Bolts High 262 [may use 271 or semi-solid 268) Red*
Studs up to 1” High 262 [may use 271 or semi-solid 268) Red*
Studs over 1” High 277 Red*
* Be careful with heat sources! Heat nut or bolt to about 450 R F, and disassemble while hot.
-----------------------------------------------------------------------------------------------------------------------------
Reasons for using a primer.
1. Primers activate “ inactive** ” surfaces that are otherwise difficult to bond to.
2. Primers speed cure time, and permit return to service in less time.
3. Primers speed curing of locking agent through larger gaps, and deep threads.
4. Primers speed cure times on cold parts.
5. Primers act as a cleaning agent.
** “Active” surfaces are brass, copper, bronze, iron, soft steel, and nickel.
** “Inactive” surfaces are aluminum, stainless steel, magnezium, zinc, black oxide, cadmium, titanium,
and others.
(IMPORTANT: Primer N cures quicker & works in colder temperatures / Primer T permits longer periods to
work before curing.)

KAWASAKI CONSTRUCTION MACHINERY CORP. OF AMERICA

KENNESAW, GEORGIA
48 / (770) 421-6843 FAX
(770) 499-7000 PHONE
 Training Materials for Models 95/115ZV-2

PRODUCT SUPPORT..........................SERVICE NEWS

BULLETIN NO.: 99-026B DATE: Nov. 15, 2004 [Rev.] PAGE: 2 of 10
TITLE: Threadlocking and sealing compounds RELEASE: Dealer/Customer
SECTION: General MODEL: All
Remove and discard Service News 99-026A and replace with this Service News 99-026B
Effects of loss of torque on fasteners.
Bolt breakage due to looseness.
x Lack of tightness [or axial forces] permits side motion from looseness and transverse or
“sheer” type torque load forces begin to take over. The mount fixture may then become
damaged, and may need to be repaired or replaced.

Frictional tightening with bolts

x Clamping force of the fastener is what creates frictional forces between two pieces, and
resists the transverse forces. When fasteners loosen, the holding power is lost, and results
in damage to components, and subsequent costly repairs. Especially rotating shafts, and
vibrating parts should be assembled with appropriate locking compounds, after being primed
with a recommended cleaning agent.

Transverse
forces
Axial
forces

Axial
Transverse forces
forces

Locking agents help to hold the ‘staying power’ of the fastener by keeping the fastener
from loosening. The result is usually a trouble free long service life.
LOCTITE® THREADLOCKER and RETAINING COMPOUND GUIDE is attached in the following pages.
These products are available through LOCTITE® distributors. (LOCTITE® is a product of LOCTITE® Corp.)
(Attached with approval of Henkel Loctite® Corporation.)
KAWASAKI CONSTRUCTION MACHINERY CORP. OF AMERICA
KENNESAW, GEORGIA
49 / (770) 421-6843 FAX
(770) 499-7000 PHONE
MAINTENANCE PRODUCTS BULLETIN NO.: 99-026B DATE: Nov. 15, 2004 [Rev.] PAGE: 3 of 10
Training Materials for Models 95/115ZV-2
Use Loctite® brand liquid or paste retaining
compounds to bond non-threaded, cylindrical
metal assemblies. Fill the inner voids in close-
fitting press fits, keyways, and splines. Mount
bearings and bushings, and make press fits
even stronger.

RETAINING

Loctite® 609™ Loctite® 620™ Loctite® 660™ Quick Metal®

Retaining Compound Retaining Compound Retaining Compound
RETAINING

Press Fit/General Purpose Slip Fit/High Temperature Press Fit Repair

A low viscosity, fast curing
adhesive used for bonding rigid
metal assemblies. Ideal for gap
distances up to 0.005" (0.13 mm).
Loctite® 609™ fixtures in just
10 minutes and provides shear
strength of 3,000 psi after 24
hours. It easily joins dissimilar
metals and withstands
temperatures up to
300°F (149°C).
A high temperature adhesive that
has the capability to operate at
450°F (232°C) for long periods.
Loctite® 620™ fixtures in 30
minutes at room temperature, but
requires a secondary heat cure to
generate the high temperature
resistance. Used to bond cylindrical
parts with gaps up to 0.015" (0.35
mm). 620 provides a shear
strength of 3,800 psi on steel after
24 hours.
A creamy, non-running gel that is
applied onto cylindrical parts to fill
surface imperfections and repair
worn areas. It contains no metal,
but once assembled hardens to a
strength that often doubles that of
a press fit. Use Loctite® 660™ to
salvage worn metallic parts, or to
keep machinery running until new
parts arrive. Use to 300°F (149°C).

Loctite® 603™
Retaining Compound
Press Fit/Oil Tolerant
A retaining compound tolerant of
oil and other contamination. Seals
and secures cylindrical assemblies
up to 0.005" radial clearance
Fixtures in 10 minutes. Prevents
fretting and corrosion of metal
50
assemblies.
 MAINTENANCE PRODUCTS
BULLETIN NO.: 99-026B DATE: Nov. 15, 2004 [Rev.] PAGE: 4 of 10
Training Materials for Models 95/115ZV-2
Loctite® 680™
Retaining Compound
Slip Fit/High Strength
A high strength, room-temperature-
curing adhesive used to join fitted
cylindrical parts. It fixtures in 10
minutes and provides a shear
strength of 4,000 psi after 24 hours.
Capable of filling diametral gap
distances up to 0.015" (0.27 mm).
Loctite® 680™ allows relaxed
machining tolerances and replaces
clamp rings, set screws, and
snap rings.

Steel/Steel (psi)*
LOCTITE® BRAND

Shear Strength

Recommended
Fill (Diametral)
Maximum Gap

Temperature
RETAINING COMPOUNDS

Set-Up Time
Appearance

Approvals
PROPERTIES CHART

Agency
Primer
Range
Item
P R O D U C T Number Container

603™ 21440 10 ml bottle Green .005" 3,770 psi -65° to 300°F Set-up: 10 minutes 7649™ –
21441 50 ml bottle Liquid (-54° to 149°C) Full strength: 24 hrs. Primer N™
21442 250 ml bottle or 7471™
Primer T™

609™ 60921 10 ml bottle Green .005" 2,300 psi -65° to 300°F Set-up: 10 minutes 7649™ CFIA,
60931 50 ml bottle Liquid minimum (-54° to 149°C) Full strength: 24 hrs. Primer N™ Conforms to
60941 250 ml bottle or 7471™ MIL-R-46082B
Primer T™ for existing designs

620™ 62015 10 ml bottle Green .015" 3,800 psi -65° to 450°F Set-up: 30 minutes 7649™ ABS,
62040 50 ml bottle Liquid (-54° to 232°C) Full strength: 24 hrs. Primer N™ CFIA
62070 250 ml bottle or 7471™
Primer T™

660™ Quick Metal® 66010 6 ml tube Silver .020" 3,335 psi -65° to 300°F Set-up: 20 minutes 7649™ CFIA
66040 50 ml tube Paste (-54° to 149°C) Full strength: 24 hrs. Primer N™

RETAINING
or 7471™
Primer T™

680™ 68015 10 ml bottle Green .015" 2,800 psi -65° to 300°F Set-up: 10 minutes 7649™ ABS,
68035 50 ml bottle Liquid minimum (-54° to 149°C) Full strength: 24 hrs. Primer N™ NSF/ANSI 61
68060 250 ml bottle or 7471™
Primer T™

*Varies with substrates.

ADDITIONAL
OFFERINGS
Loctite® Hand Pumps are
ideal for dispensing liquid
from all 50 ml and 250 ml
anaerobic bottles. See page
106 for more information.

51
MAINTENANCE PRODUCTS BULLETIN NO.: 99-026B DATE: Nov. 15, 2004 [Rev.] PAGE: 5 of 10
Training Materials for Models 95/115ZV-2
From the creator of liquid threadlocking,
choose the strength, temperature range, and
cure speed you need to prevent loosening from
shock and vibration, and stop rust and corrosion
of threaded metal fasteners. Removable to
permanent strength threadlockers are available
to fit a variety of thread sizes and conditions.
The Loctite® brand now offers the same
trusted threadlocking performance in a patented
new semi-solid stick. Available in both medium and
high strength formulas, Loctite® Sticks are
convenient, portable and less messy, making
them perfect for tough applications, especially
overhead. Loctite® Sticks are easy to store in a
toolbox, tool belt, or pocket making them the
perfect complement to the trusted Henkel line of
Loctite® branded products.

THREADLOCKING
NEW
Loctite 220 Threadlocker
® ™
Loctite® 248™
Low Strength/Wicking/Blue Threadlocker Stick
A low viscosity threadlocking adhesive Medium Strength/Removable/Blue
that allows the product to wick along New, patented semi-solid stick formula
THREADLOCKING

the threads of preassembled fasteners. offers added convenience and

Perfect for fasteners up to
1
⁄4" diameter (6 mm).
Loctite® 222MS™ Threadlocker
Low Strength/Purple
Perfect for small fasteners up to 1⁄4"
diameter (6 mm), long engagement
length fasteners, and components
requiring occasional adjustment. Apply
to threaded parts before assembly.
Parts can be disassembled with hand
tools. Approved for use in or around
food processing areas.
Loctite® 242® Threadlocker
Medium Strength/Removable/Blue
Removable strength, general purpose
threadlocking adhesive especially well
suited for fasteners between 1⁄4" to 3⁄4"
diameter (6 to 20 mm). Applied to
threaded components before assembly,
Loctite® 242® Threadlocker has
controlled lubricity for accurate clamp
loads. Parts can be separated using
hand tools. Approved for use in or
around food processing areas.
portability. Like Loctite® 242®, Loctite®
248™ Threadlocker Stick is well suited
for 1⁄4" to 3⁄4" (6 to 20 mm) fasteners
and is removable with hand tools. The
semi-solid formula also means they
won’t spill or leak.
Loctite® 262™ Threadlocker
High Strength/Red
A high strength product that is applied
to fasteners up to 3⁄4" (20 mm) in size
before assembly. Localized heat and
hand tools are required to separate
parts. Solvents will not weaken the
adhesive bond. Approved for use in or
around food processing areas.
Loctite® 7649™ Primer N™
Decreases the set-up time of Loctite®
brand threadlockers and increases
breakaway torque on most fastener
surfaces. Allows cold weather
application. Contains no ozone-
depleting compounds.
52
NEW
Loctite® 268™
Threadlocker Stick
High Strength/Red
Revolutionary semi-solid stick formula
is high strength and best suited for
fasteners up to 3⁄4" (20 mm). Semi-solid
formula offers added convenience and
portability. Localized heat and hand
tools are required to separate parts.
Loctite® 290™ Threadlocker
Wicking/Green
A low viscosity, threadlocking liquid,
that wicks along the threads of pre-
assembled fasteners to secure them in
place. Seals porosities in welds and
metal parts. Ideal for fasteners ranging
from #2 to 1⁄2" (2.2 to 12 mm) in size.
Localized heat and hand tools are
needed for disassembly. Approved for
use in or around food processing areas.
 MAINTENANCE PRODUCTS
BULLETIN NO.: 99-026B DATE: Nov. 15, 2004 [Rev.] PAGE: 6 of 10
Training Materials for Models 95/115ZV-2

Recommended
Break/Prevail

Temperature
LOCTITE® BRAND THREADLOCKERS

Steel @ 25°C
Cure Speed,

Approvals
PROPERTIES CHART

Fastener

Torque*

Agency
Primer
Range
Color
Item

Size
P R O D U C T Number Container

220™ 37388 10 ml bottle Blue Under 85/170 -65° to 300°F Fixture - 6 minutes 7649™ MIL-S-46163A
22041 250 ml bottle 1/4" (-54° to 149°C) Full strength - 24 hrs. Primer for existing designs,
N™** CFIA

222MS™ 22221 10 ml bottle Purple #2 to 1/4" 53/30 -65° to 300°F Fixture - 10 minutes 7649™ MIL-S-46163A for
22231 50 ml bottle (2.2 mm to (-54° to 149°C) (5 minutes w/primer) Primer existing designs,
22241 250 ml bottle 6 mm) Full strength - 24 hrs. N™** NSF P1,
CFIA

242® 24221 10 ml bottle Blue 1/4" to 3/4" 110/43 -65° to 300°F Fixture - 10 minutes 7649™ MIL-S-46163A for
24231 50 ml bottle (6 mm to (-54° to 149°C) (3 minutes w/primer) Primer existing designs,
24241 250 ml bottle 20 mm) Full strength - 24 hrs. N™** NSF/ANSI 61,
NSF P1,
CFIA, ABS

248™ 37684 9 gm stick Blue 1/4" to 3/4" 110/43 -65° to 300°F Fixture - 10 minutes 7649™ CFIA
NEW 37087 19 gm stick (6 mm to (-54° to 149°C) (3 minutes w/primer) Primer
20 mm) Full strength - 24 hrs. N™**

262™ 26221 10 ml bottle Red Up to 3/4" 189/275 -65° to 300°F Fixture - 5 minutes 7649™ MIL-S-46163A for
26231 50 ml bottle (up to (-54° to 149°C) (5 minutes w/primer) Primer existing designs,
26241 250 ml bottle 20 mm) Full strength - 24 hrs. N™** NSF P1,
CFIA, ABS

268™ 37685 9 gm stick Red Up to 3/4" 202/4 65° to 300°F Fixture - 20 minutes 7649™ CFIA
NEW 37686 19 gm stick (up to (-54° to 149°C) (5 minutes w/primer) Primer
20 mm) Full strength - 24 hrs. N™**

290™ 29021 10 ml bottle Green #2 to 1/2" 85/250 65° to 300°F Fixture - 20 minutes 7649™ MIL-S-46163A for
29031 50 ml bottle (2.2 mm to (-54° to 149°C) (5 minutes w/primer) Primer existing designs,
29041 250 ml bottle 12 mm) Full strength - 24 hrs. N™** NSF/ANSI 61,
NSF P1,
CFIA

7649™ Primer N™ 21347 25 gm aerosol – – – – – – MIL-S-22473E for

21348 4.5 oz. aerosol existing designs
38402 1.75 fl. oz. NSF/ANSI 61,
aluminum bottle NSF P1,
CFIA

* Break & Prevail Torque values cited are for M10 steel nuts and bolts.

THREADLOCKING
** Loctite® 7471™ Primer T™ is also an acceptable alternative. See pages 48 and 49 for more information.
ADDITIONAL
OFFERINGS
LOW STRENGTH REMOVABLE

;;;;;
Apply 222MS™ Loctite® Hand Pumps are
Apply 242®
ideal for dispensing liquid

;;;;;
or 248™
from all 50 ml and 250 ml

;;;;; ;;;
;;;;;
anaerobic bottles. See page

;;;;; ;;
106 for more information.

;;;;; ;;;
;;;;;
;;
LOCTITE® 222MS™ LOCTITE® 242® LIQUID OR
THREADLOCKER 248™ STICK THREADLOCKER
• Set screws • Machine tools and presses
• Adjustment screws • Pumps and compressors
• Calibration screws • Mounting bolts
• Meters and gauges • Gear boxes

HIGH STRENGTH WICKING

Apply 290™
Apply

;;;;;
262™

;;;
LOCTITE® 262™
;;;;;
;;
LOCTITE® 290™
THREADLOCKER THREADLOCKER
• Heavy equipment • Preassembled fasteners
• Suspension bolts • Instrumentation screws
• Motor and pump mounts • Electrical connectors
• Bearing cap bolts and studs • Carburetors 53
 BULLETIN NO.: 99-026B
ASSEMBLY PRODUCTS
THREADLOCKING
LIQUID THREADLOCKERS
THREADLOCKING
Loctite® 222MS™
Threadlocker
Low Strength/Small Screw
Ideal for fastener diameters of 1⁄4"
(6 mm) and smaller. Controlled
lubricity for accurate clamp loads.
Parts can be separated using
hand tools.
Loctite® 242® Threadlocker
Medium Strength
A general purpose, removable
threadlocker for fasteners between
1
⁄4" and 3⁄4" (6 to 20 mm) diameters.
Controlled lubricity for accurate
clamp loads. Parts can be
separated using hand tools.
DATE: Nov. 15, 2004 [Rev.] PAGE: 7 of 10
Training Materials for Models 95/115ZV-2
Invented by Loctite Corporation, now Henkel
Corporation, as a revolutionary method to lock and
seal threaded fasteners, Loctite® brand liquid
threadlockers have found wide acceptance in a
range of applications – from delicate electronic
components to heavy construction equipment.
Loctite® brand threadlockers are available in
varying viscosities and strengths for virtually any
application, including exposure to extreme
environments.
Loctite® 243™ Threadlocker Loctite® 262™ Threadlocker
Medium Strength/Oil Resistant Medium to High Strength
A general purpose, medium A permanent threadlocker for
strength threadlocker with fasteners up to 3⁄4" (20 mm)
improved oil tolerance. For diameter. High lubrication for easy
fasteners between 1⁄4" and 3⁄4" assembly. Excellent for preventing
(6 to 20 mm) diameters. rust and corrosion in extreme
chemical/environmental conditions.
Loctite® 246™ Threadlocker
Medium Strength/High Temperature Loctite® 266™ Threadlocker
This threadlocker resists oil and High Strength/High Temperature
mild surface contamination at Fast fixturing threadlocker resists
continuous temperatures to 450°F. oil and mild surface contamination
Suitable for fasteners between 1⁄4" at temperatures to 450°F. Locks
and 3⁄4" (6 to 20 mm) diameters. fasteners up to 3⁄4" (20 mm)
in diameter.
!
...Ne w Form
la o n
Formu etails
Same ge 96 for d olid
See pa new semi-s icks.
the t
adlo cking S
Thre 54
BULLETIN NO.: 99-026B
Loctite® 271™ Threadlocker
High Strength
A high strength, low viscosity
threadlocker for fasteners up to
1" (25 mm) in diameter.
Loctite® 272™ Threadlocker
High Strength/High Temperature
Withstands temperatures to 450°F.
Provides a fast cure on most
surfaces, including “as received”
fasteners. Recommended for bolts
up to 11⁄2" (36 mm) in diameter.
Heat and hand tools are required
for disassembly.
Loctite® 277™ Threadlocker
High Strength
Locks fasteners up to 11⁄2"
(36 mm). Protects threads from
rust and corrosion. Removable
with heat and hand tools.
For technical information
and/or product
availability, call:
1-800-LOCTITE (562-8483)
or visit us on the web at:
DATE: Nov. 15, 2004 [Rev.]
Training Materials for Models 95/115ZV-2
Loctite® 290™ Threadlocker
Wicking Grade
A medium strength threadlocker
for pre-assembled bolts up to 1⁄2"
(12 mm). Penetrates threads by
capillary action. Secures set
screws and other assemblies after
settings are completed. Seals
welds and porous metal parts.
Protects threads from rust and
corrosion. Localized heating and
hand tools are needed
for disassembly.
Loctite® 294™ Threadlocker
Wicking Grade/High Temperature
Ideally suited for pre-assembled
fasteners. Performs well on
oily fasteners.
Loctite® 425™ Assure™
Instant Adhesive
Surface Curing Threadlocker
Low strength, fast curing
threadlocker for plastic fasteners.
Can be used as a tamper-proofing
agent for the head of screws.
Can be applied before
or after assembly.
55
PAGE: 8 of 10
ASSEMBLY PRODUCTS
Loctite® 2432™ Threadlocker
Low Halogen/Low Sulfur
This medium strength threadlocker
was especially developed for use on
sensitive metals like Titanium, used
in the Nuclear Industry. Parts can
be separated using hand tools.
Loctite® 2440™ Threadlocker
Primerless/Medium Strength
This threadlocker is particularly
fast curing, thereby reducing or
eliminating the need for primers.
Performs well on all substrates.
It develops useable strength (100
in.-lbs.) within one hour. Parts can
be separated using hand tools.
Loctite® 2760™ Threadlocker
Primerless/High Strength
This threadlocker is particularly
fast curing, thereby reducing or
eliminating the need for primers.
Particularly suitable for heavy duty
applications where resistance to
heavy shock, vibration, and stress
THREADLOCKING
levels are required.
 BULLETIN NO.: 99-026B DATE: Nov. 15, 2004 [Rev.] PAGE: 9 of 10
Training Materials for Models 95/115ZV-2
ASSEMBLY PRODUCTS

Recommended
LOCTITE® BRAND

Torque in. lbs.

Nuts & Bolts)

Break/Prevail

Temperature
Viscosity cP

Cure Speed,
Typical Use

Oil Tolerant
Steel @25°C
LIQUID THREADLOCKERS

(M10 Steel

Approvals
PROPERTIES CHART

Specific

Agency
Gravity
Primer
Range
Color
Item
PRODUCT Number Container

220™ 37388 10 ml bottle Wicking grade Blue 20 85/170 -65°F Fixture - 6 min. No N™ 1.08 MIL-S-46163A
22041 250 ml bottle for small, to Full - 24 hrs. or for existing designs,
pre-assembled 300°F T™ CFIA
fasteners
under 1/4"

222™ 21463 10 ml bottle Small screws Purple 1,200/ 53/30 -65°F Fixture - 10 min. – N™ 1.05 –
21464 50 ml bottle under 1/4" 5,000 to Full - 24 hrs. or
Thixotropic 300°F T™

222MS™ 22205 .5 ml capsule Easy removal Purple 1,200/ 53/30 -65°F Fixture - 10 min. – N™ 1.05 MIL-S-46163A
22221 10 ml bottle small screws 5,000 to Full - 24 hrs. or for existing designs,
22231 50 ml bottle under 1/4" Thixotropic 300°F T™ NSF P1,
22241 250 ml bottle CFIA

242 ® 24205 .5 ml capsule Removable Blue 1,200/ 110/43 -65°F Fixture - 10 min. – N™ 1.07 MIL-S-46163A
24221 10 ml bottle grade up to 5,000 to Full - 24 hrs. or for existing designs,
24231 50 ml bottle 1/4" to Thixotropic 300°F T™ NSF/ANSI 61,
24241 250 ml bottle 3/4" bolts NSF P1, ABS,
24243 1 liter bottle CFIA,

243™ 23977 .5 ml capsule For 1/4" to Blue 2,250/ 180/62 -65°F Fixture - 5 min. – N™ 1.08 NSF/ANSI 61,
24077 10 ml bottle 3/4" bolts. 12,000 to Full - 24 hrs. or CFIA
24078 50 ml bottle Provides fast Thixotropic 300°F T™
24079 250 ml bottle cure on steel
21433 1 liter bottle without primer

246™ 29513 10 ml bottle High Blue 2,600 170/48* -65°F Fixture - 20 min. Yes N™ 1.15 –
29514 50 ml bottle temperature to Full - 24 hrs. or
29515 250 ml bottle med. strength 450°F T™

262™ 26205 .5 ml capsule High strength Red 1,800/ 189/ -65°F Fixture - 5 min. – N™ 1.05 MIL-S-46163A
26221 10 ml tube locking up to 5,000 275 to Full - 24 hrs. or for existing designs,
26231 50 ml bottle 3/4" bolts Thixotropic 300°F T™ NSF P1,
26241 250 ml bottle CFIA,
26243 1 liter bottle ABS

266™ 26772 10 ml bottle High strength Red- 3,750- 270/75 -65°F Fixture - 10 min. Yes N™ 1.19 CFIA
26773 50 ml bottle high orange 9,000 to Full - 24 hrs. or
26774 250 ml bottle temperature 450°F T™
THREADLOCKING

271™ 27105 .5 ml capsule High strength Red 500 250/ -65°F Fixture - 10 min. – N™ 1.10 MIL-S-46163A
27121 10 ml bottle for fasteners 275 to Full - 24 hrs. or for existing designs,
27131 50 ml bottle up to 1" diam. 300°F T™ UL Listed for U.S.,
27141 250 ml bottle CFIA
27143 1 liter bottle

272™ 27240 50 ml bottle High Red 9,500 200/ -65°F Fixture - 30 min. – N™ 1.11 CFIA
27270 250 ml bottle temperature 220 to Full - 24 hrs. or
27285 1 liter bottle applications 450°F T™

277™ 21434 10 ml bottle High strength Red 7,000 275/ -65°F Fixture - 60 min. – N™ 1.12 MIL-S-46163A
27731 50 ml bottle for large bolts 275 to Full - 24 hrs. or for existing designs
27741 250 ml bottle 300°F T™
27743 1 liter bottle

290™ 29005 .5 ml capsule Wicking Green 12 85/ -65°F Fixture - 6 min. – N™ 1.08 MIL-S-46163A
29021 10 ml bottle grade for 250 to Full - 24 hrs. or for existing designs,
29031 50 ml bottle preassembled 300°F T™ NSF/ANSI 61,
29041 250 ml bottle parts NSF P1,
29043 1 liter bottle CFIA

294™ 27934 .5 ml capsule High Green 34 289/ -65°F Fixture - 6 min. Yes N™ 1.13 –
27935 10 ml bottle temperature, 237 to Full - 24 hrs. or
27936 50 ml bottle wicking 450°F T™
27937 250 ml bottle grade

425™ 42540 20 gm bottle For small metal Blue 80 4/2 -65°F Fixture - 1.5 min. – – 1.10 –
Assure™ 42561 1 lb. bottle and plastic to Full - 24 hrs.
fasteners and 180°F
tamper-proofing

2432™ 25523 50 ml bottle Low halogen, Blue 300 150/ -65°F Fixture - 30 min. – – 1.08 –
low sulfur, 53 to Full - 24 hrs.
med. strength 300°F

2440™ 33946 10 ml bottle Primerless, Blue 1,800/ 215/ -65°F Fixture - 3 min. – N™ 1.10 –
33947 50 ml bottle medium 6,800 53* to Full - 24 hrs. or
33948 250 ml bottle strength Thixotropic 300°F T™

2760™ 32526 10 ml bottle Primerless, Red 2,900/ 325/ -65°F Fixture - 4 min. – N™ 1.15 CFIA
32525 50 ml bottle high 10,000 320* to Full - 24 hrs. or
32527 250 ml bottle strength Thixotropic 300°F T™
32528 1 liter bottle 56

Indicates worldwide availability. * Breakloose value. Brookfield RVT spindle 3.20 RPM/25 RPM.
BULLETIN NO.: 99-026B DATE: Nov. 15, 2004 [Rev.] PAGE: 10 of 10

Training Materials for Models 95/115ZV-2
CHOOSING THE RIGHT LOCTITE®
BRAND THREADLOCKER FOR THE
APPLICATION
Choosing the right Loctite® brand threadlocker for the
application is simple. Just answer these questions.
1. Do you need a threadlocker that can be removed or
one that is permanent?
Loctite® brand threadlockers are available in removable
or permanent formulations.
2. What size thread are you locking?
Loctite® brand threadlockers are available in a variety of
strengths to lock any size fastener.
3. Is the application a blind hole or a thru-hole?
The application method for blind hole assemblies differs
from standard thru-hole assemblies.
4. Are there threadlockers for pre-assembled bolts?
Henkel offers Loctite® brand wicking grade threadlockers
that secure set screws and other assemblies after
settings are completed.
5. What kind of metal(s) will be used?
On two inactive metals such as stainless steel, zinc,
magnesium, black oxide, cadmium, anodized aluminum,
passivated, titanium, and others, a primer is needed to
cure Loctite® brand threadlockers. If only one inactive
metal, no primer is needed.
6. What other environmental conditions exist?
Loctite® brand threadlockers are formulated to meet any
application need – high temperature, severe vibration,
ASSEMBLY PRODUCTS
ANSWERS TO THE MOST
FREQUENTLY ASKED QUESTIONS
(FAQ) ABOUT USING LOCTITE®
BRAND THREADLOCKERS
Q. How do I disassemble parts? What is the procedure?
A. Use standard hand tools for disassembly of low and
medium strength threadlockers. For high strength
threadlockers, apply localized heat to nut or stud for
5 minutes at 450°F. Disassemble while hot.
Q. When should I use a primer with threadlockers and
when is it not necessary?
A. Always use a primer when two inactive metals are
involved, or when you need to speed up the curing
process for faster return to service. See Surface
Preparation section for a list of active and
inactive surfaces.
Q. Can I use threadlockers on plastic threads?
A. This is not recommended as softening and/or stress
cracking can occur.
Q. I have excess squeeze-out of threadlocker product.
Why hasn’t it cured?
A. The anaerobic chemistry will cure only between metal
surfaces when deprived of air.
Q. I used a permanent threadlocker on a blind hole
application and the fastener still backed out with
vibration. Why?

THREADLOCKING
A. The application method for blind hole assemblies
and chemical resistance.
requires that product be applied to both parts. If product
7. Will your application have to meet any is only applied to the fastener, air pressure will force the
agency approval? liquid threadlocker to escape as you torque it down.
The Loctite® brand offers the broadest line of products Lack of uniform coverage creates air pockets, causing
approved by some of the most demanding regulatory incomplete cures which result in failures.
agencies – NSF*, UL*, Military.

LOW STRENGTH MEDIUM STRENGTH HIGH STRENGTH WICKING

THREADLOCKERS THREADLOCKERS THREADLOCKERS THREADLOCKERS

● Removable with hand tools ● Removable with hand tools
● Adjustment screws ● Machine tools and presses
● Calibration screws ● Pumps and compressors
● Meters and gauges ● Mounting bolts
● Up to 1/4" diameters ● Gear boxes
● Up to 3/4" diameters
● Permanent assembly
● Heavy equipment
● Suspension bolts
● Motor and pump mounts
● Bearing cap bolts and studs
● Up to 1" and larger diameters
● Removable with heat and
hand tools
● Preassembled fasteners
● Instrumentation screws
● Electrical connectors
● Carburetors
● Up to 1/2" diameters

57
®
* NSF = National Sanitation Foundation. UL = Underwriter's Laboratories. Reprint granted with written permission by Loctite