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KAWASAKI 95ZV - 115ZV Hydraulic & Electric Circuit
KAWASAKI 95ZV - 115ZV Hydraulic & Electric Circuit
• Safety
• Electrical Diagrams (refer to the latest Shop Manual for more details)
This is section 900 of the Product Support Service Training Manual. Pages in this section are numbered from
from 901~1000.
Consult the Shop Manual for specific details on each machine.
●This manual is intended for properly trained and equipped service technicians.
●Any work on the machine must be performed by the trained personnel only.
●Carefully read this manual to thoroughly understand the operation method before you operate or repair the machine.
●Be sure to wear appropriate clothes and protectors, such as safety boots, hard hat and goggles.
●Place the machine on level and solid ground, and place chocks against the wheels to prevent movement.
●Remove the cable from the battery 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.
●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 adequate
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 (20kgf (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.
●Contact tire manufacturer's local dealer for tire servicing and changing.
●Always store the tools in good condition, and use them properly.
●When working outdoors keep work areas, ladders, steps, decks and work platforms clear of snow, ice, and mud.
901
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.
902
Symbols
For safe and effective service work, the following symbols are used for notes
and useful information in this manual.
Oil or Shows the oil or water supply port and the refill
water
supply 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 performance of the product will be reduced.
The message shows the preventive measures.
Abbreviation (acronyms)
To save space, abbreviations are used in sentences. To understand the contents of this manual, refer to the
following abbreviation list. Additional abbreviations are listed on page 62-6.
903
95ZV Diagrams
Hydraulic Circuit Line Diagrams
Electrical Diagrams
Loading/Steering Hydraulic Line 95ZV HYDRAULIC 42
3 5
Down up
B2
A2
1. Hydraulic pump (loading + pilot & brake)
14 6
P T
19 2. Hydraulic pump (steering)
ø1.3 a2
b2
3. Multiple control valve (loading circuits)
A B
24.5±0.5 MPa
(250±5 kgf/cm2)
24.5±0.5 MPa
(250±5 kgf/cm2)
(3,560 psi)
(29) Solenoid valve for parking (R)
(3,560 psi) at 15 L/min Cooling fan
71 45(46) 33
at 15 L/min
(49) (32) Check valve
(74,75) 80.0 (32) ON when pressure Capacity: 3.0 L
cm3 / rev
12.3 MPa
B drops.
3.9±0.5MPa
Gas charging pressure:
2.94±0.1 MPa (49) Pressure switch (for brake oil pressure)
(125.4 kgf/cm2) (30±1 kgf/cm2)
DR (569±71 psi)
(1,778 psi)
T2
at 0 L/min
A B ACCF
(427±14 psi)
33. Accumulator
Pb
A 81
Pa T T
45. Valve assembly
To parking brake
4
(46) Reducing valve (for accumulator circuit)
solenoid valve
solenoid valve
To auto brake
P.B.
20.6±0.5 MPa (210±5 kgf/cm2)
Priority control flow rate
10 L/min
71. Fan motor
(2,990 psi) at 250 L/min P2 22 ACF
To tank
T1
PG Cut out:
11.8±0.5 MPa
72. Valve assembly (for fan motor)
(120 kgf/cm2) (29)
81 G PC P TG P1 (1,710 psi) (28) (73) Relief valve (two-step relief)
Cut in:
TS Rc1/8
High pressure set:
16.1 MPa (2,335 psi)
6.9±1.0 MPa
(70 kgf/cm2) B (74) Solenoid valve
B A 95µm Low pressure set: (995psi)
11.1 MPa (1,610 psi)
3.5 MPa
(75) Solenoid valve
(36 kgf/cm2)
17 3.5 MPa T
(512 psi)
at 0 L/min P T
81. Line filter
(36 kfg/cm2)
(18) (512 psi)
at 0 L/min
1 11 72 (73) A B
PA
82. Suction strainer
113.0 91.0 74.0 0.3±0.06 MPa
M cm3 / rev M cm3 / rev cm3 / rev (3±0.6 kgf/cm2) Z2 (G1/4)
83. Suction strainer
(43±8.5 psi)
21 T T
10µm
ACF Z PPI Z1
TS TS
2 G1/4 G1/4
1.0 kPa 29.4 kPa
(0.01 kgf/cm2) (0.3 kgf/cm2) TA
(0.14 psi) (4.3 psi)
B A
904
Loading/Steering Hydraulic Line 95ZV HYDRAULIC 42
3 5
Down up
B2
A2
1. Hydraulic pump (loading + pilot & brake)
14 6
P T
19 2. Hydraulic pump (steering)
ø1.3 a2
b2
3. Multiple control valve (loading circuits)
A B
24.5±0.5 MPa
(250±5 kgf/cm2)
24.5±0.5 MPa
(250±5 kgf/cm2)
(3,560 psi)
(29) Solenoid valve for parking (R)
(3,560 psi) at 15 L/min
45(46) 33
at 15 L/min
(49) (32) Check valve
(32) ON when pressure Capacity: 3.0 L
Cooling fan
71 12.3 MPa
B drops.
3.9±0.5MPa
Gas charging pressure:
2.94±0.1 MPa (49) Pressure switch (for brake oil pressure)
(125.4 kgf/cm2) (30±1 kgf/cm2)
(569±71 psi)
(1,778 psi)
80.0
at 0 L/min
A B ACCF
(427±14 psi)
33. Accumulator
Pb
cm3 / rev 73 81
Pa T T
45. Valve assembly
To parking brake
4
T1
(46) Reducing valve (for accumulator circuit)
solenoid valve
solenoid valve
T
To auto brake
P.B. 74 Priority control flow rate 71. Fan motor
20.6±0.5 MPa (210±5 kgf/cm2)
16.2MPa(2,349psi) 10 L/min
(2,990 psi) at 250 L/min
Radiator 22 ACF
To tank
Cut out:
11.8±0.5 MPa
72. Relief valve
(120 kgf/cm2) (29)
81 G PC P T2 Pp (1,710 psi) (28) 73. Check valve
Cut in:
TS Rc1/8
Ts P
6.9±1.0 MPa
(70 kgf/cm2) B 74. Thermo sensing valve
B A 95µm High pressure set : 16.5MPa(2,393psi) (995psi)
Low pressure set : 6.2MPa( 900psi)
3.5 MPa
81. Line filter
(36 kgf/cm2)
17 3.5 MPa T
(512 psi)
at 0 L/min P T
82. Suction strainer
(36 kfg/cm2)
(18) (512 psi)
at 0 L/min 1 11 72 A B
PA
83. Suction strainer
113.0 91.0 74.0 0.3±0.06 MPa
M cm3 / rev M cm3 / rev cm3 / rev (3±0.6 kgf/cm2) Z2 (G1/4)
(43±8.5 psi)
21 T T
10µm
ACF Z PPI Z1
TS TS
2 G1/4 G1/4
1.0 kPa 29.4 kPa
(0.01 kgf/cm2) (0.3 kgf/cm2) TA
(0.14 psi) (4.3 psi)
905
906
Diagram reflects production ~ 97C4-5140
907
Diagram reflects production ~ 97C4-5140
Diagram reflects production ~ 97C4-5140
~ 97C4-5140
MULTIPLE UNIT 1 1 A
SYNCHRONIZATION 2 2 REMOTE
IDENTIFICATION 3 3 B 21
THROTTLE
SHORTING PLUGS 4 4 C
REMOTE B 43
THROTTLE
SWITCH
A 20
48
5 C C
B 47
3 A
A 49
4 B
2 D 03
C
6 E
B 13
1 F A 09
11
TACHOMETER B
IDLE SHUTDOWN RELAY U 35
L
K 10
33
INTERMEDIATE
SPEED CONTROL
SWITCH 23
ALTERNATE IDLE
C 45
INCREMENT / DECREMENT O 14
N 24
ALTERNATE
DROOP N
SWITCH 41
E
MULTIPLE UNIT C 34
ON/OFF
T 42
ENGINE O 12
PROTECTION
R
DIAGNOSTIC / USER-ENGAGED 44
SNAPSHOT ON/OFF
MANUAL 15
FAN ON/OFF
06
ENGINE STOP LAMP (RED)
ENGINE WARNING LAMP (YELLOW) 16
MAINTENANCE LAMP 05
WAIT TO START LAMP
04
38
29
30
39
40
50
18
28
07
08
17
A
B
C 46
D
B 37
C E
36
A F
26
G
27
B
C
A
REV 8/19/02
PAGE 1 of 2
SWITCHED
OUTPUT A
SHORTING PLUG SWITCHED
OUTPUT A
CONNECTOR OEM PRESSURE +5 VOLT SUPPLY
A 1 1
OEM PRESSURE SIGNAL
C 3 3
OEM PRESSURE RETURN
B 2 2
SWITCHED OUTPUT A
5 5
SPARE
6 6
SWITCHED OUTPUT A
4 4
OPTIONAL 2-WIRE
COOLANT LEVEL A
SENSOR B
OPTIONAL COOLANT A
LEVEL MODULE FOR
B 31 PIN-OEM
2-WIRE SENSOR
CONNECTOR
C
D
30
E
D
COOLANT
A
LEVEL
D 05
SENSOR C
SHORTING COOLANT LEVEL A 06
JUMPERS B SENSOR C 07
B
19
31
OEM TEMPERATURE INPUT
OEM TEMPERATURE B 04
OEM TEMPERATURE RETURN
SENSOR A 03
SWITCHED
SWITCHED OUTPUT A
OUTPUT B SOLENOID
SOLENOID
27
PWM DEDICATED OUTPUT 08
09
GRID HEATER
SOLENOID 10
11
FAN CLUTCH A 12
ACTUATOR B 13
OEM SWITCH 28
AIR CONDITIONER
17
PRESSURE SWITCH 18
MAGNETIC
PICKUP SHAFT SHAFT SPEED (+)
SPEED SENSOR A
SHAFT SPEED (-)
21
B 22
FREQUENCY (+)
THROTTLE 16
(-)
FUSE 2A
REV 8/19/02
PAGE 2 of 2
115ZV Diagrams
Hydraulic Circuit Line Diagrams
Electrical Diagrams
Loading/Steering Hydraulic Line 115ZV HYDRAULIC 42
3
Loading/Steering Hydraulic Line 5
DOWN UP
(S/N 5001~5030) 65 (66)
(67)
B2 1. Hydraulic pump (steering)
A P T B
A2 2. Hydraulic pump
6
14
DOWN UP
19 (loading + pilot & brake)
b2 a2
TS
3. Multiple control valve (loading circuit)
P T 23.5±0.5 MPa
G1/4
ø1.3
(3,413±71 psi)
at 100 L/min TS 4. Steering valve
G1/4
B1
5. Boom cylinder
L R
A1
6. Bucket cylinder
A A 23.5±0.5 MPa
8. Steering cylinder
(3,413±71 psi)
DR DR at 100 L/min 11. Check valve (oil cooler bypass)
b1 a1 12. Return filter element
3
Loading/Steering Hydraulic Line 5
DOWN UP
(S/N 5031~) 65 (66)
(67)
B2 1. Hydraulic pump (steering)
A P T B
A2 2. Hydraulic pump
6
14
DOWN UP
19 (loading + pilot & brake)
b2 a2
TS
3. Multiple control valve (loading circuit)
P T 23.5±0.5 MPa
G1/4
ø1.3
(3,413±71 psi)
at 100 L/min TS 4. Steering valve
G1/4
B1
5. Boom cylinder
L R
A1
6. Bucket cylinder
A A 23.5±0.5 MPa
8. Steering cylinder
(3,413±71 psi)
DR DR at 100 L/min 11. Check valve (oil cooler bypass)
b1 a1 12. Return filter element
115ZV42039
Hydraulic oil cooler
83 13 12 13
Hydraulic oil tank (incorporated in radiator)
Diagram reflects production ~ 11C4-5030
Diagram reflects production ~ 11C4-5030
~ 11C4-5030
TWO
ISS THROTTLE 6-PIN 6-PIN NON-ISS THROTTLE REMOTE THROTTLE POSITION SIGNAL
DESIGN OPTION OPTION DESIGN 28
5 VDC SUPPLY
29
+5VDC +5VDC THROTTLE POSITION SUPPLY
C C C A C 04
SIGNAL SIGNAL THROTTLE POSITION SIGNAL
A B B B B 05
RETURN RETURN THROTTLE POSITION RETURN
B A A C A 06
ISS OFF-IDLE OFF-IDLE IDLE VALIDATION SWITCH OFF IDLE SIGNAL
D D C C 07
ON-IDLE IDLE VALIDATION SWITCH IDLE SIGNAL
ON-IDLE
E E B B 08
RETURN RETURN IDLE VALIDATION SWITCH RETURN
F F A A 31
UNUSED
23
OEM SWITCH / COLD IDLE INHIBIT
10
UNUSED
11
RED LAMP RED LAMP
B 16
AMBER LAMP AMBER LAMP / SHUTDOWN OVERRIDE
C 17
WHITE LAMP WHITE LAMP / DIAGNOSTIC SWITCH
P 18
DIAGNOSTIC SWITCH
A
B
9 PIN 6 PIN
DEUTSCH DEUTSCH
PUBLIC DATALINK 1+
1 A 02
PUBLIC DATALINK 1-
2 B 03
REV 1/30/03
PAGE 1 of 1
This page is intentionally blank.
Use for notes.