service repair manual

1. ©2009 Kawasaki Heavy Industries, Ltd. All rights reserved. Printed in Japan (k)
( アメリカ用 )
93217-00111
January 2009
SHOP MANUAL
WHEEL LOADER
135ZV-2
General Information
Standard Measurement Values for
Performance Check
Function & Structure
Check & Adjustment
Powered by CUMMINS QST30-C Engine
Serial No. 13C1-5301 and up
General
Information
135ZV-2
SHOP
MANUAL
93217-00111
Function
&
Structure

2. WARNING
BATTERY WARNING
CALIFORNIA PROPOSITION 65
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.
"Perchlorate Material special handling may apply,
See www.dtsc.ca.gov/hazardouswaste/perchlorate."
Applicable parts : MCU (Machine Control Unit)
Applicable state : California

3. 93217-00111
January 2009
Foreword
To ensure good machine performance, reduce failures or problems, and prolong the service life of each component,
it is necessary to operate the machine as is directed in the Operator and Maintenance Manual.
To effectively diagnose and repair the machine, it is important to follow the guidelines laid out in this Shop Manual.
General Information
Functions and structure
For the engine, refer to the engine Shop Manual provided by the engine manufacturer.
The purpose of this manual is to provide information on the product and the correct maintenance and repair meth-
ods. Please read this manual to ensure correct troubleshooting and good repair service.
This manual will be periodically reviewed and revised for more satisfactory content. If you have any opinion or
requests, please inform us.

4. 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.
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.
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.

5. CONTENTS
135ZV-2 General Information ................................................................................................................................ 00-1
How to Use Manual ........................................................................................................................................... 00-2
Safety precautions ...................................................................................................................................... 00-2
Symbols ...................................................................................................................................................... 00-3
Outline ............................................................................................................................................................... 00-4
Layout of main components ........................................................................................................................ 00-4
Inspection and maintenance table .............................................................................................................. 00-5
Recommended lubricants ........................................................................................................................... 00-8
Coolant ....................................................................................................................................................... 00-9
Lubrication chart ....................................................................................................................................... 00-10
Weight of main components ......................................................................................................................00-11
Bolt tightening torque ................................................................................................................................ 00-12
Hose band tightening torque ..................................................................................................................... 00-16
Liquid gasket and screw lock agent .......................................................................................................... 00-17
Cautions regarding welding repair service ................................................................................................ 00-19
Hydraulic Pressure Test Kit ............................................................................................................................. 00-21
135ZV-2 Measurement for Performance Check ................................................................................................... 03-1
Cautions on Safety ............................................................................................................................................ 03-2
Standard Measurement Values for Performance Check ................................................................................... 03-3
135ZV-2 Function & Structure Chassis Group ...................................................................................................... 12-1
Front Chassis .................................................................................................................................................... 12-2
Loading linkage ........................................................................................................................................... 12-2
Loading linkage pin ..................................................................................................................................... 12-4
Rear Chassis .................................................................................................................................................... 12-5
Fuel tank ..................................................................................................................................................... 12-5
Floor board mount ....................................................................................................................................... 12-6
Center Pin ......................................................................................................................................................... 12-7
Upper center pin ......................................................................................................................................... 12-7
Lower center pin ......................................................................................................................................... 12-8
Dust seal ..................................................................................................................................................... 12-9

6. 135ZV-2 Check & Adjustment Chassis Group ...................................................................................................... 13-1
Linkage Pin ....................................................................................................................................................... 13-2
Liner ............................................................................................................................................................ 13-2
Center Pin ......................................................................................................................................................... 13-6
Adjusting shim ............................................................................................................................................. 13-6
Installing bearing cover ............................................................................................................................... 13-6
Installing bearing outer ring ......................................................................................................................... 13-7
135ZV-2 Function & Structure Power Group ........................................................................................................ 22-1
Power Line ........................................................................................................................................................ 22-2
Engine / Transmission ....................................................................................................................................... 22-3
Engine mount .............................................................................................................................................. 22-3
Transmission mount .................................................................................................................................... 22-4
Radiator ............................................................................................................................................................. 22-5
Radiator mount ........................................................................................................................................... 22-6
T/C cooler mount ........................................................................................................................................ 22-7
Propeller Shaft .................................................................................................................................................. 22-8
First propeller shaft assembly ..................................................................................................................... 22-9
Second propeller shaft assembly .............................................................................................................. 22-10
Third propeller shaft assembly ...................................................................................................................22-11
Axle Assembly ................................................................................................................................................. 22-12
Axle Support .................................................................................................................................................... 22-14
Differential Gear .............................................................................................................................................. 22-16
Conventional type ..................................................................................................................................... 22-16
Function of differential gear ...................................................................................................................... 22-18
Operation of differential gear .................................................................................................................... 22-18
135ZV-2 Check & Adjustment Power Group ......................................................................................................... 23-1
Engine ............................................................................................................................................................... 23-2
Measuring engine speed ............................................................................................................................. 23-2
Measuring engine oil pressure .................................................................................................................... 23-2
Propeller Shaft .................................................................................................................................................. 23-3
Propeller shaft phase .................................................................................................................................. 23-3
Second propeller shaft alignment ............................................................................................................... 23-3
Tightening torque ........................................................................................................................................ 23-4

7. Axle ................................................................................................................................................................... 23-5
Axle ............................................................................................................................................................. 23-5
Differential gear adjustment procedure ....................................................................................................... 23-7
135ZV-2 Function & Structure Torque Converter and Transmission Group ......................................................... 32-1
Torque Converter .............................................................................................................................................. 32-2
Torque converter structure .......................................................................................................................... 32-3
Power flow path .......................................................................................................................................... 32-3
Torque multiplication ................................................................................................................................... 32-3
Lock-up clutch function (only forward) ........................................................................................................ 32-4
Torque Converter Gear Pump ........................................................................................................................... 32-5
Gear pump specifications ........................................................................................................................... 32-5
Transmission ..................................................................................................................................................... 32-6
Clutch combination ..................................................................................................................................... 32-7
Planetary gear ............................................................................................................................................. 32-7
Shift lever position ....................................................................................................................................... 32-7
Downshift button operation ......................................................................................................................... 32-7
Gear train and number of teeth ................................................................................................................... 32-8
Clutch Pack ..................................................................................................................................................... 32-13
Power Flow Path in the Transmission ............................................................................................................. 32-14
Hydraulic System Diagram ............................................................................................................................. 32-18
Hydraulic Circuit Diagram ............................................................................................................................... 32-19
Oil Flow ........................................................................................................................................................... 32-21
Oil flow in torque converter line ................................................................................................................. 32-21
Oil flow in transmission line ....................................................................................................................... 32-21
T/C and T/M Oil Circulation ............................................................................................................................. 32-24
Modulator Valve Unit ....................................................................................................................................... 32-25
Interior schematic (not exact representation) ............................................................................................ 32-26
Modulation Mechanism ............................................................................................................................. 32-27
Modulator valve operation ......................................................................................................................... 32-28
Control Valve Assembly .................................................................................................................................. 32-29
Clutch solenoid valve assembly ................................................................................................................ 32-30
Clutch valve assembly .............................................................................................................................. 32-33
Check valve assembly .............................................................................................................................. 32-34
Lock-up clutch solenoid valve ................................................................................................................... 32-35

8. Accumulator assembly .............................................................................................................................. 32-36
135ZV-2 Check & Adjustment Torque Converter and Transmission Group ......................................................... 33-1
Measuring Clutch Oil Pressure ......................................................................................................................... 33-2
Priority valve adjusting procedure ............................................................................................................... 33-3
135ZV-2 Function & Structure Hydraulic Group .................................................................................................... 42-1
Flushing Hydraulic Circuit ................................................................................................................................. 42-2
Purpose of flushing ..................................................................................................................................... 42-2
Cautions on Hydraulic Parts Replacement ....................................................................................................... 42-3
Hydraulic Circuit Symbols ................................................................................................................................. 42-4
Hydraulic lines ............................................................................................................................................. 42-4
Pumps & motors ......................................................................................................................................... 42-4
Cylinders ..................................................................................................................................................... 42-4
Operation methods ..................................................................................................................................... 42-5
Pressure control valve ................................................................................................................................ 42-5
Flow control valve ....................................................................................................................................... 42-5
Directional control valve .............................................................................................................................. 42-6
Check valve ................................................................................................................................................ 42-6
Miscellaneous hydraulic symbols ................................................................................................................ 42-7
Hydraulic System Operation ............................................................................................................................. 42-8
Hydraulic system operation outline ............................................................................................................. 42-8
Layout of Hydraulic Units ................................................................................................................................ 42-10
Hydraulic Tank ..................................................................................................................................................42-11
Hydraulic tank breather valve (tank cap) ................................................................................................... 42-12
Hydraulic tank sub tank ............................................................................................................................. 42-13
Hydraulic tank suction filter ....................................................................................................................... 42-14
Hydraulic tank return filter ......................................................................................................................... 42-15
Hydraulic tank specifications ..................................................................................................................... 42-16
Hydraulic oil level check ............................................................................................................................ 42-17
Hydraulic Pump ............................................................................................................................................... 42-18
Steering pump (K3V) ................................................................................................................................. 42-19
Loading pump (K5V) ................................................................................................................................. 42-25
Triple pump ............................................................................................................................................... 42-26
Hydraulic pump principle ........................................................................................................................... 42-27

9. Hydraulic pump wear plate ....................................................................................................................... 42-28
Hydraulic pump bushing lubrication .......................................................................................................... 42-28
Hydraulic Cylinder ........................................................................................................................................... 42-29
Boom cylinder ........................................................................................................................................... 42-29
Bucket cylinder .......................................................................................................................................... 42-29
Steering cylinder ....................................................................................................................................... 42-30
Hydraulic cylinder specifications ............................................................................................................... 42-31
Loading System .............................................................................................................................................. 42-32
Reducing Valve (for Pilot Pressure) ................................................................................................................ 42-33
Pilot Valve (TH40MS) ...................................................................................................................................... 42-34
Pilot valve (TH40MS) function .................................................................................................................. 42-34
Pilot valve (TH40MS) Installation position detail ....................................................................................... 42-35
Pilot valve (TH40MS) performance chart .................................................................................................. 42-36
Pilot valve (TH40MS) structure ................................................................................................................. 42-37
Pilot valve (TH40MS) operation ................................................................................................................ 42-38
Boom soft landing circuit ................................................................................................................................. 42-40
Boom soft landing hydraulic connection ................................................................................................... 42-41
Power boost circuit .......................................................................................................................................... 42-43
Steering unloader circuit ................................................................................................................................. 42-44
Hydraulic line connection .......................................................................................................................... 42-44
Steering unloader circuit structure ............................................................................................................ 42-45
Steering unloader circuit outline ................................................................................................................ 42-46
Steering unloader circuit function .............................................................................................................. 42-46
Solenoid valve ................................................................................................................................................. 42-47
Solenoid valve structure (Not activated) ................................................................................................... 42-47
Solenoid valve operation ........................................................................................................................... 42-47
Slow return check valve (Boom soft landing circuit) ................................................................................. 42-49
Adapter (Orifice) ........................................................................................................................................ 42-50
Slow return check valve (Boom raise) ...................................................................................................... 42-51
Multiple Control Valve (KML35A/2T401A) ....................................................................................................... 42-52
Multiple control valve specifications .......................................................................................................... 42-53
Multiple control valve main relief valve (MRV) (2 stage relief) .................................................................. 42-54
Multiple control valve overload relief valve (with make-up function) ......................................................... 42-56
Multiple control valve make-up valve ........................................................................................................ 42-57
Multiple control valve bucket spool ........................................................................................................... 42-58

10. Multiple control valve boom spool ............................................................................................................. 42-60
Pilot valve ........................................................................................................................................................ 42-63
Pilot valve structure ................................................................................................................................... 42-64
Pilot valve operation .................................................................................................................................. 42-65
Ride Control (OPT) ......................................................................................................................................... 42-66
Ride control hydraulic circuit ..................................................................................................................... 42-67
Ride control operation ............................................................................................................................... 42-69
Ride control valve assembly (Reducing valve circuit) ............................................................................... 42-71
Ride control valve assembly (Accumulator circuit) ................................................................................... 42-74
Accumulator (for ride control) .................................................................................................................... 42-77
Steering System .............................................................................................................................................. 42-78
Pilot Valve (for Steering) .................................................................................................................................. 42-79
Pilot valve (for steering) operation ............................................................................................................ 42-80
Steering Valve (KVS32-A1.0/31) ..................................................................................................................... 42-81
Steering valve operation ........................................................................................................................... 42-83
Steering spool variable throttle .................................................................................................................. 42-85
Steering valve flow control spool ............................................................................................................... 42-86
Steering valve main relief valve ................................................................................................................ 42-87
Steering valve overload relief valve .......................................................................................................... 42-89
Steering pilot circuit and its operation ....................................................................................................... 42-91
Stop Valve ....................................................................................................................................................... 42-92
Stop valve operation ................................................................................................................................. 42-93
Slow Return Check Valve ................................................................................................................................ 42-94
Slow return check valve specifications ..................................................................................................... 42-95
Steering Lock Line .......................................................................................................................................... 42-96
Efficient Loading System ................................................................................................................................. 42-97
Efficient loading system outline ................................................................................................................. 42-97
Hydraulic line ............................................................................................................................................ 42-98
Mounting of the variable kickout sensor .................................................................................................. 42-100
135ZV-2 Check & Adjustment Hydraulic Group .................................................................................................... 43-1
Loading/Steering Circuit Relief Valve ................................................................................................................ 43-2
Loading circuit relief valve setting pressures .............................................................................................. 43-2
Steering circuit relief valve setting pressures .............................................................................................. 43-7

11. Hydraulic Cylinder ............................................................................................................................................43-11
Cylinder natural drift ...................................................................................................................................43-11
Stop Valve ....................................................................................................................................................... 43-13
Stop valve adjustment procedure ............................................................................................................. 43-13
135ZV-2 Function & Structure Brake Group ......................................................................................................... 52-1
Brake System Outline ....................................................................................................................................... 52-2
Service brake .............................................................................................................................................. 52-2
Parking brake .............................................................................................................................................. 52-2
Auto brake .................................................................................................................................................. 52-2
Brake Units Layout ............................................................................................................................................ 52-3
Unloader Valve .................................................................................................................................................. 52-4
Unloader valve operation ............................................................................................................................ 52-5
Valve Unit .......................................................................................................................................................... 52-6
Reducing Valve (for Parking/Pilot Pressure/Power Boost) ................................................................................ 52-7
Accumulator ...................................................................................................................................................... 52-9
Brake Valve ..................................................................................................................................................... 52-10
Brake valve performance chart ..................................................................................................................52-11
Brake valve outline .................................................................................................................................... 52-12
Line Filter ........................................................................................................................................................ 52-14
Service Brake .................................................................................................................................................. 52-15
Service brake operation ............................................................................................................................ 52-16
Service brake disc ..................................................................................................................................... 52-17
Service brake piston ................................................................................................................................. 52-19
Service brake pedal stroke adjusting mechanism ..................................................................................... 52-20
Service brake warning system .................................................................................................................. 52-24
Brake circuit air bleeding procedure ......................................................................................................... 52-27
Parking Brake ................................................................................................................................................. 52-29
Parking brake operation ............................................................................................................................ 52-30
Parking brake friction disc ......................................................................................................................... 52-32
Parking brake solenoid valve .................................................................................................................... 52-33
Parking Brake Manual Release ...................................................................................................................... 52-34
Brake Circuit Check Valve ............................................................................................................................... 52-35

12. Auto Brake ...................................................................................................................................................... 52-36
Auto brake circuit ...................................................................................................................................... 52-36
Auto brake operation set value ................................................................................................................. 52-37
Reducing valve (for Autobrake circuit) ...................................................................................................... 52-38
Solenoid valve (for Autobrake circuit) ....................................................................................................... 52-39
Pressure Sensor (for stop lamp and declutch) ................................................................................................ 52-40
Pressure sensor (for stop lamp) ................................................................................................................ 52-40
Pressure sensor (for Declutch) ................................................................................................................. 52-41
135ZV-2 Check & Adjustment Brake Group ......................................................................................................... 53-1
Brake Circuit Oil Pressure ................................................................................................................................. 53-2
Unloader valve setting pressure ................................................................................................................. 53-2
Brake valve oil pressure .............................................................................................................................. 53-4
Service Brake .................................................................................................................................................... 53-6
Service brake performance check .............................................................................................................. 53-6
Service brake friction plate wear detection ................................................................................................. 53-7
Parking Brake .................................................................................................................................................... 53-8
Parking brake performance check .............................................................................................................. 53-8
135ZV-2 Function & Structure Electrical Group .................................................................................................... 62-1
How to Use Electrical Wiring Diagram .............................................................................................................. 62-2
Electrical Cable Color Codes ............................................................................................................................ 62-3
Electrical Circuit Symbols .................................................................................................................................. 62-4
Sensor Mount .................................................................................................................................................... 62-5
Fuse .................................................................................................................................................................. 62-7
Fuse box ..................................................................................................................................................... 62-7
Fusible link .................................................................................................................................................. 62-8
Engine Start Circuit ......................................................................................................................................... 62-10
Engine start circuit diagram ...................................................................................................................... 62-10
Neutral starter ............................................................................................................................................62-11
Starter switch ............................................................................................................................................ 62-12
Battery relay .............................................................................................................................................. 62-13
Alternator I terminal wire ........................................................................................................................... 62-13
Diode unit .................................................................................................................................................. 62-14
Neutral relay .............................................................................................................................................. 62-15

13. Magnetic switch ........................................................................................................................................ 62-16
Voltage relay ............................................................................................................................................. 62-17
Power Generating/Charging Circuit ................................................................................................................ 62-18
Alternator .................................................................................................................................................. 62-18
ECM (Engine Controller) ................................................................................................................................. 62-19
Function of ECM ....................................................................................................................................... 62-19
Connection diagram .................................................................................................................................. 62-19
Monitor lamp test ...................................................................................................................................... 62-20
Failure diagnosis ....................................................................................................................................... 62-21
Quantum fault code information ................................................................................................................ 62-24
Accelerator pedal ...................................................................................................................................... 62-31
Transmission Control Circuit and Monitor Circuit ............................................................................................ 62-33
Machine control unit (MCU) ...................................................................................................................... 62-33
MCU connection diagram ......................................................................................................................... 62-35
Machine control unit (MCU) function ......................................................................................................... 62-37
Modulator valve operation ......................................................................................................................... 62-45
Adjustable declutch preset switch ............................................................................................................. 62-47
Monitoring system ..................................................................................................................................... 62-60
Operation monitor lamps ........................................................................................................................... 62-62
Instrument Panel and Switch .......................................................................................................................... 62-63
Instrument panel ....................................................................................................................................... 62-63
Instrument panel rear surface ................................................................................................................... 62-64
Gauge circuit ............................................................................................................................................. 62-65
Fuel gauge circuit ...................................................................................................................................... 62-67
MODM ............................................................................................................................................................. 62-68
MODM function ......................................................................................................................................... 62-68
Monitor Changeover ................................................................................................................................. 62-68
Information Monitor ................................................................................................................................... 62-71
Replacement Monitor ................................................................................................................................ 62-75
Fault Log Monitor ...................................................................................................................................... 62-81
Input/Output Monitor ................................................................................................................................. 62-88
Parameter Setting Monitor ........................................................................................................................ 62-92
Specification Setting Monitor .................................................................................................................. 62-101

14. Electrical Detent Circuit ................................................................................................................................. 62-107
Bucket leveler ......................................................................................................................................... 62-107
Detent solenoid ....................................................................................................................................... 62-109
Lift kickout & lower kickout/boom soft landing ..........................................................................................62-110
Sensor assy .............................................................................................................................................62-112
Preset height adjustment .........................................................................................................................62-114
Boom soft landing ....................................................................................................................................62-114
Float .........................................................................................................................................................62-114
Diode ..............................................................................................................................................................62-115
Diode check method ................................................................................................................................62-116
Caution for diode check method ..............................................................................................................62-116
Surge voltage and surge suppression diodes ..........................................................................................62-118
135ZV-2 Drawing & Diagrams .............................................................................................................................. 92-1
Axle Assembly ................................................................................................................................................... 92-2
Torque Converter and Transmission ................................................................................................................. 92-4
Hydraulic & Brake Circuit .................................................................................................................................. 92-6
Brake Circuit ...................................................................................................................................................... 92-8
Gauge Mount .................................................................................................................................................. 92-10
Electrical Wiring Diagram (1/3) ........................................................................................................................92-11
Electrical Wiring Diagram (2/3) ....................................................................................................................... 92-12
Electrical Wiring Diagram (3/3) ....................................................................................................................... 92-13
Electrical Wiring Diagram ................................................................................................................................ 92-14
Way of looking at connectors .................................................................................................................... 92-14
Electrical wiring diagram abbreviation chart ............................................................................................. 92-16
Electrical Wiring Diagram (CAB) ..................................................................................................................... 92-17
Electrical Connection Diagram (1/2) ............................................................................................................... 92-18
Electrical Connection Diagram (2/2) ............................................................................................................... 92-19
Electrical Equipment Layout ............................................................................................................................ 92-20
Outline of MODM (Machine Operation Diagnostic Module) Operation ........................................................... 92-28
MODM: Input/Output Monitor - Input/Output Signal Correspondence Table ................................................... 92-37

15. 00-1
135ZV-2 General Information
135ZV-2 General Information
How to Use Manual................................................. 00-2
Outline..................................................................... 00-4
Hydraulic Pressure Test Kit ..................................... 00-21

16. 00-2
135ZV-2 General Information
How to Use Manual
How to Use Manual
Safety precautions
The most important point in providing repair service is
safety. To ensure safety, observe the general cautions
described below.
- 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 move-
ment.
- Remove the cable from the battery before starting
the service work, and attach a "DO NOT OPER-
ATE!" 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 device.
- 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 ser-
vicing and changing.
- Always store the tools in good condition, and use
them properly.
- Keep the work area clean. Clean up spills immedi-
ately.
- Avoid the use of flammable solvents and cleaners.
- When working outdoors keep work areas, ladders,
steps, decks and work platforms clear of snow, ice,
and mud.
- Use safe work platforms to reach higher areas of the
machine.
- Any technician that operates a refrigerant recovery
and recycling machine must first be certified through
an EPA approved testing program.
More information is available at http://www.epa.gov/
ozone/title6/608/technicians/608certs.html.
IMPORTANT
If a battery terminal is removed from a machine in
less than 30 seconds after the key is put into the
“OFF” position, it can corrupt the ECM program,
which can disable the engine. Always wait 1 full
minute to be sure to be past this “write to memory
function” prior to removing battery terminals.

17. 00-3
135ZV-2 General Information
How to Use Manual
Symbols
For safe and effective service work, the following sym-
bols are used for notes and useful information in this
manual.
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 on page 92-16.
Symbol Item Description
Reference
Shows the condition or procedure that will be useful
or efficient in doing service work.
Weight
Shows the weight of a part or unit. The weight
should be considered in selecting wire rope or cable
for slinging work or determining the working pos-
ture.
Tightening
torque
Shows the tightening torque of a section that should
be carefully tightened during assembly work.
Coating
Shows the type of coating or adhesive and the coat-
ing section.
Oil or
water
supply
Shows the oil or water supply port and the refill
amount.
Drainage
Shows the oil or water drain port and the drain
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.
E/G ........... Engine
T/C ........... Torque converter
T/M ........... Transmission
SOL ........... Solenoid valve
SW ........... Switch
F ........... Front or Forward
A/M ........... Auto/Manual
B ........... Battery
R ........... Rear or Reverse
RH ............Right hand side
LH ............Left hand side
H ............High
L ............Low
GND............Ground
OPT ............Option
Assy ............Assembly
1st ............1st speed
2nd ............2nd speed
3rd ............3rd speed
4th ............4th speed
M/C ............Machine
min-1
............RPM
ELS ............Efficient loading system
MODM ........Machine operation diag-
nostic module
MCU ...........Machine control unit

18. 00-4
135ZV-2 General Information
Outline
Outline
Layout of main components
1. Engine
2. Torque converter
3. Transmission
4. Air cleaner
5. Muffler
6. Radiator
7. Hydraulic oil cooler
8. Torque converter oil cooler
9. Front axle assembly
10. Rear axle assembly
11. 1st propeller shaft
12. 2nd propeller shaft
13. 3rd propeller shaft
14. Engine charge air cooler
135ZV00001
12
3
11
2
4 5
1 14 6
9 13 8 7
10

19. 00-5
135ZV-2 General Information
Outline
Inspection and maintenance table
Refer to Operation & Maintenance Manual for mainte-
nance procedures.
IMPORTANT
Severe application require more frequent mainte-
nance.
Severe conditions include heavy dust, extremely
abrasive material, caustic chemicals, exremely wet
conditions or abnormally hot or cold ambient temper-
atures.
: First time replacement or cleaning only
Section Item for check
Operating hours
When
Required
10 50 250 500 1000 2000
Engine
Check Engine Oil Level
Check Engine Coolant Level
Check Warning Lamps
Check Exhaust Gas
Drain Water and Sediment from Fuel Filters
Check Fuel Level
Drain Water and Sediment from Fuel Tank
Check and Adjust Belt Tension
Replace Engine Oil Filter Cartridges
Clean Crankcase Breather Tube
Check Air Intake System
Replace DCA4 Coolant Filter Cartridges
Replace Fuel Filters
Replace Engine Oil
Clean Fuel Prefilter
Check Engine Compression Pressure
Check Injection Pressure
Check and Adjust Injection Timing
Clean Fuel Tank
Check and Adjust Valve Lash Clearance
Check Vibration Damper
Greasing (Engine Trunnion Mount)
Clean or Replace Air Cleaner Element
Clean Radiator/Air cooler/Hydraulic oil cooler Fins
Clean or Replace Air Cleaner Element After six cleanings or once a year
Replace Coolant Every 2 years or 3000 hours

20. 00-6
135ZV-2 General Information
Outline
: First time replacement or cleaning only
Section Item for check
Operating hours
When
Required
10 50 250 500 1000 2000
Transmission
& Torque
Converter
Check Transmission Oil Level
Replace Transmission Oil Filter Elements
Replace Transmission Oil Filter
Replace Transmission Oil
Check and Replace Transmission and Torque Converter
Breather Element
Axle system
Check Tire for Damage, Deformation and Wear
Greasing (Axle support)
Check Tire Air Pressure
Check Differential Gear Oil
Check Planetary Gear Oil
Check Tightness of Wheel Bolts
Greasing (Front Differential)
Greasing (Rear Differential)
Greasing (1st Propeller Shaft)
Greasing (2nd Propeller Shaft)
Greasing (3rd Propeller Shaft)
Replace Differential Gear Oil
Replace Planetary Gear Oil
Steering system
Check Steering Wheel Operation
Greasing (Steering Cylinder)
Brake system
Check Service Brake Operation
Check Parking Brake Operation
Check Brake Accumulators
Clean Filter for Brake Line
Loading system
Check Hydraulic Oil Level
Greasing
Replace Hydraulic Oil Return Filter
Replace Filter in the Hydraulic Tank Cap
Replace Hydraulic Oil
Replace Bucket Teeth

21. 00-7
135ZV-2 General Information
Outline
: First time replacement or cleaning only
Section Item for check
Operating hours
When
Required
10 50 250 500 1000 2000
Chassis
Adjust and Check Rear View Mirrors
ROPS (Roll Over Protective Structure)
Greasing (Center Pin)
Check and/or Replace Seat Belt
Check Windshield Washer Fluid
Electrical
system
Check Monitor Panel Operation
Check Horn Operation
Check Back-up Alarm Operation
Check Wiring Harnesses
Check Battery Electrolyte Level
Check or Replace Fuses
Air Conditioner
Check and Adjust Air Conditioner Belt
Clean Air Conditioner and Heater Filter Element
Check Air Conditioner Refrigerant
Replace Air Conditioner Filter Elements
Clean Air Conditioner Condenser
Replace Air Conditioner Receiver Dryer Every 3 years or 6000 hours
Others Walk-Around Inspection

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23. 00-8
135ZV-2 General Information
Outline
Recommended lubricants
Refill capacity
(Approximate)
Kind of Oil
Ambient Temperature
Change Interval
(Hours)
Engine
142 liter
(37.5 gal)
Engine oil
(CH4)
∗2
500
Transmission
200 liter
(52.8 gal)
ATF
Engine oil (CD)
Mobil TRANS HD-10
Valvoline DT10
1,000
Hydraulic &
Brake system
720 liter
(190.2 gal)
∗1
[310 liter refill
(81.9 gal)]
∗3
Engine oil (CD)
2,000
Differential &
Planetary
Front:
317 liter (83.7 gal)
Rear:
317 liter (83.7 gal)
Gear Lubricant 2,000
Fuel tank
1050 liter
(277.4 gal)
Diesel fuel daily
Note: ∗1 shows "Hydraulic tank oil capacity at level gauge center."
-30ºC -20 -10 0 10 20 30
-22ºF -4 14 32 50 68 86
40
104
SAE10W-30
SAE10W
SAE15W-40
SAE10W
Mobil TRANS HD-10
Valvoline DT10
Multi-Purpose ATF
SAE10W
Mobil TRANS HD-50
Valvoline DT50
Mobil TRANS HD-50
ASTM D975 No.2
ASTM D975 No.1
Engine Use oil that meets engine oil classification API CH4 or CG4.
∗2. Change engine oil every 250 hours unless CH4 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, SAE 10W
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 &
Brake System
Use engine oil classification SAE 10W.
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.
Never mix engine oil and hydraulic oil.
∗3. In a case that fire-resistant fluid is used in the hydraulic circuit, replace hydraulic pump
every 6,000 hrs operation.
Differential &
Planetary
Use Mobil TRANS HD-50, Valvoline DT50 or equivalent with 5 % "Antichatter" additive or
friction 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.

24. 00-9
135ZV-2 General Information
Outline
Coolant
Coolant specification
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
- 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 -15ºC (5ºF)) if
the engine overheats in a high ambient temperature.
- Do not use hard water or water with high levels of
calcium and magnesium ions as the coolant water.
Expected Minimum
Ambient Temperature
-35ºC
(-31ºF)
-30ºC
(-22ºF)
-25ºC
(-13ºF)
-20ºC
(-4ºF)
-15ºC
(5ºF)
Pure
Water
liter
(gal)
127
(33.5)
140
(37)
154
(40.7)
167
(44.1)
181
(47.8)
Antifreeze
liter
(gal)
143
(37.8)
130
(34.3)
116
(30.6)
103
(27.2)
89
(23.5)
Mixture Ratio (%) 53 48 43 38 33
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 leak-
age.

25. 00-10
135ZV-2 General Information
Outline
Lubrication chart
44794-23030
135V2U00001
G
G
G
G
G
G
G
G
GO GO
GO
EO
EO
GO
HO
HO TO
TO
G G
G
G
DIFF &
GEAR BOX HYD. TANK
DIFF &
GEAR BOX
TRANSMISSION
LINK SYSTEM
BUCKET
PROPELLER SHAFT
EVERY 2000Hr
EVERY 1000Hr
EVERY 500Hr
EVERY 250Hr
EVERY 50Hr
EVERY DAY
AXLE
SUPPORT
CENTER PIN (LOWER)
DIFF
STEERING CYL.
LINK SYSTEM
DIFF
PROPELLER SHAFT
ENGINE OIL PAN
CENTER PIN (UPPER)
TRUNNION
MOUNT
Grease point
Check and add if necessary
Oil replacement
G
Multipurpose grease
GO
Gear oil
EO
Engine oil
HO
Engine oil
TO
Engine oil