Kawasaki 85ZV-2 Wheel Loader Official Workshop Service Repair Manual
Kawasaki 85ZV-2 Wheel Loader Official Workshop Service Repair Manual
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This is the COMPLETE Official Service Repair Manual for the Kawasaki Wheel Loader.
This manual contains deep information about maintaining, assembly, disassembly and servicing your Kawasaki.
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Models And Serials :
Powered by CUMMINS QSC8.3 ENGINE
Serial No. 85C5-9001 and up
CONTENTS :
85ZV-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 ...............................................................00-10
Lubrication chart .................................................00-11
Weight of main components ...............................00-12
Bolt tightening torque ..........................................00-13
Hose band tightening torque ..............................00-17
Liquid gasket and screw lock agent ...................00-18
Cautions regarding welding repair service .........00-20
85ZV-2 Measurement for Performance Check ...03-1
Cautions on Safety ................................................03-2
Standard Measurement Values for Performance Check ...03-3
85ZV-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 (S/N 9001-9139) ........................................................12-5
Fuel tank (S/N 9140-) ................................................................12-6
Floor board mount .....................................................................12-7
Center Pin ..................................................................................12-8
Upper center pin .........................................................................12-8
Lower center pin ..........................................................................12-8
Dust seal ......................................................................................12-9
85ZV-2 Check & Adjustment Chassis Group ...........................13-1
Linkage Pin ...................................................................................13-2
Liner ..............................................................................................13-2
Center Pin .................................................................................... 13-4
Adjusting shim .............................................................................. 13-4
Installing bearing cover ······················································ 13-4
Installing bearing outer ring ..........................................................13-5
85ZV-2 Function & Structure Power Group................................22-1
Power Line ....................................................................................22-2
Engine/ Transmission ..................................................................22-3
Engine/ transmission mount ...........................................................22-3
Radiator (S/N 9001~9100) ............................................................ 22-4
Radiator mount .............................................................................. 22-5
Radiator (S/N 9101~) .................................................................... 22-6
Radiator mount ................................................................................22-7
Propeller Shaft ............................................................................. 22-8
Second propeller shaft assembly ...................................................22-9
Third propeller. shaft assembly ...................................................... 22-10
Axle Assembly ..............................................................................22-11
Axle Support .................................................................................22-12
Differential Gear ............................................................................22-14
Torque proportioning type ...............................................................22-14
Limited Slip Differential (option) ..................................................... 22-18
85ZV-2 Check & Adjustment Power Group ..................................23-1
Engine ............................................................................................ 23-2
Measuring engine speed ................................................................ 23-2
Measuring engine oil pressure ........................................................ 23-3
Propeller Shaft ..............................................................................23-4
Propeller shaft phase .................................................................... 23-4
Second propeller shaft alignment ................................................. 23-4
Tightening torque ...........................................................................23-5
Axle ............................................................................................... 23-6
Axle nut tightening procedure ....................................................... 23-6
Differential gear adjustment procedure...........................................23-7
85ZV-2 Function&Structure Torque Converter and Transmission Group..32-1
Torque Converter ............................................................................32-2
Torque converter structure ..............................................................32-2
Power flow path ..............................................................................32-2
Torque multiplication ......................................................................32-2
Torque Converter Gear Pump ........................................................32-3
Gear pump specifications ...............................................................32-3
Transmission ....................................................................................32-4
Clutch combination .............................................................................32-4
Shift lever position ..............................................................................32-4
Downshift button operation .................................................................32-4
Gear train and number of teeth ..........................................................32-5
Clutch specifications ...........................................................................32-6
Clutch Pack .......................................................................................32-7
Forward and 3rd speed clutches ...................................................32-7
Reverse and 2nd speed clutches .................................................. 32-8
1st speed clutch .................................................................................32-9
4th speed clutch ................................................................................32-10
Power Flow Path in the Transmission ........................................32-11
Hydraulic System Diagram ..........................................................32-14
Hydraulic Circuit Diagram ............................................................32-15
Oil Flow ..........................................................................................32-16
Oil flow in the torque converter line .................................................32-16
Oil flow to the clutch ........................................................................32-16
T/C and T/M Oil Circulation ............................................................32-17
Control Valve ..................................................................................32-19
System diagram ..............................................................................32-20
Modulation Mechanism ...................................................................32-21
Clutch control oil pressure curve .......................................................32-22
Traveling at forward 1st speed ..........................................................32-23
Changing from forward 1st speed to reverse 1st speed ....................32-24
Trimmer engagement ........................................................................32-25
Clutch engagement starting ...............................................................32-26
Clutch Solenoid Valve ....................................................................32-27
For forward/reverse and speed clutches ...........................................32-27
For trimmer ........................................................................................32-29
85ZV-2 Check &Adjustment Torque Converter and Transmission Group..33-1
Clutch Oil Pressure ....................................................................33-2
Measuring clutch oil pressure .......................................................33-2
85ZV-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 specifications ............................................................42-11
Hydraulic oil level check ...................................................................42-11
Hydraulic Tank (S/N 9001-9250) ......................................................42-12
Hydraulic Tank (S/N 9251-) ..............................................................42-14
Hydraulic Pump ..............................................................................42-16
Hydraulic pump specifications ..........................................................42-16
Hydraulic pump principle ................................................................. 42-17
Hydraulic pump wear plate ...............................................................42-18
Hydraulic pump bushing lubrication ..................................................42-18
Hydraulic Cylinder ......................................................................... 42-19
Boom cylinder ...................................................................................42-19
Bucket cylinder ................................................................................ 42-20
Steering cylinder ..............................................................................42-20
Hydraulic cylinder specifications ......................................................42-21
Loading System .............................................................................42-22
Reducing Valve (for Pilot Pressure) ..............................................42-23
Pilot Valve (S/N 9001-9214) ............................................................42-24
Pilot valve function ...........................................................................42-26
Pilot valve operation (modulated position) ......................................42-26
Pre-detent and detent magnet solenoid ..........................................42-28
Pilot Valve (S/N 9215-) ....................................................................42-29
Pilot valve function ...........................................................................42-31
Pilot valve operation (modulated position) .......................................42-31
Pre-detent and detent magnet solenoid ..........................................42-33
Multiple Control Valve (KML28/2T002) ........................................42-34
Multiple control valve specifications ................................................42-35
Multiple control valve main relief valve ............................................42-36
Multiple control valve overload relief valve (with make-up function) .42-38
Multiple control valve make-up valve ................................................42-40
Multiple control valve bucket spool ...................................................42-41
Multiple control valve boom spool..................................................... 42-43
Adapter (Orifice) ..............................................................................42-46
Ride Control (OPT) ..........................................................................42-47
Ride control hydraulic circuit .............................................................42-47
Ride control function .........................................................................42-47
Ride control operation ......................................................................42-48
Ride control valve assembly ............................................................42-50
Accumulator (for ride control) ..........................................................42-55
Steering System .............................................................................42-56
Orbitrol............................................................................................42-57
Orbitrol structure .............................................................................42-57
Orbitrol specifications ......................................................................42-58
Orbitrol operation .............................................................................42-59
Orbitrol feed-back mechanism operation .........................................42-61
Steering speed and flow rate control ...............................................42-62
Hydraulic pump oil amount and steering force ................................42-62
Orbit rotor operation principle ...........................................................42-63
Steering Valve (KVS25-A3.0/20) ....................................................42-64
Steering valve operation ..................................................................42-66
Steering plunger variable throttle .....................................................42-68
Steering valve flow control plunger ..................................................42-69
Steering valve main relief valve .......................................................42-70
Steering valve overload relief valve .................................................42-72
Steering pilot circuit and its operation ..............................................42-74
Stop Valve ........................................................................................42-76
Stop valve function ............................................................................42-77
Stop valve operation ..........................................................................42-77
Reducing Valve (for Orbitrol) .........................................................42-78
Steering Line Filter .........................................................................42-79
K-Lever (OPT) ..................................................................................42-80
Hydraulic circuit .................................................................................42-80
Hydraulic line diagram ......................................................................42-81
Hydraulic line ....................................................................................42-82
Solenoid valve assembly (1/2) ........................................................42-83
Solenoid valve assembly (2/2) ........................................................42-84
Efficient Loading System ..............................................................42-85
Efficient loading system outline .......................................................42-85
Mounting of the ELS valve ...............................................................42-86
Mounting of the variable kick out sensor .........................................42-87
Efficient loading system operation ...................................................42-88
Fan Motor System .........................................................................42-89
Mounting of fan motor .....................................................................42-89
Fan Motor Line .................................................................................42-90
Hydraulic circuit (fan motor normal rotation) .....................................42-92
Reversing Fan Motor Line (OPT) .................................................. 42-98
Reversing fan motor function.............................................................42-98
Hydraulic circuit (Reverse rotation) .................................................42-102
Secondary Steering ......................................................................42-103
Secondary steering operation .........................................................42-104
Secondary steering motor and pump ..............................................42-105
85ZV-2 Check & Adjustment Hydraulic Group ..............................43-1
Loading/Steering Circuit Relief Valve/Ride Control Circuit Reducing Valve (OPT) .........43-2
Loading circuit relief valvesetting pressures ......................................43-2
Ride control circuit reducing valve setting pressures (OPT) ............. 43-8
Steering circuit relief valve setting pressures ....................................43-10
Hydraulic Cylinder ...........................................................................43-15
Cylinder natural drift ......................................................................... 43-15
Stop Valve ....................................................................................... 43-17
Stop valve adjustment procedure ......................................................43-17
85ZV-2 Function & Structure Brake Group ....................................52-1
Brake System Outline ..................................................................... 52-2
Service brake .................................................................................... 52-2
Parking brake ................................................................................... 52-2
Adjustment of axle internal pressure ................................................ 52-2
Brake Units Layout ............................................................................52-3
Unloader Valve ..................................................................................52-4
Unloader valve operation................................................................... 52-6
Valve Unit ........................................................................................ 52-7
Accumulator ...................................................................................... 52-9
In-Line Filter .................................................................................. 52-10
Brake Valve ....................................................................................52-11
Brake valve performance chart ...................................................... 52-12
Brake valve outline ......................................................................... 52-13
Service Brake ..................................................................................52-15
Service brake operation ................................................................. 52-15
Service brake friction plate.............................................................. 52-16
Service brake steel plate .................................................................52-16
Service brake piston ........................................................................52-17
Brake circuit air bleeding procedure ................................................52-18
Parking Brake ..................................................................................52-20
Parking brake operation ...................................................................52-21
Parking brake solenoid valve ...........................................................52-22
Parking Brake Manual Release ....................................................52-23
Parking Brake Spring Chamber ...................................................52-25
Brake Circuit Check Valve ...........................................................52-26
Pressure Sensor (for stop lamp and declutch) ..........................52-27
Pressure sensor (for declutch) .......................................................52-27
Pressure sensor (for stop lamp) ....................................................52-27
85ZV-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 measurement ..................................53-7
Cautions on installing brake discs ......................................................53-8
Parking Brake ..................................................................................53-9
Parking brake performance check .....................................................53-9
Parking brake clearance adjustment............................................... 53-10
85ZV-2 Function & Structure Electrical Group .............................62-1
How to Use Electrical Wiring Diagram ........................................62-2
Utilisation des sch~mas des c~blages ~lectriques (FRAN&AIS) .62-3
Verwendung des elektrischen Schaltplans (DEUTSCH) ..62-4
Modalit~ di utilizzo dello schema dei collegamenti elettrici (ITALIANO)...62-5
C6mo utilizar un Diagrama de Alambrado El~ctrico (ESPANOL)..62-6
Como Utilizar o Diagrama de Ligacoes El~ctricas (PORTUGU~S)62-7
Electrical Cable Color Codes .........................................................62-8
Electrical Circuit Symbols ..............................................................62-9
Sensor Mount ..................................................................................62-10
Fuse .................................................................................................62-11
Fuse box .........................................................................................62-11
Fusible link .....................................................................................62-13
Engine Start Circuit .......................................................................62-14
Engine start circuit diagram ............................................................ 62-14
Neutral starter .................................................................................62-15
Starter switch ................................................................................. 62-16
Battery relay .................................................................................. 62-17
Alternator R terminal wire ...............................................................62-18
Diode unit .......................................................................................62-18
Neutral relay ...................................................................................62-19
Magnetic switch ..............................................................................62-20
Voltage relay ................................................................................. 62-21
Power Generating/Charging Circuit .......................................... 62-22
Alternator ........................................................................................62-22
ECM (Engine Controller) ..............................................................62-23
Function of ECM ............................................................................62-23
Connection diagram ..................................................................... 62-23
Monitor lamp test ..........................................................................62-24
Failure diagnosis ..........................................................................62-25
Quantum fault code information ...................................................62-28
Accelerator pedal ........................................................................ 62-34
Transmission Control Circuit and Monitor Circuit .................62-37
Machine control unit (MCU) .........................................................62-37
Machine control unit (MCU) connection diagram ..........................62-39
Machine control unit (MCU) function ............................................ 62-41
Adjustable declutch preset switch .................................................62-46
Monitoring system ..........................................................................62-53
Instrument Panel and Switch ........................................................ 62-55
Instrument panel ............................................................................62-55
Instrument panel rear surface ........................................................62-56
Gauge circuit ..................................................................................62-57
Fuel level sensor (S/N 9001 -9139) ...............................................62-59
Fuel level sensor (S/N 9140~) ........................................................62-60
MODM ........................................................................................... 62-61
MODM function ...............................................................................62-61
Monitor Changeover .......................................................................62-61
Information Monitor .........................................................................62-64
Replacement Monitor ......................................................................62-68
Fault Log Monitor.............................................................................62-74
Input/Output Monitor ........................................................................62-81
Parameter Setting Monitor .............................................................. 62-85
Specification Setting Monitor ...........................................................62-94
Electrical Detent Circuit ............................................................ 62-100
Bucket leveler .............................................................................. 62-100
Detent solenoid .............................................................................62-101
Lift kickout & lower kickout ............................................................62-102
Sensor assy ................................................................................. 62-104
Detent solenoid ............................................................................ 62-106
Preset height adjustment ............................................................ 62-106
Diode .......................................................................................... 62-107
Diode check method ...................................................................62-108
Caution for diode check method ..................................................62-108
Surge voltage and surge suppression diodes ............................ 62-110
85ZV-2 Function & Structure Operator Station Group ................72-1
Cabin ........................................................................................... 72-2
Glass .............................................................................................. 72-3
Wiper mount .................................................................................. 72-6
Wiper motor ................................................................................... 72-7
Operator Seat ..................................................................................72-9
Steering and Transmission Shift Lever .......................................72-10
Tilt case ...........................................................................................72-11
Column shaft ...................................................................................72-12
Shift lever ........................................................................................72-12
Air Conditioner ..............................................................................72-13
Denso air conditioner components .................................................. 72-13
Denso air conditioner structure ........................................................ 72-14
Function of cooling mechanism ...................................................... 72-19
Cooling circuit .............................................................................. 72-22
Electrical circuit ............................................................................. 72-23
Air conditioner functions of components .........................................72-24
Charge of refrigerant ...................................................................... 72-52
Air conditioner troubleshooting .......................................................72-69
85ZV-2 Check &Adjustment Operator Station Group .................... 73-1
Air Conditioner ................................................................................73-2
Adjustment of lubricating oil quantity when components of air conditioner are replaced ................... 73-2
Adjustment of air gap (between hub and rotor) in compressor magnetic clutch ...............................73-5
Compressor V-belt adjustment ...........................................................73-6
Parts to be replaced periodically..........................................................73-8
85ZV-2 Drawing &Diagrams .............................................................92-1
Axle Assembly ................................................................................. 92-2
Torque Converter and Transmission ............................................. 92-3
Hydraulic &Brake Circuit ................................................................ 92-4
Brake Circuit ...................................................................................92-5
Electrical Wiring Diagram (1/3) (S/N 9001-9042) ........................... 92-6
Electrical Wiring Diagram (2/3) (S/N 9001-9042) ............................ 92-7
Electrical Wiring Diagram (3/3) (S/N 9001-9042) ............................ 92-8
Electrical Wiring Diagram (1/3) (S/N 9043-9100) ........................... 92-9
Electrical Wiring Diagram (2/3) (S/N 9043-9100) ...........................92-10
Electrical Wiring Diagram (3/3) (S/N 9043-9100) .......................... 92-11
Electrical Wiring Diagram (1/3) (S/N 9101-9200) ...........................92-12
Electrical Wiring Diagram (2/3) (S/N 9101-9200) ...........................92-13
Electrical Wiring Diagram (3/3) (S/N 9101-9200) ...........................92-14
Electrical Wiring Diagram (1/3) (S/N 9201-) .................................. 92-15
Electrical Wiring Diagram (2/3) (S/N 9201-) ................................. 92-16
Electrical Wiring Diagram (3/3) (S/N 9201-) ...................................92-17
Electrical Wiring Diagram .............................................................. 92-18
Way of looking at connectors ......................................................... 92-18
Electrical wiring diagram abbreviation chart ...................................92-20
Electrical Wiring Diagram (CAB) ....................................................92-21
Electrical Connection Diagram (1/2) (S/N 9001-9100) ..................92-24
Electrical Connection Diagram (2/2) (S/N 9001-9100) ..................92-25
Electrical Connection Diagram (1/2) (S/N 9101-9200) ..................92-26
Electrical Connection Diagram (2/2) (S/N 9101 -9200) ...............92-27
Electrical Connection Diagram (1/2) (S/N 9201-) ........................ 92-28
Electrical Connection Diagram (2/2) (S/N 9201~) .......................92-29
Electrical Wiring Diagram (Cabin Air Conditioner) ...................... 92-30
Electrical Circuit Diagram (Cabin Air Conditioner) ......................... 92-31
Equipment Operation Table (Cabin Air Conditioner) ........................92-32
Electrical Equipment Layout ....................................................... 92-33
Electrical Equipment Layout (K-Lever) .........................................92-46
Outline of MODM (Machine Operation Diagnostic Module) Operation ..92-47
MODM:Input/Output Monitor-Input/Output Signal Correspondence Table.92-56
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