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Kawasaki 85ZV-2 Wheel Loader Official Workshop Service Repair Manual
Kawasaki 85ZV-2 Wheel Loader Official Workshop Service Repair Manual
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Kawasaki 85ZV-2 Wheel Loader Official Workshop Service Repair Manual

Regular price $40.00

Kawasaki 85ZV-2 Wheel Loader Official Workshop Service Repair Manual

The Best  PDF Manuals Online Includes : Bookmarks + Searchable Text + Index = Fast Navigation And Best Organization ! 

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.
 

This PDF file is Bookmarked and SEARCHABLE to make what you need easy to find. 

This Manual contains information and data to this model. has specs, diagrams, and actual real photo illustrations, and schemes, which give you complete step by step operations on repair, servicing, technical maintenance & troubleshooting procedures for your machine. this manual offers full information you need for repair your machine. the information in this manual will enable you to find trouble and to understand how to repair and maintain your machine without going into service. all pages are printable, so run off what you need and take it with you into the garage or workshop. 
 

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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