Kawasaki 85ZV-2 WHEEL LOADER Shop Manual 93211-00432 – PDF DOWNLOAD

Description

Kawasaki 85ZV-2 WHEEL LOADER Shop Manual 93211-00432 – PDF DOWNLOAD

FILE DETAILS:

Kawasaki 85ZV-2 WHEEL LOADER Shop Manual 93211-00432 – PDF DOWNLOAD

Language :English
Pages :563
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Kawasaki 85ZV-2 WHEEL LOADER Shop Manual 93211-00432 – PDF DOWNLOAD

General Information
Standard Measurement Values for
Performance Check
Function & Structure
Check & Adjustment

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
Function 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 methods.
  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

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.

TABLE OF CONTENTS:

Kawasaki 85ZV-2 WHEEL LOADER Shop Manual 93211-00432 – PDF DOWNLOAD

General Information
Standard Measurement Values for
Performance Check
Function & Structure
Check & Adjustment

Foreword 2
Safety Symbols 3
CONTENTS 4
00 General Information 16
How to Use Manual 17
Safety precautions 17
Symbols 18
Outline 19
Layout of main components 19
Inspection and maintenance table 20
Recommended lubricants 23
Coolant 25
Coolant specification 25
Recommended mixture of antifreeze 25
Lubrication chart 26
Weight of main components 27
Bolt tightening torque 28
Hexagon bolt 28
Flanged hexagon bolt 31
Hose band tightening torque 32
Liquid gasket and screw lock agent 33
Cautions regarding parts removal 33
Cautions regarding reassembly 33
Screw lock agent application procedure 34
How to wind a seal tape 34
Cautions regarding welding repair service 35
03 Measurement for Performance Check 38
Cautions on Safety 39
Standard Measurement Values for Performance Check 40
12 Function & Structure Chassis Group 44
Front Chassis 45
Loading linkage 45
Loading linkage pin 47
Rear Chassis 48
Fuel tank (S/N 9001~9139) 48
Fuel tank (S/N 9140~) 49
Floor board mount 50
Floor board 50
Viscous mount 50
Center Pin 51
Upper center pin 51
Lower center pin 51
Dust seal 52
13 Check & Adjustment Chassis Group 54
Linkage Pin 55
Liner 55
Adjustment 56
Center Pin 57
Adjusting shim 57
Installing bearing cover 57
Installing bearing outer ring 58
22 Function & Structure Power Group 60
Power Line 61
Engine / Transmission 62
Engine / transmission mount 62
Radiator (S/N 9001~9100) 63
Radiator mount 64
Radiator (S/N 9101~) 65
Radiator mount 66
Propeller Shaft 67
Second propeller shaft assembly 68
Front differential – Transmission 68
Third propeller shaft assembly 69
Transmission – Rear differential 69
Axle Assembly 70
Axle Support 71
Differential Gear 73
Torque proportioning type 73
Function of TPD 75
Operation of TPD 76
Limited Slip Differential (option) 77
Structure 77
LSD function 80
LSD operation 80
23 Check & Adjustment Power Group 82
Engine 83
Measuring engine speed 83
Measurement instrument 83
Standard measurement value 83
Measuring engine oil pressure 84
Measurement instrument 84
Install position 84
Standard measurement value 84
Propeller Shaft 85
Propeller shaft phase 85
Second propeller shaft alignment 85
Tightening torque 86
Axle 87
Axle nut tightening procedure 87
Differential gear adjustment procedure 88
Preload adjustment 89
Bearing installation 89
Oil seal installation 89
Adjusting tooth contact 90
32 Function & Structure Torque Converter and Transmission Group 92
Torque Converter 93
Torque converter structure 93
Power flow path 93
Torque multiplication 93
Torque Converter Gear Pump 94
Gear pump specifications 94
Transmission 95
Clutch combination 95
Shift lever position 95
Downshift button operation 95
Gear train and number of teeth 96
Clutch specifications 97
Friction plate: mm (in) 97
Clutch Pack 98
Forward and 3rd speed clutches 98
Reverse and 2nd speed clutches 99
1st speed clutch100
4th speed clutch101
Power Flow Path in the Transmission102
Forward 1st speed power flow path102
Forward 2nd speed power flow path102
Forward 3rd speed power flow path103
Forward 4th speed power flow path103
Reverse 1st speed power flow path104
Reverse 2nd, 3rd, and 4th speeds power flow path104
Hydraulic System Diagram105
Hydraulic Circuit Diagram106
Oil Flow107
Oil flow in the torque converter line107
From torque converter gear pump to torque converter107
From torque converter to cooling circuit107
From cooler to lubrication circuit107
Oil flow to the clutch107
To forward and reverse clutches107
To speed clutch107
T/C and T/M Oil Circulation108
Control Valve110
System diagram111
Modulation Mechanism112
Clutch control oil pressure curve113
Traveling at forward 1st speed114
Pressure holding114
Changing from forward 1st speed to reverse 1st speed115
Releasing forward clutch and feeding initial oil to reverse clutch115
Trimmer engagement116
Low-pressure holding116
Clutch engagement starting117
Pressure increase117
Clutch Solenoid Valve118
For forward/reverse and speed clutches118
After power-off (clutch disengaged status)118
After power-on (clutch engaged status)119
For trimmer120
After power-off (high clutch pressure status)120
After power-on (just after switching clutch)121
33 Check & Adjustment Torque Converter and Transmission Group122
Clutch Oil Pressure123
Measuring clutch oil pressure123
42 Function & Structure Hydraulic Group124
Flushing Hydraulic Circuit125
Purpose of flushing125
Cautions on Hydraulic Parts Replacement126
Hydraulic Circuit Symbols127
Hydraulic lines127
Pumps & motors127
Cylinders127
Operation methods128
Pressure control valve128
Flow control valve128
Directional control valve129
Check valve129
Miscellaneous hydraulic symbols130
Hydraulic System Operation131
Hydraulic system operation outline131
Loading system131
Steering system131
Efficient loading system132
Fan motor system132
Ride control system (OPT)132
Layout of Hydraulic Units133
Hydraulic Tank134
Hydraulic tank specifications134
Hydraulic oil level check134
Hydraulic Tank (S/N 9001~9250)135
Hydraulic tank breather valve (tank cap) (S/N 9001~9250)136
Hydraulic Tank (S/N 9251~)137
Hydraulic tank breather valve (tank cap) (S/N 9251~)138
Hydraulic Pump139
Hydraulic pump specifications139
Hydraulic pump principle140
Hydraulic pump wear plate141
Hydraulic pump bushing lubrication141
Hydraulic Cylinder142
Boom cylinder142
Bucket cylinder143
Steering cylinder143
Hydraulic cylinder specifications144
Loading System145
Reducing Valve (for Pilot Pressure)146
Pilot Valve (S/N 9001~9214)147
Pilot valve function149
Pilot valve operation (modulated position)149
Pre-detent and detent magnet solenoid151
Pilot Valve (S/N 9215~)152
Pilot valve function154
Pilot valve operation (modulated position)154
Pre-detent and detent magnet solenoid156
Multiple Control Valve (KML28/2T002)157
Multiple control valve specifications158
Multiple control valve main relief valve159
Main relief valve operation159
Adjusting set pressure160
Multiple control valve overload relief valve (with make-up function)161
Overload relief valve operation161
Make-up valve operation162
Adjusting set pressure162
Multiple control valve make-up valve163
Make-up valve operation163
Multiple control valve bucket spool164
Bucket spool operation164
Multiple control valve boom spool166
Boom spool operation166
Adapter (Orifice)169
Ride Control (OPT)170
Ride control hydraulic circuit170
Ride control function170
Ride control operation171
Preparation mode (ride control switch is OFF)171
Running mode (ride control switch is ON)172
Ride control valve assembly173
Solenoid valve176
Accumulator (for ride control)178
Accumulator function178
Steering System179
Orbitrol®180
Orbitrol® structure180
Valve part180
Rotor part181
Orbitrol® specifications181
Orbitrol® operation182
Neutral182
Turn183
Orbitrol® feed-back mechanism operation184
Steering speed and flow rate control185
Hydraulic pump oil amount and steering force185
Orbit rotor operation principle186
Steering Valve (KVS25-A30/20)187
Steering valve operation189
Neutral position (steering spool in “Neutral”)189
Left turn position190
Steering plunger variable throttle191
Steering valve flow control plunger192
Steering valve main relief valve193
When the pressure is at the preset value or less193
When the pressure exceeds the preset value194
Steering valve overload relief valve195
Overload relief valve operation196
Make-up valve operation196
Steering pilot circuit and its operation197
Flow amplifier notch and pilot orifice198
Stop Valve199
Stop valve function200
Stop valve operation200
Reducing Valve (for Orbitrol®)201
Steering Line Filter202
K-Lever (OPT)203
Hydraulic circuit203
Hydraulic line diagram204
Hydraulic line205
Solenoid valve assembly (1/2)206
Solenoid valve assembly (2/2)207
Adjustment method207
Efficient Loading System208
Efficient loading system outline208
The operation condition of ELS208
Mounting of the ELS valve209
Mounting of the variable kickout sensor210
Efficient loading system operation211
While the ELS is not operating211
While the ELS is operating211
Fan Motor System212
Mounting of fan motor212
Fan Motor Line213
Hydraulic circuit (fan motor normal rotation)215
Safety valve (with suction function)215
Flow control valve216
Flow control solenoid valve217
Fan motor218
Reversing Fan Motor Line (OPT)221
Reversing fan motor function221
Fan motor222
Reversing fan control chart224
Hydraulic circuit (Reverse rotation)225
Secondary Steering226
Secondary steering operation227
Secondary steering motor and pump228
43 Check & Adjustment Hydraulic Group230
Loading/Steering Circuit Relief Valve/Ride Control Circuit Reducing Valve (OPT)231
Loading circuit relief valve setting pressures231
Measuring loading circuit main relief pressure233
Measuring loading circuit overload relief pressure235
Measuring pilot circuit relief pressure236
Ride control circuit reducing valve setting pressures (OPT)237
Measuring ride control circuit reducing pressure238
Steering circuit relief valve setting pressures239
Measuring steering circuit main relief pressure241
Measuring steering circuit overload relief pressure242
Measuring pilot circuit relief pressure (reducing pressure)243
Hydraulic Cylinder244
Cylinder natural drift244
Stop Valve246
Stop valve adjustment procedure246
52 Function & Structure Brake Group248
Brake System Outline249
Service brake249
Parking brake249
Adjustment of axle internal pressure249
Brake Units Layout250
Unloader Valve251
Unloader valve operation253
Valve Unit254
Accumulator low pressure sensor255
Accumulator256
In-Line Filter257
Brake Valve258
Brake valve performance chart259
Brake valve outline260
While the valve is not operating260
While the valve is operating261
While the valve is releasing261
Service Brake262
Service brake operation262
Service brake friction plate263
Service brake steel plate263
Service brake piston264
Brake circuit air bleeding procedure265
Bleeding air from brake pipes and axle housing hubs266
Parking Brake267
Parking brake operation268
Parking brake solenoid valve269
Solenoid valve operation269
Solenoid valve specifications269
Parking Brake Manual Release270
Parking Brake Spring Chamber272
Brake Circuit Check Valve273
Pressure Sensor (for stop lamp and declutch)274
Pressure sensor (for declutch)274
Pressure sensor (for stop lamp)274
53 Check & Adjustment Brake Group278
Brake Circuit Oil Pressure279
Unloader valve setting pressure279
Unloader valve setting pressure measurement280
Brake valve oil pressure281
Brake valve oil pressure measurement281
Brake valve performance282
Service Brake283
Service brake performance check283
Service brake friction plate wear measurement284
Cautions on installing brake discs285
Parking Brake286
Parking brake performance check286
Condition286
Parking brake clearance adjustment287
Brake lining abrasion check288
62 Function & Structure Electrical Group290
How to Use Electrical Wiring Diagram291
Utilisation des schémas des câblages électriques (FRANÇAIS)292
Verwendung des elektrischen Schaltplans (DEUTSCH)293
Modalità di utilizzo dello schema dei collegamenti elettrici (ITALIANO)294
Cómo utilizar un Diagrama de Alambrado Eléctrico (ESPAÑOL)295
Como Utilizar o Diagrama de Ligações Eléctricas (PORTUGUÊS)296
Electrical Cable Color Codes297
Electrical Circuit Symbols298
Sensor Mount299
Fuse300
Fuse box300
Fusible link302
Engine Start Circuit303
Engine start circuit diagram303
Neutral starter304
Shift lever neutral (N) position304
Shift lever forward/reverse (F/R) position304
Starter switch305
ECM safety features306
Battery relay306
Battery relay operation306
Alternator R terminal wire307
Diode unit307
Neutral relay308
Magnetic switch309
Voltage relay310
Power Generating/Charging Circuit311
Alternator311
ECM (Engine Controller)312
Function of ECM312
Connection diagram312
Monitor lamp test313
Failure diagnosis314
Engine diagnostic switch (option)314
Failure diagnostic chart315
Increment decrement switch (option)316
Quantum fault code information317
Accelerator pedal323
Accelerator pedal installation325
Transmission Control Circuit and Monitor Circuit326
Machine control unit (MCU)326
Connector327
Machine control unit (MCU) connection diagram (S/N 9001~9400)328
Machine control unit (MCU) connection diagram (S/N 9401~)330
Machine control unit (MCU) function332
Forward/reverse (F/R) shifting and speed change332
Automatic shift334
Machine speed sensor335
Switching from automatic to manual336
Downshift button operation336
Adjustable declutch preset switch337
Back-up alarm338
Parking brake339
Machine control unit (MCU) failure warning341
Secondary steering function342
Monitoring system344
Items to be monitored and operation condition344
Operation monitor lamps345
Instrument Panel and Switch346
Instrument panel346
Instrument panel rear surface348
Gauge circuit350
Fuel level sensor (S/N 9001~9139)352
Fuel level sensor (S/N 9140~)353
MODM354
MODM function354
Monitor Changeover354
Changing display from one function to next355
Information Monitor357
Information monitor display357
Unit conversion and language selection360
Replacement Monitor361
Replacement time check361
Replacement interval set (timer reset)365
Replacement interval pop-up366
Display language367
Fault Log Monitor367
Fault log history check367
Selection of machine fault log and engine fault log368
Machine fault log navigation369
Engine fault log navigation369
Clear fault log369
Clear active fault log (error pop up) (S/N 9001~9112)370
Input/Output Monitor374
Input/Output monitor display374
Parameter Setting Monitor378
Parameter setting monitor display378
Specification Setting Monitor387
Specification setting monitor display387
All setting reset390
Electrical Detent Circuit393
Bucket leveler393
Proximity switch393
Detent solenoid394
Lift kickout & lower kickout395
Location395
Lift kickout395
Lower kickout396
Sensor assy397
Detent solenoid399
Preset height adjustment399
Diode400
Diode check method401
Caution for diode check method401
Continuity check mode401
Diode check mode401
Resistance check mode402
Surge voltage and surge suppression diodes403
72 Function & Structure Operator Station Group404
Cabin405
Glass406
Wiper mount409
Front wiper409
Rear wiper409
Wiper motor410
Operator Seat412
Steering and Transmission Shift Lever413
Tilt case414
Column shaft415
Shift lever415
Air Conditioner416
Denso air conditioner components416
Air conditioner specifications (system performance)416
Denso air conditioner structure417
Cooling unit417
Heater and accessories419
Air distributor (hood & defroster selection box)419
Air compressor (with magnetic clutch)420
Condenser unit420
Control unit421
Function of cooling mechanism422
Principle of cooling422
Refrigerant423
Refrigerant characteristics424
Cooling circuit425
Electrical circuit426
Control schematic drawing426
Air conditioner functions of components427
Control panel427
Air conditioner unit434
Compressor and magnetic clutch443
Condenser unit446
Receiver dryer448
Sight glass450
Pressure switches450
Pressure relief valve452
Relay A453
Relay B453
Refrigerant hose454
Charge of refrigerant455
Work procedure456
Refrigerant charging tools458
Refrigerant charging procedure461
Troubleshooting using the gauge manifold467
Air conditioner troubleshooting472
Fault diagnosis procedure472
73 Check & Adjustment Operator Station Group480
Air Conditioner481
Adjustment of lubricating oil quantity when components of air conditioner are replaced481
When the compressor is replaced482
When the evaporator is replaced483
When the condenser is replaced483
Adjustment of air gap (between hub and rotor) in compressor magnetic clutch484
Compressor V-belt adjustment485
Belt adjustment procedure486
Belt adjustment value486
Parts to be replaced periodically487
Air filters487
Receiver dryer487
INDEX488
Maintenance Log495
Notes499
92 Drawing & Diagrams503
Axle Assembly504
Torque Converter and Transmission505
Hydraulic & Brake Circuit506
Brake Circuit507
Electrical Wiring Diagram (1/3) (S/N 9001~9042)508
Electrical Wiring Diagram (2/3) (S/N 9001~9042)509
Electrical Wiring Diagram (3/3) (S/N 9001~9042)510
Electrical Wiring Diagram (1/3) (S/N 9043~9100)511
Electrical Wiring Diagram (2/3) (S/N 9043~9100)512
Electrical Wiring Diagram (3/3) (S/N 9043~9100)513
Electrical Wiring Diagram (1/3) (S/N 9101~9200)514
Electrical Wiring Diagram (2/3) (S/N 9101~9200)515
Electrical Wiring Diagram (3/3) (S/N 9101~9200)516
Electrical Wiring Diagram (1/3) (S/N 9201~9400)517
Electrical Wiring Diagram (2/3) (S/N 9201~9400)518
Electrical Wiring Diagram (3/3) (S/N 9201~9400)519
Electrical Wiring Diagram (1/3) (S/N 9401~)520
Electrical Wiring Diagram (2/3) (S/N 9401~)521
Electrical Wiring Diagram (3/3) (S/N 9401~)522
Electrical Wiring Diagram523
Way of looking at connectors523
Electrical wiring diagram abbreviation chart525
Electrical Wiring Diagram (CAB)526
Electrical Connection Diagram (1/2) (S/N 9001~9100)529
Electrical Connection Diagram (2/2) (S/N 9001~9100)530
Electrical Connection Diagram (1/2) (S/N 9101~9200)531
Electrical Connection Diagram (2/2) (S/N 9101~9200)532
Electrical Connection Diagram (1/2) (S/N 9201~9400)533
Electrical Connection Diagram (2/2) (S/N 9201~9400)534
Electrical Connection Diagram (1/2) (S/N 9401~)535
Electrical Connection Diagram (2/2) (S/N 9401~)536
Electrical Wiring Diagram (Cabin Air Conditioner)537
Electrical Circuit Diagram (Cabin Air Conditioner)538
Equipment Operation Table (Cabin Air Conditioner)539
Electrical Equipment Layout540
Electrical Equipment Layout (K-Lever)553
Outline of MODM (Machine Operation Diagnostic Module) Operation554
MODM: Input/Output Monitor – Input/Output Signal Correspondence Table563

S.M 3/2/2025