Kawasaki 85ZV-2 WHEEL LOADER Shop Manual 93211-00441 – PDF DOWNLOAD

Description

Kawasaki 85ZV-2 WHEEL LOADER Shop Manual 93211-00441 – PDF DOWNLOAD

FILE DETAILS:

Kawasaki 85ZV-2 WHEEL LOADER Shop Manual 93211-00441 – PDF DOWNLOAD

Language :English
Pages :326
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Kawasaki 85ZV-2 WHEEL LOADER Shop Manual 93211-00441 – PDF DOWNLOAD

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.

• 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.

Safety precautions

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 93211-00441 – PDF DOWNLOAD

Foreword 2
Safety precautions 3
Safety Symbols 4
CONTENTS 6
00 General Information 12
Symbols 13
Weight of Main Components 14
Bolt Tightening Torque 15
Hose Band Tightening Torque 19
Liquid Gasket and Screw Lock Agent 20
Cautions regarding parts removal 20
Cautions regarding reassembly 20
Screw lock agent application procedure 21
How to wind a seal tape 21
Cautions Regarding Welding Repair Service 22
Cautions Regarding Handling of Bearing 24
Bearing installation cautions 24
Interference fits for a bearing 24
Bearing operation test after installation 25
Bearing removal cautions 25
Applying and Storing Articulation Stopper 26
Applying articulation stopper 26
Storing articulation stopper 26
14 Disassembly & Reassembly Chassis Group 28
Deck 29
Deck removing and installing 29
Deck removing 29
Deck installing 30
Fuel Tank 31
Fuel tank removing and installing 31
Fuel tank removing 31
Fuel tank installing 31
Fuel tank installation cautions 31
Hydraulic Tank 32
Hydraulic tank removing and installing 32
Hydraulic tank removing 32
Hydraulic tank installing 34
Hydraulic tank installation cautions 34
Engine Room 35
Engine room removing and installing 35
Engine room removing 35
Engine room installing 37
Engine room installation cautions 37
Cab 38
Cab removing and installing 38
Cab removing 38
Cab installing 39
Floor Board 40
Floor board removing and installing 40
Floor board removing 40
Floor board installing 42
Floor board installation cautions 42
Boom 43
Boom removing and installing 43
Boom removing 43
Boom installing 45
Boom installation cautions 45
Center Pin 46
Upper center pin 46
Center pin shim adjustment 46
Lower center pin 47
Center pin removing and installing 48
Center pin removing 48
Center pin installing 51
Center pin installation cautions 51
Partition Plate 52
Partition plate removing and installing 52
Partition plate removing 52
Partition plate installing 53
15 Service Standard Chassis Group 54
Linkage 55
Linkage Pin Standard Clearance Values 56
Liner clearance adjustment 56
Center Pin 57
Center pin shim adjustment 57
Bearing cover installing 57
Lower center pin bearing outer ring installing 58
Attachment Leveler 59
Attachment leveler 60
Attachment leveler adjustable angle 60
24 Disassembly & Reassembly Power Group 62
Power Line 63
Power line tightening torque 63
Radiator 64
Radiator tightening torque 64
Radiator removing and installing 66
Radiator removing 66
Radiator installing 68
Radiator installation cautions 68
Fan 69
Fan removing and installing 69
Fan removing 69
Fan installing 70
Fan installation cautions 70
Engine 71
Engine removing and installing 71
Engine removing 71
Engine installing 73
Engine installation cautions 73
Propeller Shaft 74
Propeller shaft removing and installing 74
Second propeller shaft removing 74
Third propeller shaft removing 75
Propeller shaft installing 75
Propeller shaft installation cautions 75
Air Cleaner 76
Air cleaner removing and installing 76
Air cleaner removing 76
Air cleaner installing 77
Air cleaner installation cautions 77
Muffler 78
Muffler removing and installing 78
Muffler removing 78
Muffler installing 78
Muffler installation cautions 78
Front Axle Assembly 79
Front axle assembly tightening torque 79
Axle nut tightening procedure 80
Floating seal installing 80
Front axle assembly removing and installing 81
Front axle assembly removing 81
Front axle assembly installing 83
Front axle assembly installation cautions 83
Air bleeding procedure 83
Front axle disassembling and assembling 84
Front axle disassembling 84
Front axle assembling 87
Front axle assembly cautions 88
Floating seal installing 88
Internal gear hub installing 90
Axle nut tightening 90
Brake adjustment 91
Internal Gear Hub 93
Internal gear hub disassembling and assembling 93
Internal gear hub disassembling 93
Internal gear hub assembling 94
Internal gear hub assembly cautions 95
Spider Assembly 96
Spider assembly disassembling and assembling 96
Spider assembly disassembling 96
Spider assembly assembling 96
Spider assy assembly cautions 97
Special Tool 98
Special tool for axle 98
Rear Axle Assembly103
Rear axle assembly tightening torque103
Axle nut tightening procedure104
Floating seal installing104
Rear axle assembly removing and installing105
Rear axle assembly removing105
Rear axle assembly installing107
Rear axle disassembling and assembling107
Axle Support108
Axle support tightening torque108
Axle support disassembling and assembling109
Axle support disassembling109
Axle support assembling109
Axle support assembly cautions110
Differential Assembly111
Differential assembly removing and installing111
Differential assembly removing111
Differential assembly installing113
Differential assembly installation cautions113
Differential assembly disassembling and assembling114
Front differential tightening torque114
Rear differential tightening torque115
Differential assembly disassembling116
Differential assembly assembling120
25 Service Standard Power Group126
Propeller Shaft Service Standard127
Axle and Differential Service Standard128
Axle group128
Differential129
34 Disassembly & Reassembly Torque Converter and Transmission Group130
Torque Converter and Transmission Assembly131
Torque converter and transmission assembly tightening torque131
Torque converter and transmission assembly removing and installing132
Torque converter and transmission assembly removing132
Torque converter and transmission assembly installing137
Transmission assembly installation cautions138
Torque Converter Assembly140
Torque converter assembly bolt tightening torque140
Torque converter assembly disassembling and assembling141
Torque converter assembly disassembling141
Torque converter assembly assembling143
Transmission Assembly148
Transmission assembly bolt tightening torque148
Transmission assembly disassembling and assembling149
Transmission assembly disassembling149
Transmission assembly assembling153
Transmission Forward/Reverse Clutch Pack160
Forward/reverse clutch pack disassembling and assembling160
Forward/reverse clutch pack disassembling160
Forward/reverse clutch pack assembling162
Forward/reverse clutch pack assembly cautions162
Transmission 1st/3rd Speed Clutch Pack163
Transmission 1st/3rd speed clutch pack disassembling and assembling163
Transmission 1st/3rd speed clutch pack disassembling163
Transmission 1st/3rd speed clutch pack assembling164
Transmission 1st/3rd speed clutch pack assembly cautions164
Transmission 2nd Speed Clutch Pack165
Transmission 2nd speed clutch pack disassembling and assembling165
Transmission 2nd speed clutch pack disassembling165
Transmission 2nd speed clutch pack assembling166
Transmission 2nd speed clutch pack assembly cautions166
Transmission 4th Speed Clutch Pack167
Transmission 4th speed clutch pack disassembling and assembling167
Transmission 4th speed clutch pack disassembling167
Transmission 4th speed clutch pack assembling168
Transmission 4th speed clutch pack assembly cautions169
Control Valve Assembly170
Control valve tightening torque170
Control valve removing and installing171
Control valve removing171
Control valve installation cautions172
Control valve disassembling and assembling173
Control valve disassembling173
Control valve assembling174
Control valve assembly cautions174
35 Service Standard Torque Converter and Transmission Group176
Transmission Assembly177
Control Valve178
Gear Pump180
Gear pump specifications180
Clutch Plate Thickness/Piston Stroke181
Clutch plate182
Piston stroke182
Clutch Oil Pressure183
Clutch oil pressure standard value183
44 Disassembly & Reassembly Hydraulic Group184
Hydraulic Parts Removal and Installation Warning185
Hydraulic Parts Disassembly and Assembly Cautions186
Hydraulic parts disassembly cautions186
Hydraulic parts assembly cautions186
Hydraulic Pump Assembly187
Hydraulic pump assembly removing and installing187
Hydraulic pump assembly removing187
Hydraulic pump assembly installing187
Hydraulic pump installation cautions187
Hydraulic pump assembly disassembling and assembling188
Hydraulic pump assembly cross section and tightening torque189
Oil seal replacement procedure190
Hydraulic Cylinder191
Boom cylinder removing and installing191
Boom cylinder removing191
Boom cylinder installing193
Boom cylinder installation cautions193
Bucket cylinder removing and installing194
Bucket cylinder removing194
Bucket cylinder installing195
Bucket cylinder installation cautions195
Steering cylinder removing and installing196
Steering cylinder removing196
Steering cylinder installing197
Steering cylinder installation cautions197
Hydraulic cylinder disassembling and assembling198
Hydraulic cylinder cross section and tightening torque198
Hydraulic cylinder disassembling200
Hydraulic cylinder assembling202
Hydraulic cylinder assembly cautions202
Pilot Valve (S/N 9001~9214)204
Pilot valve removing and installing204
Pilot valve removing204
Pilot valve installing205
Pilot valve installation cautions205
Pilot valve disassembling and assembling206
Pilot valve cross section and tightening torque206
Pilot valve disassembling (S/N 9001~9214)207
Pilot valve assembling214
Pilot valve assembly cautions214
Pilot Valve (S/N 9215~)215
Pilot valve removing and installing215
Pilot valve removing215
Pilot valve installing216
Pilot valve installation cautions216
Pilot valve disassembling and assembling217
Pilot valve cross section and tightening torque217
Pilot valve disassembling (S/N 9215~)218
Pilot valve assembling224
Pilot valve assembly cautions224
Multiple Control Valve225
Multiple control valve removing and installing225
Multiple control valve removing225
Multiple control valve installing227
Multiple control valve installation cautions227
Multiple control valve disassembling and assembling228
Multiple control valve cross section and tightening torque228
Multiple control valve disassembling229
Multiple control valve assembling231
Multiple control valve assembly cautions231
Orbitrol®232
Orbitrol® removing and installing232
Orbitrol® removing232
Orbitrol® installing233
Orbitrol® installation cautions233
Orbitrol® disassembling and assembling234
Orbitrol® cross section and tightening torque234
Orbitrol® disassembling235
Orbitrol® assembling238
Steering Valve242
Steering valve removing and installing242
Steering valve removing242
Steering valve installing243
Steering valve installation cautions243
Steering valve disassembling and assembling244
Steering valve cross section and tightening torque244
Steering valve disassembling245
Steering valve assembling246
Stop Valve247
Stop valve removing and installing247
Stop valve removing247
Stop valve installing247
Stop valve installation cautions248
Stop valve disassembling and assembling249
Stop valve cross section and tightening torque249
Stop valve disassembling250
Stop valve assembling250
Fan Motor251
Fan motor removing and installing251
Fan motor removing251
Fan motor installing253
Fan motor installation cautions254
45 Service Standard Hydraulic Group256
Hydraulic Cylinder257
Pilot Valve259
Steering Valve261
54 Disassembly & Reassembly Brake Group262
Unloader Valve263
Unloader valve removing and installing263
Unloader valve removing263
Unloader valve installing264
Unloader valve installation cautions264
Unloader valve disassembling and assembling265
Unloader valve cross section and tightening torque265
Unloader valve disassembling268
Unloader valve assembling268
Manifold Valve Assembly269
Valve assembly removing and installing269
Valve assembly removing269
Valve assembly installing270
Valve assembly installation cautions270
Valve assembly disassembling and assembling270
Valve assembly cross section and tightening torque271
Accumulator272
Accumulator removing and installing272
Accumulator removing272
Accumulator installing273
Accumulator installation cautions273
Accumulator disassembling and assembling274
Accumulator disassembling274
Accumulator assembling275
Nitrogen gas charging276
Nitrogen gas charging procedure276
Brake Valve278
Brake valve removing and installing278
Brake valve removing278
Brake valve installing279
Brake valve installation cautions279
Brake valve disassembling and assembling280
Brake valve cross section and tightening torque (main valve)280
Brake valve disassembling281
Brake valve assembling285
Brake valve assembly cautions285
Service Brake286
Service brake disassembling and assembling286
Service brake installation cautions286
Parking Brake Actuator287
Parking brake actuator removing and installing287
Parking brake actuator removing287
Parking brake actuator installing287
Parking brake actuator adjusting288
Parking brake actuator adjustment procedure288
Parking brake actuator disassembling and assembling289
Parking brake actuator cross section and tightening torque289
Parking brake actuator disassembling290
Parking brake actuator assembling291
Parking Brake292
Parking brake removing and installing / disassembling and assembling292
Parking brake removing and disassembling292
Parking brake installing and assembling293
55 Service Standard Brake Group294
Brake Valve295
Service Brake297
Parking Brake298
74 Disassembly & Reassembly Operator Station Group300
Air Conditioner301
Air conditioner removing and installing301
Air conditioner removing301
Air conditioner installing302
Air conditioner disassembling and assembling303
Air conditioner tightening torque303
Air conditioner disassembling306
Air conditioner assembling310
75 Service Standard Operator Station Group312
Air Conditioner313
Periodical Inspection/Servicing313
Tightening Torque313
Tightening torque for hose and pipes313
Tightening torque for screws and bolts in special control regions313
INDEX314
Maintenance Log319
Notes323

S.M 3/2/2025